Gemeinschaftsprojekt "Multispin" Rundtaktmaschine WMW

Description

Research - Development - Prototyping

In our joint project with the Fraunhofer Institute, we have developed a new, more powerful spindle drive for rotary transfer machines for machining stainless steels!

The project was supported by the Sächsische Aufbaubank (SAB) with funds from the European Regional Development Fund (ERDF).

planned publications:

Metav Düsseldorf 2022

Intec Leipzig 2023

Development status:

Machine and processing units have been put into operation.

The testing of the technology is being prepared.

Compared to the Gnutti units, the new machining units have the following

design advantages:

• 1 type of machining unit instead of 2 types (drilling, tapping)


• coaxial direct drives for spindle and Z axis (innovation)


• 7 times higher spindle power (from 2.98 kW to 21 kW)


• 6 times higher speed (from 1005 min-1 to 6000 min-1)


• 1.3-fold increase in volume (from 52.2 dm³ to 67.6 dm³)


• 5.4-fold higher power density (7 / 1.3 = 5.4)

and technological advantages:

• higher torques and forces for machining stainless steel instead of brass


• freely programmable S-speed, Z-feed via CNC program


• synchronization of a spindle and feed movement via cycles


• synchronization of the 6 machining units via 6 NC channels


• water cooling of motor spindles reduces heat input into workpiece


• Internal tool cooling through spindle shaft increases tool life


• HSK tool clamping reduces service times


• No retooling of the thread copying gear in case of changed workpiece geometry

Details

Technical data

Main dimensions:

Total mass: approx. 6500 kg

length: approx. 5900 mm

width: approx. 3800 mm

height: approx. 2200 mm

Workpiece specifications:

max. workpiece length 120 mm

min. workpiece length 20 mm

max. workpiece diameter 65 mm

min. workpiece diameter 15 mm

max. workpiece thickness 10 mm

min. workpiece thickness 2 mm

Material stainless steel

Data of the plant:

Plant capacity 10 pieces / min

number of spindles 6

max. traverse range Z-axes 125 mm

type tool holder HSK80/HSK100

max. tool diameter 60 mm

min. tool diameter 3 mm

max. tool length 250 mm

min. tool length 20 mm

Drilling: up to diameter 20mm

Boring: up to diamter 88mm

Thread cutting: up to diamter 85mm

Facing and Centering : up to 100mm

Electrical data

voltage 220/400 V

power 200 kW

CNC control SINUMERIK 840D sl

Manufacturer Siemens

Control voltage 24V/DC

Spindle Type HBE21-125E:

The high efficiency machining unit MultiSpin HBE 21 – 125 E developed by WMW AG in cooperation with the Fraunhofer IWU (Institute for Machine Tools and Forming Technology) is the result of years of experience and research. Advantages are:

capable of continuous operation in 3-shift system due to the innovative coolant systems

higher safety for man and machine thanks to integrated safety functions in the drive train and the control system sealing air protects spindle bearings and glass scales from any dirt and coolant

less wear due to the coaxial feed motor and spindle

Technical data: Hollow shaft motor with DRIVE-CLiQ from Siemens

Power: 21 kW

Torque: max. 210 Nm Power density: 310,45 kW/cm

Feed rate: 6 m/min

Feed length: max. 125 mm Rotation speed: max. 6000 U/min

Tool holder: HSK 80 or HSK 100 Internal and external cooling

Planned measures

Improvements compared to the old version:

Conversion to CNC control and thus:

easy resetting (workpiece setup adjustments)

Adaptability of machining processes

simple, faster operation

Increased cutting and drilling performance

Adaptation to all common tool holders

Reduction of space and weight

up to 35% energy saving

work performed

Compared to the Gnutti units, the new machining units have the following

design advantages:

• 1 type of machining unit instead of 2 types (drilling, tapping)


• coaxial direct drives for spindle and Z-axis (innovation)


• 7 times higher spindle power (from 2.98 kW to 21 kW)


• 6 times higher speed (from 1005 min-1 to 6000 min-1)


• 1.3-fold increase in volume (from 52.2 dm³ to 67.6 dm³)


• 5.4-fold higher power density (7 / 1.3 = 5.4)

and technological advantages:

• higher torques and forces for machining stainless steel instead of brass


• freely programmable S-speed, Z-feed via CNC program


• synchronization of a spindle and feed movement via cycles


• synchronization of the 6 machining units via 6 NC channels


• water cooling of motor spindles reduces heat input into workpiece


• Internal tool cooling through spindle shaft increases tool life


• HSK tool clamping reduces service times


• No retooling of the thread copying gear in case of changed workpiece geometry

Subject to changes and errors in technical details and specifications, as well as prior sale.