FEATURE MACHINE BUILDING, FRAMEWORKS & SAFETY
A servo solution for metal processing
W
hen building its MS40C-8 eight- spindle metal processing machine,
southern-Germany based Index chose permanent magnet servomotors from Kollmorgen. As well as selling standard machines, the company supplies fully equipped machinery with all tools assembled. Its MS40C-8, for example, is not only designed for the fully-automated production of complex components but, with its double four-spindle machining, it is also available for cost-effective production of simple parts with double the output quantity. As a result, it can be used to produce high quantities of precision parts as well as smaller batches.
MACHINING According to the company, multi-spindle machines are mostly used for parts that will be on the road at some point in the future – including injection pump components, valve needles, small gears or injector nozzles – and accuracy is needed. The lathe features a compact spindle
drum with eight fluid-cooled motor spindles using synchronised technology. These can reach speeds of up to 7,000rpm with 24kW of power and torques of up to 57Nm. They feature infinitely variable speed control, high torques, have a compact design, and they require no maintenance. As a result of the increased number of main spindles and tool carriers, the MS40C-8 is capable of machining highly complex components in a single operation. There are also two pivoting synchronous spindles available, each able to work on up to seven rear- end machining tools, with four of these capable of being powered. The capacity for two rear-end machining tools to work on the workpiece at the same time is a new feature.
CROSS SLIDES With the machine, it is possible to program the optimum speed and feed rate for each spindle location and each cutting edge, and modify these during the cutting process. The eight fluid-cooled motor spindles integrated in the spindle drum are infinitely variable, require no maintenance, and are driven with
14 JUNE 2018 | DESIGN SOLUTIONS
A manufacturer based in Germany specified permanent magnet servo motors from Kollmorgen when constructing its new eight-spindle metal processing machine
synchronous motors. The Kollmorgen AKM permanent magnet servomotors are installed in the cross slides. The motors are used, in part, as
positioning axes for the tools. Of benefit here is the high-power density which enables a more compact design, while the torque density has enabled Index to convert the rotation movement of the motors into a linear motion without gears. The ball bearing spindles are connected directly to the motor shaft for this. The lack of gears not only means there are fewer moving parts, but it helps to improve the zero backlash and the overall stiffness of the drive. The AKM servomotors can be installed directly with the cross slides thanks to their special washdown exterior paint. This allows the units to be introduced directly into the machining process without impairing their service life. The connecting cables, however, are
also exposed to constant bombardment from metal chips. As a result, Kollmorgen placed these in a metal cable duct specifically designed to meet Index’s needs. Today, this co-engineering initiative securely protects the servo drive, together with its wiring, from the metal chips that fly around and from the cutting oil that gets into the work area at pressures up to 80 bar.
ADAPTING TO REQUIREMENTS The motors need to fit seamlessly into the machine’s overall automation mechanism without time-consuming adjustments. The connection via DRIVE-CLiQ is of benefit here as it allows the performance benefits of the AKM synchronous servo motors to be used for CNC applications directly with Sinumerik control units in metal machining, without needing to compromise on the connection technology. Until now, anyone who wanted to use motors from other
The Kollmorgen AKM permanent magnet servomotors are installed in the cross slides of Index’s (
https://uk.index-
traub.com/en/) metal processing machine
manufacturers outside these Siemens world proprietary motors had to rely on DRIVE-CLiQ sensor modules, the company explains. “DRIVE-CLiQ is available for the AKM motors, allowing us to continue processing the position signals 1:1 without requiring any SMC modules. They cost space and money,” commented, Metin Han, key account manager at Kollmorgen. “This leaves us free to exploit the performance benefits of the AKM motors in full in this application.” With the use of DRIVE-CLiQ, the synchronous servo motors can adapt to the diversity of CNC and automation technology – particularly for metal machining. This lets machine constructors use drives outside of closed systems, without losing any of the convenience or performance benefits.
Kollmorgen
www.kollmorgen.com
BUILDING A DRONE USING SLS AND COMPOSITE MATERIALS
Additive Manufacturing technology (SLS) and composite materials have been used in the construction of a drone prototype. The aim of the project, which was carried out by CRP Technology and Hexadrone, was to build a fully modular and easy-to-use drone for industrial and multi- purpose tasks, that would be rugged enough to withstand extreme weather conditions. Called the Tundra-M, the drone features rapidly
swappable arms and three quick release attachments, ensuring its flexibility for a range of tasks. Windform 3D Printing materials, which were originally
developed for the motorsports industry by CRP Technology, have been used in this project. The body as well as the main parts have been conceived with the composite polyamide based material carbon filled Windform SP and Windform XT 2.0. Those two materials are shaped into pieces using the selective laser sintering 3D printing technology. The four arms supporting the body frame were 3D printed using Windform XT 2.0 composite material, while the rest of the components were developed with the Windform SP composite material. Visit
www.connectingindustry.com/designsolutions for
the full story. CRP Technology
www.crptechnology.com
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