Tradition. Since 2012, BURKHARDT+WEBER has been part of Brazil s largest machine tool manufacturer, Indústrias Romi S.A.

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2 Tradition We have been producing machine tools at our Reutlingen site since Today, some 0 employees continue the long tradition of making high-precision machining centres and special purpose machines. Since the company was founded and the first special design of a circular saw was produced, BURKHARDT+WEBER has been respected as a skilled, dependable partner for complex manufacturing tasks. The first NC-controlled machining centre was made as early as 1958 back then with punched tape control. In 1993, BW pioneered and introduced digital control technology. 005 saw the world s first tool magazine featuring 570 pockets. On-going training and the use of the latest CAD and ERP systems ensure our technological lead. We welcome our customers ideas. Suggestions for improvement and special requirements are implemented rapidly. Look into the serial production on joint spindle drilling machines at BW in the 1940 s. Since 01, BURKHARDT+WEBER has been part of Brazil s largest machine tool manufacturer, Indústrias Romi S.A. The first NC-controlled machining centre was delivered back in Transfer line with multi-spindle drilling heads for steering knuckle machining. 1

3 Quality The latest expertise, quality assurance, failure prevention and continuous training guarantee BURKHARDT+WEBER s high product quality. A closed quality control loop, into which all suppliers are integrated too, exists between Service, Design and Assembly. Every machine has to pass extensive endurance tests, which are recorded, before being delivered. Assembly halls and measuring rooms are air-conditioned to ensure precision manufacturing. All assemblies have their own test bays and have to pass strict pre-tests. We have, of course, been certified according to ISO 9001 for several years. Spindle test stand in the BW plant: Extensive tests prior to every delivery go without saying. Our high degree of vertical integration has paid off. It enables us to maintain our expertise, continuously develop our products further and ensure our consistently high quality. We produce all our components just-in-time. Made by BW means that all important core components are developed and manufactured in our plant. These include: machine bed and column, machining unit, machine table, tool magazine, pallet system, control cabinet, hydraulic unit, fixtures, special tools and special equipment. Controlled precision: Workpiece measurement in an air-conditioned measuring room. All important core components are developed and manufactured by ourselves. 3 4

4 No matter whether trucks, tractors, earth-moving machinery or mining opera- Cast or welded gearbox housing, narrow key dimensions and concentricities, Powerful Enduring tion vehicles, whether diesel engines, gearboxes, frames or axes, from small batch quantities through to volume production BW offers a turnkey solution on machining centres or, for higher batch quantities on special machines. as well as finely toleranced angular positions that s where the BW machine comes into its own. Rigid table drives with high handling quality and pre-loaded rotary table drives allow the precision cutting of deep bores. Prograed intermediate measurements, fixture technology, tool design and automatic loading systems everything from just one source. The high, longterm accuracy of BW machines guarantees a stable process for many years. Blind holes at depth are realised using the automatic tool extension. Every standard tool weighing up to 40 kg can thus be automatically extended by

5 Dependable Diesel engines from 6-cylinders, inline or as a V-Block, V 0 and V 4 engines with block lengths of up to 5.000, partial or complete machining, including crank and camshaft bores having supplied 160 machining centres, we boast a broad range of references. Special equipment such as facing slides, automatic boring bar changer, customised contact-actuated tools and series boring bars, complete fixture systems from BW. Efficient Deep compressor bores, interrupted cuts on screw compressors, the toughest and hardest materials such as Superduplex and laser-welded Inconel, deep bores with difficult lengths and diameters. We respond with a robust basic structure, e.g. with high-damping sliding guideways and machine frames from cast iron, high-performance and high-torque gear spindles and tool lengths of up to 1.00 in automatic changeover. 7 8

6 Precise Our specialist fields are general machine engineering and machine tool engineering. Diverse materials, a broad range of batch sizes and demanding accuracies call for powerful, precise and highly-flexible machining centres. Flexible Super-alloy steam turbine blades, large generator housing, wind-powered planetary gearboxes and cast hubs all components are expansive, difficult to machine and call for the utmost expertise. Numerous options permit optimised process design and hence the extremely efficient machining of small and medium batch sizes. The world s leading tool magazine with up to 570 tools and automatic pallet changing systems ensure maximum flexibility. Spindle drives with 4-step automatic gear units up to 80 kw and Nm permit effective machining of even difficult materials with large chip volumes. Weights of up to 40 tonnes can be loaded automatically via pallet changer, thus dramatically cutting set-up times. 9 10

7 MCX Roller-guided machining centres For optimised dynamics All MCX machining centres are powerfully dimensioned, feature high-torque gear spindles and have, on all axes, pre-loaded ball screw drives or a high-accuracy pinion rack drive. This guarantees high long-term accuracy, even while roughing in parallel with precision-machining. On all MCX models, we use generously dimensioned roller linear guideways in order to further guarantee long-term accuracy. Rapid traversing speeds of up to 60 m/min and accelerations of up to 5 m/s² offer high dynamics and guarantee short non-productive times. The cast gantry column offers especially high damping properties and thermal inertia. Installed at its gravitational centre are additional guide carriages for optimised load and power distribution. The large-scale machining centre MCX 100. Generously dimensioned roller linear guideways. Rock solid: heavy machine base design of the MCX series. 11 1

8 Technical Details MCX series MCX 750 MCX 800 MCX 900 MCX 1000 MCX 1100 MCX 100 MCX 1400 MCX 1600 MCX 000 Swing diameter Basic machine Working range X,Y, Z Working range X,Y, Z, optional Working range X,Y, Z, optional Workpiece swing diameter, diameter x height Pallet size, standard (similar to DIN 5501-A1/B1) Pallet size, optional Load (workpiece + fixture) Feed force X,Y, Z Rapid traverse X,Y, Z, standard axis travel Acceleration a, X,Y, Z kg kn m/min m/s / 900 / / / x x x 800 (800 x 800) / 17 / / 60 / 60 5,0 / 5,0 / 5, / / / 1.00 / x x x / 17 / / 60 / 60 5,0 / 5,0 / 5, / / / / x x x / 0 / 0 60 / 60 / 60 4,0 / 4,0 / 4,0.00 / / / / x x x / 0 / 0 45 / 60 / 60,5 / 4,0 / 4, / / / / x x x / 30 / / 45 / 45 4,0 /,5 /,5.800 / / /.00 / /.00 / x x x / 45 / 45,5 /,5 /, /.00 / /.500 / / / x x x / 45 / 45 1,5 /,5 /, /.00 / /.500 / / / x x x / 45 / 45 1,5 /,5 /, /.500 / / / / / x x x / 45 / 45 1,1 /,5 /,5 Rotary table B-axis, NC table Table speed Tilting torque Tangential torque, NC table degrees rpm Nm Nm Machining unit Spindle power 100% duty rating, (optional 4 gear steps) Torque 100% duty rating (optional 4 gear steps) Speed range (optional 4 gear steps), standard Speed range (optional 4 gear steps), optional Gear steps (optional) Bearing diameter main spindle (optional 4 gear steps) Tool adaptor, standard Tool adaptor, optional Tool clamping force HSK-A 100 (optional 4 gear steps) Tool clamping force, ISO 50 (optional 4 gear steps) kw Nm rpm rpm N N (3.500) (4.000) (6.000) (4) 10 (130) (55.000).000 (37.000) 1.0 (3.500) (4.000) (6.000) (4) 10 (130) (55.000).000 (37.000) 1.0 (3.500) (4.000) (6.000) (4) 10 (130) (55.000).000 (37.000) 1.0 (3.500) (4.000) (6.000) (4) 10 (130) (55.000).000 (37.000) Tool magazine Number of tool pockets Tool diameter, standard (bar tools) Tool length, standard (optional) 600 (750) 600 (750) Tool changer Tool weight (optional) kg Control Machine control, Siemens Machine data Floor space required l x w x h approx. Weight, approx. kg x x x x x x x 7.00 x x x x x x x x x x x

9 µ Basic version of the MCX 900 µ. Precision measurement of the machine geometry. Optimised precision with manual work: scraped guideway supports. µ series For extreme precision The µ series developed by BW is based on decades of experience garnered in the manufacture of high-precision machine tools. Increasingly precise components measuring just a few µ call for the highest-precision machining centres. BW has just the right solution its µ series. An inherently rigid, heavy machine bed with manually scraped linear guideways in accuracy class G0, coupled with temperature-controlled active cooling throughout the machine bed and machine frame provide the basis for optimised precision. All axis drives are water-cooled. In order to guarantee optimum temperature stability, the entire machine is made from materials with very similar thermal expansion coefficients. The machines are fitted with a stable, powerful high-performance spindle that has a water-cooled drive and hollow shaft motor. 3 kw of drive output and 610 Nm of torque at 100 % duty cycle permit effective precision machining. Ingenious sensor technology monitors spindle expansion, spindle temperature and fine vibration behaviour. The slightest changes are compensated in a matter of milliseconds. The machine table developed and manufactured by BW is fitted with high-precision axial roller bearings, a precision, backlash-free worm gear and lapped pallet supports. NC valves with minimal heat radiation are also installed. The lock valves are energised only during switching operations. All peripheral assemblies, including pallet changer and tool magazine, are from the tried and proven MCX standard series. Technical Details µ series MCX 750 µ MCX 900 µ MCX 100 µ Swing diameter Basic machine Working range X,Y, Z / 900 / / / / / Workpiece swing diameter, diameter x height x x x.100 Pallet size, standard (similar to DIN 5501-A1/B1) 630 x 630 / x x 1.50 Feed force X,Y, Z kn 17 / 17 / 17 0 / 0 / 0 5 / 5 / 5 Rapid traverse X,Y, Z, standard axis travel m/min Accuracies acc. to VDI/DGQ 3441 Positional uncertainty P, X,Y, Z 0,004 0,004 0,004 Positional deviation Pa, X,Y, Z 0,003 0,003 0,003 Positional uncertainty P, B Angular sec Positional deviation Pa Angular sec. Rectangularities X- to Z-axis µm/ X- to Y-axis µm/ Y- to Z-axis µm/ Machining unit Spindle power 100 % ED kw Torque 100 % ED Nm Speed range rpm All further features equal to the MCX series

10 MCR Slide-guided machining centres For the toughest requirements The MCR series is the perfect solution for all applications that call for heavy-duty machining with optimised damping properties coupled with high-accuracy precision machining. MCR machining centres are very strongly dimensioned and feature powerful gear spindles and over-wide sliding guideways on all axes. The sliding guideways guarantee very high long-term accuracy thanks to low surface pressures. The guideways are bedded in manually by experienced specialists and fabricated as sliding guideways on all sides. The cast gantry column offers especially high damping properties and thermal inertia and features long, wide guideways for guaranteeing high stability. The large-scale machining centre MCR 100. Generously dimensioned guideway design for optimised damping. Powerful: Machine base design of the MCR series

11 Technical Details MCR series MCR 750 MCR 800 MCR 900 MCR 1000 MCR 1100 MCR 100 MCR 1400 MCR 1600 MCR 000 Swing diameter Basic machine Working range X,Y, Z Working range X,Y, Z, optional Working range X,Y, Z, optional Workpiece swing diameter, diameter x height Pallet size, standard (similar to DIN 5501-A1/B1) Pallet size, optional Load (workpiece + fixture) Feed force X,Y, Z Rapid traverse X,Y, Z, standard axis travel Acceleration a, X,Y, Z kg kn m/min m/s / 800 / / 800 / x x x / 17 / 17,5 /,5 /, / 900 / x x x / 17 / 17,5 /,5 /, / 1.50 / / / x x x / 0 / 0,5 /,5 /,5.00 / 1.50 / / / x x x / 0 / 0 0 / 30 / 30 /,5 /, / 1.50 / / / x x x / 30 / / 0 / 0,5 / /.400 / / /.00 / /.00 / x x x / 0 / 0 / / 3.00 / / /.00 / /.00 / x x x / 0 / 0 1,5 / / /.00 / /.00 / /.00 / x x x / 0 / 0 1,5 / / /.500 / / / / / x x x / 45 / 45 1,1 /,5 /,5 Rotary table B-axis, NC table Table speed Tilting torque Tangential torque, NC table degrees rpm Nm Nm Machining unit Spindle power 100% duty rating, (optional 4 gear steps) Torque 100% duty rating (optional 4 gear steps) Speed range (optional 4 gear steps), standard Speed range (optional 4 gear steps), optional Gear steps (optional) Bearing diameter main spindle (optional 4 gear steps) Tool adaptor, standard Tool adaptor, optional Tool clamping force HSK-A 100 (optional 4 gear steps) Tool clamping force, ISO 50 (optional 4 gear steps) kw Nm rpm rpm N N HSK-A 100, DIN HSK-A 100, DIN HSK-A 100, DIN HSK-A 100, DIN HSK-A 100, DIN (3.500) (4.000) (6.000) (4) 10 (130) HSK-A 100, DIN 9893 (55.000).000 (37.000) 1.0 (3.500) (4.000) (6.000) (4) 10 (130) HSK-A 100, DIN 9893 (55.000).000 (37.000) 1.0 (3.500) (4.000) (6.000) (4) 10 (130) HSK-A 100, DIN 9893 (55.000).000 (37.000) 1.0 (3.500) (4.000) (6.000) 10 (130) (55.000).000 (37.000) Tool magazine Number of tool pockets Tool diameter, standard (bar tools) Tool length, standard (optional) 600 (750) 600 (750) 600 (750/1.000) 15 /.350 (40) 600 (750/1.000) Tool changer Tool weight (optional) kg Control Machine control, Siemens Machine data Floor space required l x w x h approx. Weight, approx. kg x x x x x x x 7.00 x x x x x x x x x x x

12 Machining unit -step Powerful gear spindles up to 5 kw and.000 Nm. Speeds of between and rpm are available for machining operations using the latest technologies. 4-step Powerful gear spindles up to 80 kw and Nm for heavy-duty machining. Heavy bearing assembly with speeds of up to or rpm. Machine table NC machine table Only NC tables we develop and produce ourselves are used in our machining centres. The pallet loading capacity ranges from kg to kg. Especially high tilting and tangential moments with low table construction and generously-dimensioned bearing arrangement guarantee optimised machining performance and outstanding geometric results. From a pallet load of kg, only hydrostatically-beared NC tables are used. Horizontal/vertical swivel head NC-controlled with two gear steps. Swivel time 1,8 sec at full speed up to rpm. 5-axis simultaneous machining up to 56 kw and.000 Nm. Complete machining of precision components in a single set-up. Quill With -step gear unit up to 60 kw,.000 Nm and rpm. Optionally, there are quills in 130 with 700 extended length or 160 with extended length. A-axis With -step gear unit up to 50 kw,.000 Nm and rpm. Demanding machining operations in practically all angular positions in combination with the NC table axis. Milling/turning table We offer MCX series machining centres up to MCX 100 as combined milling/turning centres. Powerful torque drives up to 500/min ensure effective machining in milling and turning operation. The integrated balancing software and special imbalance sensor technology offer optimised protection. When using turning tools, the main spindle bearing is uncoupled from the tool adapter during the machining operation. This stops any pulses impacting the high-quality spindle bearing arrangement. Rotary/tilting table For simultaneous 5-axis machining, we offer both our swivel head and a rotary/tilting table for the MCX series. This rotary/tilting table comprises a bridge clamped between two NC reversible clamping devices and the inserted NC table unit. 1

13 Tool magazine The modular, highly-flexible tool magazines have a maximum capacity of 570 tools at traversing speeds of up to 00 m/min. Tool lengths up to 1.00, 75 kg change weight and 900 diameter for boring bars cover practically every requirement when it comes to the choice of tool. The automatic detection of the tool tilting moment and weight, processoptimised loading and unloading, use-based advancement and an extensive tool management system ensure the operator works with a high degree of comfort. Each and every magazine can be individually equipped at the time of ordering. Years later, it is also easy to retrofit and expand as required. There are three versions to choose from For series production: our basic version with 180 tool pockets For machining workpiece families: the tool magazine with up to 330 pockets For a broad component spectrum: the large tool magazine offering maximum flexibility and up to 570 tool pockets The tool magazine is loaded and unloaded during machining time efficiently and ergonomically by a loading station with x 7 pockets. Operator and magazine robot operate completely independently of each other. A highlyadvanced tool magazine management system and a 19 touchpanel support the operator for all inputs. For special applications, we develop customised solutions like the automatic feed device for extra-long line boring bars up to in length or additional magazines for rapid change of special tools weighing up to 500 kg. For our tool magazines, numerous options are available. These include automatic cleaning of all tools, break and wear monitoring and the storage of special tools. 3 4

14 Automation Pallet changer All BW machining centres are equipped with a double pallet changer. This enables ergonomic setting-up during machining. Load-dependent speeds and servo-driven links ensure a fast pallet change. Special purpose machines Our special purpose machines and interlinked overall systems are geared towards meeting our customers requirements for a high output, optimised quality and efficient ergonomics. The durable, customised designs are based on a modular system. Pallet pool Smaller batch sizes can be cost-effectively completed by a pallet pool. Up to six pallets are managed in the system. An automatically rotating set-up station permits the use of clamping cubes and enables clamping/unclamping at any position. 3rd and 4th pallet changing station In the case of more than two set-ups or an unmanned third shift, the economic solution is a 3rd or even a 4th pallet changing station. This provides several autonomous set-up stations. Simple integration into high-rack systems Every one of our machining centres can simply be integrated into modern high-rack systems for workpiece automation. Experience and technology combined guarantee maximum productivity. We realise well-proven special solutions for the manufacturing task at hand. Single or multi-spindle, CNC-controlled modules are employed for flexible production. Precision machining operations are monitored by modified measuring equipment and, where required, also by controlled cutting edge compensations. Our proprietary, special-purpose machines are used predominantly in industries with high annual volumes and tight tolerances, such as coercial vehicle production for making crankcases, cylinder heads, gearbox housings or conrods. Linear interlinking systems The integration of multiple machining centres into a BW own rail-guided interlinking system permits unmanned operation. Special equipment options, including height-adjustable or tilting loading stations, barcode systems etc. dramatically increase a system s productivity. 5 6

15 Strong service Hotline and remote diagnostics Order acceptance and expert advice given over our Hotline. Thanks to fast online connections to the BW machine, the customer has its diagnosis in no time at all. Our service technicians guarantee to provide on-site support to our customers. Our customer service team can access a machine s data and functions via remote diagnostics. Maintenance To avoid production outages, we maintain installed machines according to a comprehensive checklist. We also offer full maintenance contracts that can be tailored to your needs. Spare parts The computerised, central stock of spare parts guarantees short lead times. A dedicated spare parts team offers expert advice and, in urgent cases, consignments are dispatched within 4 hours by Express. Reliable service technicians working all over the world. BW supports its customers exclusively through its own service technicians. The computerised stock of spare parts guarantees short lead times. 7 8

16 Good advice all round Training BW training courses are structured to suit machine type and customer. All courses are run by qualified training managers and consolidated through practical courses on machine and test control systems. Technology Experienced engineers in our technology department possess a broad knowledge of machining, and provide expert support for process design and optimisation. We optimise tool technology and design manual as well as hydraulic fixtures to suit customers specific needs. Retrofit Our experienced specialists overhaul, retrofit and modernise your existing system. BW machines remain intact, even after prolonged running times. The original efficiency is restored, modern systems are installed for monitoring purposes and performance is enhanced through improved controls. Well-trained users are motivated users who are able to identify with their task. Manufacture of complex fixtures. Process optimisation through advice from our technology experts. 9 30

17 BURKHARDT+WEBER Fertigungssysteme GmbH Postfach Reutlingen, Germany Burkhardt+Weber-Straße Reutlingen, Germany Tel Fax Deutsch, August 01, Indústrias Romi S.A. Rod. SP 304, Km 141,5 Santa Bárbara d Oeste SP Brazil Tel Fax export-mf@romi.com Romi Machine Tools, Ltd Airport Exchange Blvd. Erlanger KY 41018, USA Tel Fax sales@romiusa.com BURKHARDT+WEBER / ROMI (Shanghai) Co., Ltd. Room 50 B, Bldg.10, Lane 198, Zhangheng Road Zhangjiang High-Tech Zone 0104 Shanghai, P.R. China Tel Fax info@cn.burkhardt-weber.net