Technical Description Portal type Milling Machine Type PFM Portal Milling Machine type PFM 36 make ROTTLER
Page 2 Technical Description Portal Milling Machine type PFM 36 1. Technical data 1.1 Milling unit Spindle power (S1-mode) Spindle power (S6-mode) Spindle speed (maximum) 36 kw 47 kw 24,000 RPM 1.2 Machine axis (PFM 36 / 15 NC) X-axis (machine table) Maximum travel 15.800 mm Rapid speed 20.000 mm min -1 Speed range 0-6.000 mm min -1 Torque 200 kn Y-axis (vertical slide) (ball screw 100 x 20) Maximum travel 3.000 mm Rapid speed 8.000 mm min -1 Speed range 0-6.000 mm min -1 Torque 50 kn Z-axis (milling unit) (ball screw 80 x 20) Maximum travel 1.000 mm Rapid speed 8.000 mm min -1 Speed range 0-4.000 mm min -1 Torque 50 kn W-axis (adjustable cross beam) Maximum travel 1.000 mm Speed range 0 2.500 mm min -1 1.3 Milling unit Tool holder Taper HSK A 63 as per DIN 69871 Clamping bolts as per DIN 69872 tool clamping force 19 kn 1.4 Machine table Machine type PFM 36 / 6 NC width 3,000 mm length 6,000 mm table load maximum 5 to/m distance of T-slots in cross direction 160 mm
Page 3 Technical Description Portal Milling Machine type PFM 36 Machine type PFM 36 / 8 NC width 3,000 mm length 8,000 mm table load maximum 5 to/m distance of T-slots in cross direction 160 mm Machine type PFM 36 / 15 NC width 3,000 mm length 15,000 mm table load maximum 5 to/m distance of T-slots in cross direction 160 mm 1.5 Electrical connection Voltage 3 x 400 V 50 Hz Total connection load approx. 180 kva
Page 4 Technical Description Portal Milling Machine type PFM 36 2. Description 2.1 General The portal milling machine PFM 36 / 15 NC is specially designed for high quality machining operations. Three position-controlled NC axes (X-, Y-, and Z-axis) enable machining of any path contour including circular milling. In addition, the machine features a W-axis to move the crossbar. By adding a variety of vertical milling heads the machine can be extended to 5 axles. Up to 2 milling heads (more to be discussed during next meeting) can be placed at a pickup station. The very rigid construction of the machine enables economic performance also in extreme working positions and with the slider extended. For superior machine rigidity and guide precision, all linear axles are provided with generously dimensioned slide ways. X- axis: hydrostatic slide ways Y- axis: combined slip-in/anti-friction slide ways W-axis: slide-controlled Z- axis: slide-controlled This concept has an extremely positive effect on the static and dynamic characteristics of the machine. The Y-, W- and Z-axes are equipped with generally dimensioned ground ball caster spindles complete with a backlash-free, pre-stressed nut and counter-nut. The table drive operates via two contra directionally braced pinions. To actuate the milling spindle, the system includes an A/C main spindle drive in combination with an automatically controlled two-stage anti-torsion epicyclical gear. The basic design of the drive enables customized configuration with different basic setups for the speed/torque ration. For the linear axles, only linear measuring systems using seal air are applied. High precision is warranted in combination with the backlash-free, pre-stressed drive elements. Electrical equipment in accordance with VDE 00113 for three-phase alternating current, 400 V operating voltage, 50 Hz, 230 V control voltage, control cubicle IP 54. The main spindle drive is a frequency-controlled three-phase motor (AC), make Siemens, type of enclosure IP 54. (Caution: Verify voltage variations in China!) The system includes a Siemens SINUMERIK CNC 840 control system to achieve a consistently digital concept in combination with the integral drives.
Page 5 Technical Description Portal Milling Machine type PFM 36 2.2 Bed plate with X drive Bed in steel-welded construction, stress-relieved, The bed consists of 4 sections which are geometrically adjusted to fit at the relevant joints (shaped; wide joint faces for forward travel transmission) bolted and pinned. Joint faces sealed with round cord (Viton) Slide way paths complete with bonded, hardened and ground steel strips (HRc 60+2) Spacious, narrow slide way Oil collecting conduit for hydrostatic/leak oil feedback Positive and friction-type connection between drive unit and bed for table operation; backlash of tooth profile by means of V-ledges Drive unit comprising two servomotors with driving pinion; backlash by means of integral electronic restraint Axle drive motors: 1 FT6, Siemens, water-cooled (to exclude thermal effect on bed geometry) Constant temperature maintenance for both axle drives by means of compressor cooler (make Hydac) Linear incremental path measuring system for X path recording (by means of seal air supply) Protection of bed slide ways by means of telescopic steel plate covers Bed and foundation joined by means of foundation anchors (BW fixation); 500 mm fixation pitch; Positive and friction-type connection between the bed and support portal by means of robust brackets in steel-welded construction Bed length: approx. 31,000 mm (PFM 36 / 15 NC) 2.3 Machine table Machine table in cast iron construction, superior rigidity due to stable ribbing Table length: 15,000 mm (PFM 36 / 15 NC) Table in two sections; joints geometrically adjusted to fit by means of scrapers Both table sections bolted and pinned Table clamping surface provided with slots for assembly of magnetic holding plates and hydraulic tensioners
Page 6 Technical Description Portal Milling Machine type PFM 36 o 7 T slots; T slot pitch b= 160 mm in accordance with DIN 55200; edge spacing b R = 145 mm o centre T slot intended as standard guide slot; T slot 28 H8 DIN 650 o all other slots in accordance with T slot 28 H12 DIN 650 Hydrostatic table slide way Slide way path coating: Bi-Plast, including narrow slide way, bonded Milled hydrostatic pockets Narrow slide way and counter grips with V-ledges for backlash adjustment Helically geared, hardened and ground toothed rack for table motion (X axis) Oil supply via multiple circuit pump system complete with oil flow monitoring Added protection of slide ways by means of double scrapers Cable drag chain to ensure power supply 2.4 Machine columns complete with cross tie and W axis (for adjustment of cross beam) Machine support in cast iron construction Finely milled slide way paths Both supports joined with foundation by means of foundation anchors (BW fixation) Connecting cross ties in steel weld construction, stress relieved Cross tie complete with drive unit for crossbar adjustment Cross bar adjustment under gantry operation Both drive units comprising three-phase servo motors complete with angular gear box as well as the two pre-stressed (backlash-free) ball screw Drive motor: 1 FT6, Siemens, servo unit with integral break; brake power control Two absolute, linear path measuring systems for gantry axles Slide way path protection below cross tie by means of steel plate cover Slide way path protection above cross tie by means of a bellows cover 2.5 Cross beam with Y-axis Cross beam made from gray cast iron with optimal cross section and large slide way path spacing (1,300 mm) Finely milled slide way paths Upper end of narrow slide way and upper counter grips equipped with hardened and ground V ledges
Page 7 Technical Description Portal Milling Machine type PFM 36 Y axis drive via ball screw with pre-stressed nut and counter-nut Drive motor: 1 FT6, Siemens, with brake, brake power control Absolute, linear measuring system for Y axis (by means of with seal air) Telescopic slide way path covers for slide way cover protection (Y axis) Counter slide way of W axle coated with Bi-Plast, shaped slide way Oil lubrication via piston distributor (central oil lubrication, make Vogel) Additional hydraulic clamping of W axle; control by means of path seat valves to compensate leak oil losses via pressure fluid receiver; clamping function monitoring via electronic pressure switch Protection of W slide way by means of double slide way path scrapers 2.6 Table bed and (2) milling units with Z axis Table bed and milling unit with integral Z axis in cast iron construction Table bed guided on crossbar by means of combined slip-in/anti-friction slide ways, significant reduction of frictional forces due to integral roller circulating elements in the narrow slide way (compensation of weight forces) Counter slide way of Y axis coated with Bi-Plast, shaped slide way Oil lubrication via piston distributor (central oil lubrication, make Vogel) Protection of Y slide way by means of double scrapers Table bed drive (Y axis) via ball screw with pre-stressed nut and counter-nut Z axis (slip-in type slide way) with largely dimensioned spaces for low surface pressure also in case of extreme pull-out torques, lubrication via piston distributor Milling scraper with generously dimensioned steel block V ledges (hardened and ground) positive and friction-type bolting on both sides, Counter slide way of Z axle coated with Bi-Plast, shaped slide way Z axis drive via ball screw with pre-stressed nut and counter-nut Drive motor: 1 FT6, Siemens, with integral brake, brake power control Absolute, linear measuring system (Z axis) Hydraulic weight compensation for Z axis
Page 8 Technical Description Portal Milling Machine type PFM 36 Main drive with A/C main spindle drive and two-stage epicyclical gear (hydraulically actuated) Torque transmission via helically geared and ground spur gear drive Circulating lubrication of gear stages incl. cooling by means of external cooling system; Spindle system in torsion-free construction for superior rigidity; storage in largely dimensioned precision anti-friction bearings Spindle diameter Ø 220 mm Spindle with integral hydraulic tool feeder system SK 60 in accordance with DIN 69871 / 69872, make OTT Complete with connection for quick-release taper purging (spindle standstill) (mechanical working) Automatic feeding for angular or add-on heads (anti-friction type via Cytec tensioner, slip-in type via Hirth ring) complete with media transfer Scraper with integral C axis 2.7 Milling head Various types of milling heads are available. More detailed information to be submitted later. 2.8 Tool changer (2 pieces) for 40 tools (additional number of tools to be discussed) Tool changing system provided as a chain type system Number of tools 40 Tool holding HSK A63 Including changing unit and angle control Changing position horizontal Chain pitch 140 mm Tool width (single tool), maximum 315 mm
Page 9 Technical Description Portal Milling Machine type PFM 36 Tool weight, maximum Tool length, maximum Total weight of all tools, maximum Maximum weight for loading only one side 40 kg 400 mm 1.600 kg 600 kg 2.9 Pick-up-station Pick-up-station provided to accommodate the angular heads. Rigid unit with complete housing provided to accommodate the milling head. With support and indexing bolts for placing the heads in the right position. 2.10 Hydraulic Hydraulic unit consisting of hydraulic tank, pumps, filter, valve system, safety valves, surveillance unit and piping provided for the following functions: Weight relief Z-axis
Page 10 Technical Description Portal Milling Machine type PFM 36 Clamping cross beam (W-axis) Clamping milling unit (Z-axis) Gear boxes Tool clamping main spindle Cytec-clamper for additional heads Tool clamping additional head Axis clamping angular head Hydraulic equipment, make BOSCH/REXROTH Control voltage of magnets 24 V DC Valve plugs with LED-display Hydraulic oil: ISO VG 46 2.11 Hydrostatic (X-axis) Hydrostatic unit for supply to: o Hydrostatic guide ways in X- axis o Lubrication rack and pinion as well as X-axis drive Consisting of tank, pump unit, filter, pressure and flow controllers Provided as multi-circuit pump system (1 pump per pocket); make Vogel Pre-pressure pump for supply to the multi-circuit pumps Back-flow tanks mounted at the end oft he bed with pumps and electrical level switches hydrostatic oil: ISO VG 46 2.12 Path lubrication (W /Y /Z axis) Path lubrication for W / Y / Z axis, nuts of KGT W-, Y-, Z axis lubricated via Vogel central lubrication plant with piston distributor, pressure switch for p max and p min at the end of each line, special axle lubrication Separate lubrication system for each axle central lubrication supply system Gear pump system MFE5 complete with 6 L metal container volume flow 0.5 l/min Electric monitoring of minimum filling volume Oil viscosity: ISO VG 220 (bed path oil)
Page 11 Technical Description Portal Milling Machine type PFM 36 2.13 Pressure lubrication / cooling main drive Pressure lubrication, temperature stabilized, of main gear box as well as planetary gear box Oil flow to planetary gear box oil back flow planetary gear box oil filling screw main gear box Abb.: main drive with planetary gear box Oil level gauge minimum electrical Optical oil level gauge Oil volume : 40 liter Oil viscosity: ISO VG 46 Abb.: oil cooler with oil filter and temperature sensor for lubrication of main drive and gear box
Page 12 Technical Description Portal Milling Machine type PFM 36 2.14 Cooling system Temperature maintenance on both water-cooled servo drives of the x drive Compact compressor cooling system Cooling medium: water/glycol mixture Integral circulating pump with storage tank Safety and control equipment Precise tempering of cooling medium by means of microprocessor-controlled technology Metal filter grid at air inlet Alarm annunciation as a potential-free contact for availability 2.15 Taper purging / Cooling lubricant supply 2.15.1 Basic design Taper purging (spindle standstill) with compressed air p max = 10 bar Axial compressed air supply through spindle for tool cooling (spindle rotating); p max = 5 bar 2.15.2 Coolant supply (optional) Optional: internal or external coolant supply Interlinked valve system with check valves to regulate tool tensioner (discharge air/kss) Cooling lubricant supply unit with tank of 2,000 L useful volume, level switch, paper band filter, pump: approx. 20 L/min at 60 bar max. Pressure switch, volume flow monitor Millings conveyor suited for cooling lubricant supply; joints sealed by means of round Viton cord Transverse conveyor design with pass-over container, lifting pump and level switch 2.16 Chip conveyor chip conveyors assembled on either side of the bed; Apron-type conveyor, straight design, without discharge neck Robust, wear-resistant high capacity roller chain Slide ways coated with special wear-resistant steel (Creusabro)
Page 13 Technical Description Portal Milling Machine type PFM 36 Bolted flange connection Feed width 230 mm, Feed length approx. 16 m (PFM 36 / 15 NC) Both millings conveyors supply millings into a container positioned in a pit at the bed end Drive monitored by means of over-current relay and run control 2.17 Pneumatics Series-connected refrigeration air drier (Ultrafilter) for compressed air demisting Machine equipped with pneumatic control elements (maintenance units, pressure reducing valves, pressures switches) for compressed air supply for: Taper purging Seal air measuring systems Pneumatic equipment, FESTO, BOSCH/REXROTH Valve plug with LED Additional special maintenance unit DA 300 (Heidenhain) to monitor airflow for seal air treatment 2.18 Machine color Finish in dual-pack paint Customized RAL No. Unit parts requiring enhanced attention by the operator are coated with special paint.
Page 14 Technical Description Portal Milling Machine type PFM 36 3. Electrical equipment / control 3.1 Scope of supply electric cabinet and control panel complete wiring of the machine Siemens Sinumerik 840 D machine control system, Simodrive 611 D, Simatic S7-300 measuring systems (linear, rotary encoders) make HEIDENHAIN cable chain for X-/Y- and Z- axis integration of tool changer and chip conveyor (if required Option) run-off and acceptance test in your facility 3.2 Electrical equipment power connection: 400V AC / 3 phases / 50 Hz cable length between machine and electric cabinet maximum 10 meters electric cabinet, dust proof, maximum length of cabinet 7.500 mm cooling unit for constant temperature inside electrical cabinets, door mounted auxiliary power 230 V (AC) control power DC 24 V only cables coated with PUR (make LAPP) are used keys and relays, make SIEMENS main spindle drives, AC motors, make SIEMENS axis drives make SIEMENS, digital AC motors, self cooled; X-axis water cooled Emergency stop buttons, provided with protection against faults use Electric cabinet, make Rittal: In accordance with VDE 0113 respectively EN 60204-1. The electric cabinet is completely wired and tested. Cable inlet through bottom of the cabinet. The cabinet is dust proof at doors and cable sockets. Spare space inside cabinet of minimum25 per cent provided. Each section of the cabinet is provided with lightning and service socket. Main switch can be locked. The electric cabinet is divided into a power section and a control section. Provided with service hour meter.
Page 15 Technical Description Portal Milling Machine type PFM 36 Power section Power unit is provided with feed for main drive, all axis drives as well as for the various rotary current drives. SIEMENS Simodrive 611 D for axis and spindles. Supply unit for the drives consists of filter package (net filter with ripple filter choke), regulated in- and out-put unit with over voltage trip-out. Power module including control units for axis and spindles. Control section Control unit PCU PCU 50.3 Sinumerik CNC control type 840D/DE with SPS S7-300 control panel SIEMENS OP 015 / TFT CNC keyboard SIEMENS KB 483C CNC machine control panel SIEMENS 19 MCP 483 control panel housing made from steel sheets, vertical operation panel
Page 16 Technical Description Portal Milling Machine type PFM 36 handheld control panel B-MPI with electronic hand wheel Control NCU Sinumerik CNC control NCU with integrated PLC; PLC control S7-300 Racks and decentralized peripheral units ET200M/S with inlets and outlets, extension with modular E/A system is possible, coverage of all machine signals external signals are handled by decentralized units via BUS system (Profibus- DP) Interface for data transfer Profibus-DP/MPI interface COM, LPT, SYN-DNC Ethernet 10/100 Mbit/s disc drive 3,5, USB 1.1 Control panel Model Rose mounted vertical control panel can be swiveled 3.3 Additional components provided with diagnostic system for connection via internet; phone line provided by customer 3.4 Software / documentation circuit diagrams, electrical parts list, Providing of PLC-programs PLC-programs stores on disc,
Page 17 Technical Description Portal Milling Machine type PFM 36 Programming machine data Language of control software German (additional languages upon request possible) Run-off and optimizing of axes and spindles Providing error messages 4. Documentation Scope of supply provided by Rottler (3 paper copies and 1 copy on CD): The preliminary documentation will be handed over at start-up of the machine, the final version will be provided latest 8 weeks after final acceptance and handed over tot he customer. Electrical documentation (please refer to point 3.4), Assembly drawings with part numbers, Operator manual, CE-certification, Service manual, Lay out plan with load plan, Spare and wear parts list, Hydraulic plan and parts list, Pneumatic plan and parts list, Lubrication plan, in German language 5. Training training of maintenance personnel during assembly and start-up phase (1 week => detailed planning and fixing of date during project work) operator personnel trained during start-up phase (1 week) 6. Machine acceptance / installation and start-up of machine 6.1 Pre-acceptance pre-acceptance at Rottler in Mudersbach acceptance of machine geometry including acceptance protocol Positioning accuracy as per VDI DGQ 3441 for all axes
Page 18 Technical Description Portal Milling Machine type PFM 36 Function test of the machine including of all safety units Function test, no performance test 6.2 Installation and start-up of machine The installation of the machine at customers facility will be done by customers personnel, under surveillance of two specialist provided by Rottler. It is included in the basic machine price. The customer will provide skilled mechanical and electrical personnel, to set-up the machine under guidance of the Rottler-engineers. Accommodation costs will be born by customer during installation and start-up phase of the machine in Poland. 6.3 Final acceptance The final acceptance of the machine will be carried out directly after finish of the machine assembly at customer s site. Final acceptance will be carried out by Rottler personnel. Function test It will be checked, that all technical data is provided in accordance with the specification of the machine fixed in the contract. Further details to be discussed during next meeting. 7. Labeling and machine certification The machine will be provided in accordance with the latest international standards. CE-certificate will be provided with the machine documentation.
Page 19 Technical Description Portal Milling Machine type PFM 36 Reference list portal type milling machine (new machines and modernization) CUSTOMER COUNTRY MACHINE TYPE Stahlbau Krämer, Siegen Deutsche Edelstahlwerke, Witten Deutsche Edelstahlwerke, Witten Germany Modernization machine make Droop + Rein PROJECT NUMBER M 956 Germany ZF 3 / 120 NC KM 999 Germany ZF 3 / 120 NC KM 1000 Gröditzer Stahlwerke Germany Convertion planing machine to milling machine Airbus, Varel Germany Modernization machine make Droop + Rein BWG, Butzbach Germany Modernization machine make Waldrich Coburg Deutsche Edelstahlwerke, Witten Germany Modernization machine make Reichel & Knödler Airbus, Varel Germany Modernization machine make Waldrich Siegen BWG, Brandenburg Germany Modernization machine make Waldrich Siegen Dieffenbacher, Eppingen Deutsche Edelstahlwerke, Witten Deutsche Edelstahlwerke, Witten Deutsche Edelstahlwerke, Witten Germany Germany Germany Germany Modernization machine make Waldrich Modernization machine make Rottler Modernization machine make Bohle Modernization machine make Ingersoll Bohle KM 1167 KM 1222 KM 1224 KM 1228 KM 1232 KM 1244 KM 1253 KM 1100 KM 1282 KM 1285 Customer in China China PFM 100 / 15 NC KM 1292
Page 20 Technical Description Portal Milling Machine type PFM 36 CUSTOMER COUNTRY MACHINE TYPE BWG, Gotha Germany Modernization machine make Boehringer Heupel, Wilnsdorf Germany Modernization machine make Fritz Werner PROJECT NUMBER KM 1297 M 2453