ROBOFORM 350/550

Step into a dynamic manufacturing

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ROBOFORM 350/550

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Communication: cellular phone

Advanced technology

The ROBOFORM 350/550 series is

exceptionally versatile since it delivers

unequalled performance in a wide

variety of applications: automotive,

connectors, communication, medical,

aeronautics, household appliances

and many more.

The ROBOFORM 350/550 are the first

to integrate Dynamic Process Control

(DPControl), the new generation

of numeric controls developed

by CHARMILLES.

With a user interface dedicated

to die-sinking, operators benefit from

the unparalleled ease and efficiency

of their working environment.

Connectors:fibre-optic connector

Automotive connector

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Tail lights

Automotive: GPS for dashboard

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DPControl, dedicated to die-sinking

A tailor-made interfaceThe new DPControl (Dynamic Process Control) interface has been developed,based on the findings of a survey conductedamong mold-making professionals. The study was instrumental in designinginterface functions and optimizing screen

Interactive graphics All operations such as measuring and machining cycles as well as cavity positioningare illustrated by graphics/icons designed to facilitate intuitive and spontaneous comprehension by the operator.

Integrated e-documentationLarge, cumbersome manuals are a thing ofthe past because they are now replaced bydocumentation in electronic format (HTML).When help is needed, the operator pressesthe F1 key on the keyboard to instantlyreceive easy-to-understand information aboutthe current function.

Standard Windows platform:

• Integrated PC

• Touch screen

• Windows controlled

• CD-ROM, floppy drive

• Network

ergonomics. The user-friendliness of CHARMILLES interfaces – already a recognized standard in the industry – hasbeen further enhanced to satisfy even morethe stringent requirements of die-sinkingprofessionals.

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DPControl, active integration into the workshop

EDM parameter input

Multicavity

Verification and simulation

Job execution

Electrode manufacturing

Measuring at preset station

Measuring on machine

Measuring offset and positions

Absolutely imperative for preparing the job,measurements performed on a preset stationare directly accessible via DPControl.

Electrode design

DPControl suggests ideal electrode undersizeand rationalizes the number of electrodesnecessary for effective machining.

Flexible job organization

Whether you work on a PC or on theROBOFORM 350/550, DPControl allows you to organize the jobs according to your own priorities.

Close monitoring

Due to the automated protectionfeatures of Expert Systems, DPControldelivers the results you demand.

Notification via SMS

All information related to machiningstatus may be transmitted directly to the operator via SMS.

Evaluation of completed job

DPControl automatically creates a full report on job execution readily accessible to the operator via thenetwork or directly on the machine.

Dynamic manufacturing processWith DPControl’s new functions, the ROBOFORM 350/550 play a key active role in themanufacturing process.

Job report

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Interactive graphics programming

Innovative set-up functionsNew automatic measuring cycles using high axis speeds considerably shorten job preparation time. What’s more, DPControlcommunicates with a preset station, thusavoiding the need to enter values manually.

Automated sequencing

Choose your prioritiesBased upon machining strategies, number of electrodes and workpieces, the Sequencescreen automatically organizes successivemachining phases.

If required, this can be modified according to criteria defined by the operator throughthe Sequence Assistant. Following validation,the ISO program is generated prior to machining.

Optimum machining strategyDPControl offers clear choices for eachapplication and generates the optimummachining strategy for top performance.

On just one screen the operator entersmachining parameters such as surface finish,machining depth, machining cycle andtype of application in order to obtain thebest possible generator performance.

Measuring cycle

Electrode set-up

Machining cycle

Orbit patterns

EDM description

Sequence Assistant

Machining sequence

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Detailed check by graphics simulationThis last phase prior to machining allows to visually verify on screen the propersequencing. In other words, any verificationby real axis movement is no longer needed.What’s more, machining progress can be monitored during machining.

Close monitoring With DPControl the operator has a preciseoverview of the evolution of output efficiencyand of machining conditions. A multitude of functions are available such as graphicsmonitoring, visualization of current sequenceas well as machining history.

Complete machining reportWhen job is completed, all details are described in reports listing, machining strategy, spark time, interruption, etc.

This information is most valuable in order to:• Check completed jobs.• Archive data.• Expand know-how.• Calculate production costs.

Job simulation

Machining monitoring

Job List

Job archiving

Machining report

Maximize productive timeTo address this need, DPControl deliversunique solutions:• Part Express: allows to interrupt

the operation in progress in order to insert a more urgent job.

• Job List: organizes job sequenceaccording to manufacturing priorities.

Part Express

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CHARMILLES Expert Systems: quality and performance

POWER CONTROLEXPERT

Mastering the spark POWER CONTROL EXPERT checkseach spark to ensure a perfect quality of surface finish. It also allows to determine in real time the intensity of machining discharge as the electrode’s surface increases.

PILOT-EXPERT 3

Around-the-clock monitoring and optimization PILOT-EXPERT 3 guarantees top performance while taking into accountmachining conditions at all times. It provides forunattended machining anddelivers perfect jobreproducibility.

Machining deep ribsDue to increased axis speed and acceleration linked to PILOT-EXPERT 3, the ROBOFORM 350/550 reach exceptional performance. Without flushingand therefore without lateral deformation of the cavity, workpieces comply with the most stringent tolerances of geometry.

Dovetail ribMaterial: Graphite /SteelDimensions: 0.59 x 0.04 inMachining time: 1h 06 minTechnology: Rib

100 mm deep ribDimensions: 0.59 x 0.08 inWithout flushingMaterial: fine Graphite and copper /SteelTechnology: Rib

Surface finish: CH 24/Ra 1.65 µmAverage: 1.68, distortion: 2.1%Standard deviation: 3.4%Max. tolerance: ±10%Measurement outside tolerance: 0

SPAC®

A CHARMILLES exclusiveSPAC® allows to eliminate any shortcircuit by applying a specific dischargeduring a fraction of a second. No longer slowed downdue to short circuits,machiningcontinues atfull speed andwithout interruption,thus improvingproductivity.

Surface finish qualityThe uniformity of workpiece texture is directlylinked to the quality of the mold surface. To obtain a perfect surface, CHARMILLES hasdeveloped Surface technology to satisfy themost stringent criteria of consistent surfacefinish.

GPS moldMaterial: Graphite /SteelDimensions: 19.4 in2

Surface finish: CH 22/Ra 1.26 µmTechnology: Surface

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Mold for phone connectorMaterial: Copper /SteelSurface finish: CH 22/Ra 1.26 µm Precision: ± 0.0002 inTechnology: Micro-machining

Micro MachiningWhen electrode dimensions are reduced in micro-machining, speed and wear becomecritical factors. CHARMILLES has developed a spark circuit capable of reducing machining time, lowering electrode wear bya factor of 3 while machining the surfacefinish.

Mold subgatesEach mold has at least one injection point.This type of machining requires a 3D cycleand a strategy adapted to evolving electrode surfaces. The calculated geometricdata necessary to describe the electrodemovement is automatic, based on workshopdrawings.

ContouringContouring technology allows the use ofcylindrical electrodes to accommodatecomplex geometries. These simple electrodesare easy to produce and reduce the cost ofelectrode manufacturing and optimizesflushing conditions and part straightness.Contouring widens the potential of die-sinking EDM.

Carbide dieMaterial: Copper tungsten /CarbideSurface finish: CH 6/Ra 0.12 µm Precision: ± 0.0002 inTechnology: Carbide

Quality and precision for carbide machiningIn-depth research has allowed CHARMILLESto develop a new generator module (K-HM). It has been developed to deliver unequalledperformance in terms of surface finish andgeometry. The results are simply spectacular:CH 6/Ra 0.2 µm, 40% of time savings and 50% less wear.

SubgatesMaterial: Copper /SteelSurface finish: CH 18/Ra 0.80 µmMachining cycle: ORBIT 3DTechnology: Subgate

Fine blanking dieMaterial: Copper /SteelSurface finish: CH 21/Ra 1.12 µmTechnology: Contouring

New Micro-machining circuit

Conventional

Factor of 3

New type of machining for carbide pieces

Conventional

Time savings

Improved surface finish

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Precise, rugged and designed to last

Rugged mechanical designA short oversized cast-iron C frame deliversmechanical stability and precision for the lifeof the machine – regardless of workpieceweight or dielectric volume. In addition, a rugged design absorbs all machiningforces in order to maintain a precise gapbetween workpiece and electrode.

High speed and accelerationBased on studies conducted to define optimum values, CHARMILLES has multipliedpulse and acceleration speeds of the Z axisin order to improve particle removal in thespark gap cavities. This technology allowsdeep down machining without flushing andtherefore without cavity deformation. This ballscrew technology not only deliversprecision but it also provides job repeatability.

Fast, convenient workpiece set-upDrop tank for easy access on two sides of thework area. In addition, the operator is able to program work tank level to accommodateworkpiece height and therefore to facilitateautomation. The fixed table prevents any riskof damage to the guides when loadingheavy workpieces.

Short C frame

Large oversized ballscrews and linear guideways

High-speed pulse in machining

High-speed pulse for completeparticle removal

Easy access

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Guaranteed quality

Linear glass scales for lifetime precisionTo obtain lasting precision, only linear glassscales are truly effective. They eliminate all common errors caused by backlash,expansion and ballscrew wear.The Dual Loop Positioning System (DLPS)developed by CHARMILLES is a true closed-loop feedback solution designed todeliver high precision regardless of travel. It does away with the need for regular maintenance and calibration.

VDI axis positioning checkBefore delivery, each machine is checked by laser to verify compliance of each axis movement with VDI 3441 standards (morethan 150 positions checked per axis). Thesestringent standards include positional uncertainty, maximum positioning dispersion,positional deviation and maximum backlash.

Ongoing quality assuranceAt each step of the manufacturing process,our products’ stringent inspections are conducted by qualified technicians. Compliance protocols and signatures guarantee product quality and accountability.

Linear glass scales for repeatable precision

Result of VDI tests

VDI laser check

Assembly line

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Technical specifications

ROBOFORM 350/550

Machine ROBOFORM 350 ROBOFORM 550Architecture Compact machine with fixed table Short C frame, fixed tableDimensions (*) in 74.80 x 66.54 x 99.29 108.27 x 124.02 x 118.11Total weight (without dielectric) lbs 6200 9700Complies with “Machines, Safety and Health” directive 89/392/CEE 89/392/CEEComplies with “Electromagnetic Compatibility” directive 89/336/CEE 89/336/CEE

X, Y, Z axesX, Y, Z travel in 13.78 x 9.84 x 11 .81 23.62 x 15.75 x 17.72Movement measurement system Linear glass scales Linear glass scalesX, Y, Z measurement resolution in 0.000004 0.000004

Work areaTank type Drop tank Drop tankTank dimensions (*) in 31.50 x 21.65 x 14.57 48.08 x 34.25 x 18.50Min./max. dielectric level in 3.94/12.80 programmable 5.71/17.32 programmableTable dimensions (**) in 19.69 x 15.75 29.53 x 23.62T-Slot dimensions (number) in 0.47 (3) 0.47 (5)

Electrode and workpieceMax. electrode weight lbs 110 220Max. workpiece weight lbs 1100 3530Max. workpiece dimensions (*) in 30.71 x 20.87 x 11.81 47.24 x 33.46 x 15.75Min./max. distance between table and chuck in 5.91/17.72 5.91/23.62

Dielectric systemFilter type 4 built-in paper cartridges 8 paper cartridgesReservoir volume gal 108 216

* Width x depth x height** Width x depth*** Optional

118.11 in�

�

99.3

0 in�

�

160.24 in

25.39�

in

51.18 in

124.0

2 in

39.7

6 in

82.2

8 in

23.62�

in

66.5

4 in�

�

74.8 in�

�

51.18 in

125.98 in

82.2

8 in

108.27 in

15.7

5

21.6

5

31.50

19.69

Y =

9.8

4

X = 13.78

23.6

2

34.2

5

29.53

X = 23.62

Y =

15.7

5

9.8

4

9.8

4

47.24

ROBOFORM 550QCRi.2ROBOFORM 350QCRi.2

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Modules ROBOFORM 350 ROBOFORM 550C axis (***) Max. electrode inertia lbs x in2 683

Measurement resolution ° 0.001Electrode weight lbs 55

Spindle chuck (***) System 3R Macro/CombiMecatool GPS70Erowa ITS/ITS-CompactHirschmann H8.11.7

Tool changer (***) Linear (standard tooling) 4 pos./2.95 x 16.73 in 6 pos./2.76 x 16.73 in

Linear (Combi tooling) 5 pos./2.36 x 16.73 in 6 pos./2.36 x 16.73 inRotary (standard tooling) 16 pos./2.95 x 9.84 inRotary (Combi tooling 32 pos./1.42 x 9.84 in

Multicavity flushing (***) 6 outputs

Additional power module (***) A – 64Adapter kit for external robot OptionalK-HM Optionale-ConnecT OptionalProgramming system on PC StandardAutorestart StandardHS-EDM Standard

Power supplyThree-phase input voltage V 400Main network frequency Hz 50 or 60

GeneratorType ISOPULSEStandard machining current A 64PILOT-EXPERT 2 and 3: Optimization and automatic monitoring of machining parameters StandardPOWER CONTROL EXPERT: Machining current, self-adapting according to electrode geometry StandardMICRO-MACHINING: Monitors electrode wear in applications of small dimensions StandardSPAC®: Protection against short circuits (CT patent) Standard

Numerical controlArchitecture PC multiprocessorsOperating system WindowsProcessor Pentium®

Screen LCD 12” TFTData input Touch screen – keyboardKeyboard PC-style alphanumeric standardRemote control StandardHard drive 10 GBFloppy disk 1 .44 MBCD-ROM drive StandardPCMCIA Port, Ethernet RJ45, Parallel, RS 232C Series (with Windows standards) Standard

DPControl functions D-JOB (Direct-Job) for machining simple jobsInteractive graphics assistant for simpler data inputAutomatic measurement cycles for workpieces and electrodesImportation of measurement results from preset station 3D machining cycles with geometrical patternMachining strategy for all combinations of materialsDedicated technologies for each type of applicationAid to define undersize and number of electrodesMachining sequencing assistant according to manufacturing prioritiesGraphic machining simulationMachining report for each job executionJob List – Management of pending jobs by order of priorityPart Express – Instant insertion of urgent jobsContextual aid with graphics explanationsEmbedded documentation (e-doc) on the use of the machine

QCRi.2 OptionRobot dimensions (*) in 51.18 x 82.28 x 97.64Robot weight lbs 2050Max. electrode weight lbs 44Max. pallet weight lbs 110Magazine configuration (electrode/pallet) 54/4; 54/8; 90/4Choice of tooling System 3R/Mecatool/Erowa

ROBOFORM 350/550

Technical specifications

© The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change.

Please consult the General Sales Conditions of Charmilles Technologies SA.

Printed in Switzerland

Charmilles Technologies Corporation560 Bond StreetUSA - Lincolnshire, IL 60069Telephone: (847) 913-5300Fax: (847) 913-5340www.charmillesus.com

AGIE CHARMILLES Group

GEORG FISCHER ‡ Manufacturing Technology

5980274/03.03/US