Presentation To

Honda Car s India . Ltd

Date: 16/01/2013
Machine order Details
Machine Name No of machines
MCV 650-50
For Cylinder Head 2
For Cylinder Block 4
CMH 500-40

For Machine Case 6

Total No of Machines 12
MCV650-50
MACHINE DESCRIPTION

AMS Machining Center–Vertical–MCV 650-50 is a general purpose, flexible, productive & Robust
machine equipped for working to cater different kind of prismatic / circular components and suitable
for tool rotating and job stationery process.
The machine is equipped with a tool magazine and with a twin arm Automatic tool changer to
increase the productivity by cutting down the unproductive time.

MACHINE CAPACITY
This Machine can be used for face milling, drilling, slot milling, rough boring, precision boring
profile slot milling, tapping etc.,

 Worktable size : 650mm x 1200 mm

 Job loading height : 1040mm
 Maximum load on table : 800Kg
MCV650-50 machine layout
MCV650-50 Specification
Description Unit MCV-650-50

TABLE
TABLE SIZE mm 1200 x 650
NxWx
T-SLOT DIM. 6 x 18 x 100
P
MAX. LOAD ON TABLE Kgf 800
DIST. FROM FLOOR TO TABLE TOP mm 940

MACHINE CAPACITY
X - AXIS TRAVEL mm 1020
Y - AXIS TRAVEL mm 650
Z - AXIS TRAVEL mm 600
DIST. FROM SPINDLE FACE TO TABLE TOP mm 140 - 740
DIST. FROM SPINDLE CENTER TO COLUMN
mm 715
GUIDEWAYS
COOLANT SUPPLY - FLOOD COOLANT AROUND
lpm 60
THE SPINDLE
 Description Unit MCV-650-50
SPINDLE
SPINDLE NOSE TAPER 7 / 24 No.50
SPINDLE SPEED - INDIRECT DRIVE rpm 50 - 5000
SPINDLE BEARING DIAMETER mm 100

FEED
RAPID TRAVERSE X, Y & Z AXES m / min. 40 / 40 / 30

CUTTING FEED mm / min. 1 - 10000

GUIDEWAYS FOR X, Y & Z AXES Linear Motion

AUTOMATIC TOOL CHANGER

NUMBER OF TOOLS - STD. Nos. 20
MAX. TOOL DIA mm 125
MAX. TOOL DIA. WITH ADJACENT POCKETS EMPTY mm 250
TOOL SELECTION Bi - Directional
TOOL LENGTH MAX. mm 350
TOOL WEIGHT MAX / TURNING MOMENT MAX. Kg / NM 20 / 30
CHIP TO CHIP TIME (WITH Z ONLY / WITH X & Y ALSO) Sec. 6.8 / 9.4
TOOL CHANGE SYSTEM Twin Arm
TOOL SHANK TYPE BT-50

PULL STUD TYPE DIN 69872 Form-B

 Description Unit MCV-650-50

ACCURACY WITH ROTARY ENCODER

POSITIONING FOR X, Y & Z AXES AS PER VDI DGQ 3441 mm 0.015

POSITIONING FOR X, Y & Z AXES AS PER ISO 230-2 mm 0.010

REPEATABILITY FOR X, Y & Z AXES AS PER VDI DGQ 3441 mm ± 0.005

REPEATABILITY FOR X, Y & Z AXES AS PER ISO 230-2 mm ± 0.003

MOTORS

SPINDLE POWER 30 MIN./CONT. (FANUC) - αP40 MOTOR kW 22 / 18.5

FEED MOTOR X, Y & Z AXES (FANUC) Nm 22 / 22 / 30

 Special features
ADDITIONAL FEATURES - MECHANICAL
FLOOD COOLANT SYSTEM AROUND THE SPINDLE
CHIP FLUSHING SYSTEM ON THE BASE
COOLANT GUN
GUARDING TO ACCOMMODATE HSCI SPECIALS
FRONT AUTO DOOR (MANUAL CLOSE & AUTO OPEN)
LIMIT SWITCH FOR AUTO DOOR OPEN CONFIRMATION
UPPER /LOWER LIMIT BY A FLOAT SWITCH FOR COOLANT LEVEL
CONCEALED TYPE CARRYING HANDLE FOR ENCLOSURE (WHEREVER POSSIBLE) FOR
MAINTENANCE PURPOSE
OIL SKIMMER (UPT MAKE WITH BONIFIGLOLIO MOTOR)
SAFETY SWITCHES FOR ALL DOORS WITH BY PASS IN THE ELECTRICAL CABINET
AIR GUN FOR CLEANING COMPONENTS OUTSIDE THE MACHINE
SEAT CHECK BY-PASS SWITCH INSIDE THE CABINET
OPERATOR CONTROL PANEL - FANUC MAKE

SMC PNEUMATIC ELEMENTS IN LIEU OF FESTO

HYDRAULIC HOSES - GATES MAKE
HYDRAULIC FITTINGS - HYLOCK MAKE
PRESSURE GAUGES - WARRIE OR DP MAKE [UNIT- MPA, METAL BODY,GYL. FILLED,]
PNEUMATIC VALVES - SMC MAKE VQ7 SERIES [COIL VOLTAGE - 24 V DC]

PNEUMATIC CYLINDERS - SMC MAKE [SHOULD BE COOLANT PROOF ITS IN COOLANT

EXPOSED AREA]

AIR TUBING - SMC MAKE TU SERIES

PNEUMATIC FITTINGS - SMC MAKE
PNEUMATIC FITTINGS - SMC MAKE
TIMING & V-BELT - GATES MAKE
ROTARY JOINT - DEUBLIN MAKE
BEARING - FAG / NTN MAKE & FOR SPINDLE NSK MAKE CAN BE USED
NEEDLE BEARING - IKO / NTN MAKE
CAM FOLLOWER - IKO / NTN MAKE
BALL SCREW - TSUBAKI MAKE
LM GUIDEWAYS - SCNEEBERGER MAKE
OIL SEALS & O-RINGS - SIMIRIT / NOK MAKE (STANDARD) / EQUIVALENT MAKE (SPECIAL)
FLOW SWITCH - IFM MAKE
ACCUMULATOR – EPE MAKE
OIL / COOLANT LEVEL GAUGE - VIDYUTH MAKE
COUPLINGS - MAYR MAKE.
 Machine configuration
X -Axis longitudinal SLIDE
The longitudinal slide is a table having T slots for clamping the
fixtures.

The table is having enough area for mounting the fixtures.

The slide will move on the Linear Motion guide ways mounted on
cross-slide (saddle)
y -Axis cross SLIDE

The cross slide which carries the Preloaded LM guide

ways for longitudinal slide (X axis) is made up of close
grained cast iron. (Grade 30)
The slide will move on the Preloaded LM guideways
mounted on the base.
X &y drive assembly
Vertical slide (z-axis)

The vertical slide which carries spindle assembly and is made up of close
grained cast iron.
The vertical slide has extremely rigid housing design adding to stability and
free from vibration. The optimal distance between spindle centre and slide way
makes the spindle to be unaffected due to any thermal deformation.
The slide moves over the Preloaded LM guide ways mounted on the column.
 The weight of the vertical slide is continuously balanced both in static and
dynamic conditions by means of HYDRAULIC counter balancing.
Z axis DRIVE assembly
X & y axis stroke setting
550
Machine setting parameters

550
Z -Axis
HEAD STOCK ASSEMBLY
Pulley and motor mounting
Belt drive selection procedure

1.Power requirement and type of driveN machine

2. The rpm of the driveR machine
3.The rpm of the driveN machine
4. The approximate centre distance for the drive
5.Hours per day operation

Calculation
L = (2 *285) + π/2 (59+59)*8/ π + {(59-59)*8/ π}2 /(4*285)
Spindle motor = αP40
Power = 18.5/22 kW
Base speed = 575 rpm ( Say 600 rpm)
Now, Speed of the faster pulley (v) = πd N/60,000 , where ‘d’ is the diameter of pulley
from data handbook , Vmax = 40m/s
For 56 teeth, power = 9.36 kW @ 600rpm/20 mm belt width
design power = 1.6 (FOS) * 22 kW (Max power of motor)
= 35.2
For 60 teeth power @ 575 rpm= 35.2/9.61 = 3.663 there fore belt width @ 575 rpm = 20*3.663= 73.7 = 80
mm belt width
SPINDLE AND SPINDLE DRIVE

Spindle
Play free mounting of spindle with precision bearings lubricated with grease for life,
ensures minimum heat generation. Spindle bearings are adequately protected
Extremely rigid, robust spindle.
High maximum speed ensures most economic rates of metal removal on work ranging
from the largest to the smallest piece.
No maintenance is required, as the grease lubrication is provided for bearings in the
completely enclosed spindle body. There is no necessity for adjustment of the bearings.
Absolute protection of the bearing from penetration by dirt and coolant.
Cartridge type of spindle allows easy dismantling & assembling of the spindle, reducing
machine down time.
The spindle head is located in wide spaced guides of Z axis which assures smooth metal
removal with high repeatability
SPINDLE DRIVE

The spindle is driven through a system of toothed belt drive ensuring slip less
rotation.
The speed regulation of the spindle occurs sleeplessly from a transistor controlled
(PWM) A.C. spindle motor over a wide speed range. This facilitates the constant
cutting speed for achieving uniform surface finish on the work of varying sizes.
Constant power of 22/18.5 kW is available for 5000 rpm IDD.
The spindle speeds are programmable through S code of CNC system and hence it
is easy for the operator to select the required speed.
Tool clamp & declamp assembly
TOOL CLAMPING SYSTEM

The tool is clamped securely by a draw bar mechanism, mechanically pulling

the tool retention stud with the help of disc spring stacks. The fast operating jaws of the
automatic power draw bar system provides powerful fail safe clamping of the tool. The
jaws are closed due to the sliding over of the controlled wedge due to the disc spring
force exerted on the power draw bar. Tool de-clamping is done by a hydraulic cylinder,
which unlocks the tool holder as the jaws are opened.
Hydraulic elements for tool declamp
ATC ASSEMBLY
The Automatic tool changer is mounted on the vertical
column of the machine. Tools are selected at random
bi-directional shortest path and by variable pocket
coding system. Position encoder is used for tool pocket
identification. Tool changing takes place in the tool
changing zone, of Z axis slide which is sensed by limit
switch. It is easy to load/accommodate tools up to
125mm in diameter and 350mm long and 20kg in
weight in tool drum.

The tool to be changed is tilted down from the magazine by pneumatic cylinder at the tool
change position and upon tilting the pocket the tool automatically gets released
First arm rotation of 90° is done by globoidal cam. Tool release from the spindle takes
place by an oscillating swing lever mechanism.
Arm up/down function is done by plate cam with an oscillating follower lever mechanism.
Arm 1800 indexing is accomplished by globoidal cam
ATC Data sheet
COUNTER BALANCE ASSEMBLY
 LINEAR SCALE
• Linear scale are ideal for machines whose feed
axes are in closed loop.
• Linear encoder measures the position of linear
axes without additional mechanical transfer
elements.
• Transfer errors from the mechanics can be
detected by linear encoder on the slides and
corrected by control electronics.
 Linear Scale
• This can eliminate number of potential errors
 Due to thermal behaviour of recirculating
ballscrews.
 Hysteresis.
 Kinematic error through ballscrew pitch
error.
Linear encoders are therefore indispensable for
machines that fulfil high requirement for
positioning accuracy and machining speed.
 Linear Scale
• Linear encoders for machine tools are sealed
encoders.
• An aluminium housing protects the scale,
scanning carriage and its guideway from chips,
dust and coolant.
• Downward directed elastic lips seal the
housing.
• The scanning carriage travels in low friction
guide within the scale unit.
 Linear scale
Thermal behaviour
• The combination of increasingly rapid machining
processes with completely enclosed machines
leads to ever-increasing temperatures within the
machine’s work envelope.
• Therefore, the thermal behaviour of the linear
encoders used becomes increasingly important,
since it is an essential criterion for the working
accuracy of the machine.
LINEAR SCALE ASSEMBLY x & y axis
Foundation Plan Layout
LOSMA (MIST SEPARATOR)

Air filter for removing oil mist from workshop

atmosphere , also with presence of heavy amount of particulate

Working Process

The LOSMA Galileo is equipped with a specially designed turbine that sucks in the oil mist and pollutants
dispersed in the air from the working area. Due to the acceleration effect caused by the centrifugal
force, the oil mist coalesces and converts to the liquid state. This oil in the liquid state is then sent back
to the machine through the LOSMA drainage system for re-use. A filter fitted at the rear of the unit,
blocks and captures the smallest pollutants, preventing contaminants to be released into the workshop
atmosphere.
 Appropriate Losma (mist separator) selection

For selection of the appropriate model of Losma oil mist collectors, we consider:

2 changes of volume of air / sec. to clear the chamber (based on air chamber experiments in laboratory)
Therefore, 120 changes / hour.

From the graphs (flow rate Vs. pressure) given in the brochure, we have,

In our case on the VMC m/c MCV650/50 it is 7 Cu.Mts and for the HMC 11 Cu.Mts.

max. flow rate of G500 model: 500 m3/hr

G1000 model: 910 m3/hr
G2000 model: 1500 m3/hr ***
G3000 model: 1800 m3/hr
*** Revised to 1500 m3/hr as against 1050 m3/hr given in brochure
Above max. flow rates are divided by the above 120 m3/hr to obtain max. chamber size the Galileo model can be
used for.

Thus,
G500: 500 / 120 = 4.2 m3
G1000: 910 / 120 = 7.5 m3
G2000: 1500 / 120 = 12.5 m3
G3000: 1800 / 120 = 15 m3

The model G2000 for the VMC and HMC respectively are appropriate and will clear the chamber of mist, in real
time.

Hence AMS has been recommended G2000 LOSMA model for both VMC and HMC
Pneumatic assembly
The pneumatic system is provided in the machine for the following purpose.

To clean the spindle nose for removal of chips or dust during tool change.
To actuate the pneumatic cylinder for opening of front door.
For ATC pocket up/down.
For Linear Scale.
Air Gun.
ATC isolation door
For seat check function in components
Hydraulic circuit

Tank capacity: 100 liters

Operating Pressure : 6 & 7 Mpa
Pump Discharge : 11 & 12 l/min
Electric Motor : 1.5 kW,1440 rpm, 3 phase,415V,50 Hz
 Nikuni hydro-cyclone separator
Vortex dynamic filter (VDF)
Hydrocyclone is a device to classify, separates or sort particles in a
liquid suspension based on the ratio of their centripetal force to fluid
resistance. This ratio is high for dense (where separation by density is
required) and coarse (where separation by size is required) particles,
and low for light and fine particles.
VDF + SLUDGE POD
1) Sludge- containing fluid flows into the separator via the supply
pump through the inlet positioned tangential to the periphery at
the top of the separator.
2) The fluid flows along the inner wall of the separator, and thereby
pressure energy is converted into rotational energy. While turning
under strong centrifugal force, the sludge descends towards the
narrowed nozzle, the sludge is discharged.
3) The discharged sludge rapidly loses its turning force, precipitates inside the concentration pod and stays
deposited.
4) On the other hand, ultra fine sludge which is unable to get sufficient centrifugal force and slow in its
descending speed is carried up with ascending clean full stream before reaching the inner wall of the
separator and discharged from the top opening. During this process, a long narrow cavity of vacuum is
present in the core of separator
Coolant tank assembly
 Coolant Pumps Details
COOLANT RATED
APPLICATION HEAD DISCHARGE
PUMPS POWER
(RAJAMANE
MAKE)

RKM 206 - 270 FLOOD COOLANT AROUND THE SPINDLE 1.5kW 20m 125 LPM

RKM 206 - 270 DRUM WASH 1.5kW 20m 125 LPM

COOLANT GUN, CHIP FLUSHING @ CHUTE

RKM 206 - 270 1.5kW 20m 125 LPM
AREA

RKM 0604/8 -
TRANSFER PUMP FOR CTS APPLICATION 0.54kW 20m 50 LPM
290

RK 275 - 300 BASE FLUSH/ SHOWER 0.75kW 10m 150 LPM

TOTAL 5.79 Kw
Rotary drum filter
Rotary drum filter type coolant tank

 Filcon rotary drum filters are designed to separate floating fines from coolant. These filters are
particularly effective in removing aluminium chips that tend to remain suspended in coolant for long time.

The rotary drum filter can be directly connected to the machine outlet from where the chip s with coolant
discharge.

The integral scraper conveyor carries the heavier chips away, while the fine or light weight particles
that do not settle are trapped by the rotary drum, which has fine stainless steel mesh around it. After
filtration, the coolant is collected in integral clean coolant tank.

The coolant jet from the drum back wash pump continuously cleans the drum and scarper conveyor
carries away the fine chips deposited on the drum .

The system works on simple upward flow principle and is highly effective in handling floating chips.
COOLANT SYSTEM

Coolant tank is specially designed to suit this machine. Coolant tank is mounted on castor wheel. This
facilitates easy movement for the coolant tank for maintenance and also to have minimum floor space by
moving the tank for maintenance purpose.

Coolant with chips returning from the machine falls on to the conveyor. Here chips get carried to the chip bin
and the finer chips with coolant will go to the tank through a drum which is capable of filtering up to 100µm.
Then with the help of transfer pump, coolant is dumped to clean tank area through hydro cyclone separator
from where coolant is supplied to spindle for CTS application. The machine is provided with coolant pumps
for pushing the chips from the machine to the chip collection area and for supplying the coolant around the
spindle. As an optional feature, one more pump is mounted to flush the chips from the machine base to the
rear of the machine. The centrifugal pump provided in the coolant system delivers the coolant to the cutting
zone while machining. The tank is provided with fluid level gauge at convenient place, which shows the
coolant level in the tank. When the fluid level gauge shows the minimum level, the coolant should be filled to
the tank up to maximum capacity.
 COOLANT MANAGEMENT SYSTEM
Principle of operation:

 The filter draws fluid from the pump through inlet.

 The fluid gets filtered through the bag retaining all the suspended particles of 25 micron &
above.

 The filtered fluid exits through the outlet port connected to Flow switch.

 The pressure difference across inlet & outlet ports indicates the amount of contamination
in the bag.

 Pressure difference of 2.5 bar is allowable & Pressure difference more than 2.5 bar
differential pressure switch gives message “Bag filter clogged interchange the Filter”.

 Then remove quick release bolts on cover & take out the bag.

 Clean bag by water & check for any damage.

 In case of damage we recommend to change the filter bag.

 Bottom most portion in the vessel has a drain valve for the purpose of draining the liquid.
 COOLANT MANAGEMENT SYSTEM

Flow switch:
 The Flow switch detects the flow velocity or discharge of liquid
flowing through a line.
 It is connected to out let port of bag filter.
 It gives the message “flow not ok “ when the flow less than set
Flow.
 Normal set flow rate is 2 lpm

Rotary Joint:
 RIX rotary joint is used for direct drive arrangement & Dublin for Indirect
drive.
 Deublin is mounted directly on the drawbar & RIX is mounted on Direct
drive Servo motor.
 Rix joint consists of two parts, one is fixed on the motor shaft and other one on the housing
mounted on the motor
55
 Rotary joint (DEUBLIN) for indirect drive arrangement

NO LOAD (FREE) Model No.

3/8" BSP 902-120-188
DEUBLIN
Deublin R/o
checking
'O' RING

DRAIN HOSE M16x1.5 (LH)

• Ensure the draw bar run out with in 10 micron

• Assemble the Deublin rotary joint, as per the assembly shown in the drawing.
Check for run out on rotary joint. Permissible – is 0.030 mm
• Connect the hoses. (Both inlet & drain)

• Make sure that coolant hose connected from rotary joint to head stock is free.
• Switch on the H.P coolant Check for leakage.

56
 7. ROTARY JOINT CTS DEUBLIN

Check point Method Remarks

Leakage Visual Replace if Req
 Rotary joint (RIX) for Direct drive arrangement
Union housing

Installation procedure:
a. Clean rotary joint each parts (Do not use solvents)
b. Assemble rotary joint on the motor with little grease on the threads
c. Check for the run out on the outer dia .should be below 10 micron.
d. Mount aluminium housing on the motor top. ensure sufficient gap bet housing and
rotary element.
e. Clean the carbide of the stationary part rotary joint.
f. Mount this on the aluminium housing with right orientation
g. Mount the distance block on the motor .
h. Mount the drain block on the aluminium housing
i. Mount the fan.
j. Ensure for the free rotation of the motor shaft by hand.

Maintenance:

Extreme care should be taken while handling the rotary joint ,carbide face should not be
damaged
After 10,000 hours of coolant through spindle running the union, ends its service life (Replace Union set) 58
 Rotary joint (RIX) for Direct drive arrangement

Coolant line

Rotary joint

Air line

Housing

Run out checking

59
CMH 500-40
CMH 500-40 Machine layout
Machine Floor Plan Layout
MACHINE DESCRIPTION
 AMS Machining Centre –Column Moving Horizontal CMH-500 is a general purpose compact flexible,
productive, Robust & high precision machine equipped for working to cater different kind of prismatic / circular
components suitable for tool rotating and job stationery or job indexing process. All the axis X,Y & Z have got
movements and where as Rotary Table is fixed.
The machine is equipped with Automatic tool changer & pallet changer to increase the production by cutting
down the unproductive time.

MACHINE CAPACITY
This Machine can be used for face milling, drilling, slot milling, rough boring, precision boring,
profile slot milling etc.
Pallet size : 500x500/500x630 option (For M/s Honda supplied with 500x 630 pallets)
Job loading height : 1060 mm

GUIDEWAYS
The X, Y & Z axes are provided with linear re-circulating roller motion guide-ways for high
positioning accuracy. The use of LM roller guide-way significantly reduces the co-efficient of
friction and eliminates stick slip motion , high load carrying capacity compared to ball type
guideways and also reduces heat generation during high speed slide movement.
MACHINE ACCURACY AS PER VDI DGO 3441

a) Positioning accuracy X, Y and Z axes (Std.) for full stroke : 0.015mm

b) Repeatability X, Y & Z axes (Std.) : 6 0.005mm

HYDRAULIC POWER PACK

a) Motor power : 3.7kw/1.5kw (Two pumps)

b) Tank Capacity : 100 Ltrs.
c) Hydraulic Oil :Castrol AWS 32
d) Make : Yuken for further details please refer Yuken technical and maintenance
manual supplied with machines
CMH 500-40 Specification
CMH-500 with
Description Unit
APC

AUTOMATIC PALLET CHANGER (ROTARY TYPE)

NUMBER OF ROTARY TABLE No. 1
PALLET SIZE mm 500 x 630
NUMBER OF PALLETS Nos. 2
INDEXING POSITION Deg. 0.001°
PALLET CHANGE TIME WITH ROTARY JOINT Sec. 13
POSITIONING ACCURACY – OPTIONAL Arc Sec. ±7.5"
MAX. LOAD ON PALLET Kg. 400
SWING DIA OF PALLET mm 700

MACHINE CAPACITY
X - AXIS TRAVEL mm 800
Y - AXIS TRAVEL mm 550
Z - AXIS TRAVEL mm 550
DIST. FROM SPINDLE FACE TO PALLET CENTER mm 150 - 700
DIST. FROM SPINDLE CENTER TO PALLET TOP mm 120 - 670
COOLANT SUPPLY - FLOOD COOLANT AROUND THE SPINDLE Lpm 40
FEED THRUST X, Y & Z AXES Kgf. 600
PALLET HEIGHT FROM FLOOR mm 1100
 CMH-500
Description Unit
with APC
SPINDLE
SPINDLE NOSE TAPER 7 / 24 No. 40
SPINDLE SPEED - DIRECT DRIVE rpm 100 - 10000
SPINDLE BEARING DIAMETER mm 70
FEED
RAPID TRAVERSE X, Y & Z AXES (MACHINE IS TO BE
M / Min 40 / 40 / 40
GROUTED)
CUTTING FEED mm / Min 1 - 10000
GUIDEWAYS FOR X, Y & Z AXES (ROLLER TYPE) LM Guideway
AUTOMATIC TOOL CHANGER
NUMBER OF TOOLS Nos. 40
MAX. TOOL DIA. WITH ADJACENT POCKET FULL mm 80
MAX. TOOL DIA WITH ADJACENT POCKET EMPTY mm 155
TOOL SELECTION Bi - Directional
TOOL LENGTH MAX. mm 350
TOOL WEIGHT MAX / TURNING MOMENT MAX. Kg / NM 8 / 12
TOTAL WEIGHT OF 40 TOOLS MAX. Kg 275
TOOL TO TOOL TIME Sec. 2
CHIP TO CHIP TIME Sec. 5.5
TOOL CHANGE SYSTEM TWINARM
TOOL SHANK TYPE - STD. BT-40
MAS 403 /
PULL STUD
FORM A
 CMH-500
Description Unit
with APC

ACCURACY AS PER VDI DGQ 3441

POSITIONING FOR X, Y & Z AXES WITH ROTARY ENCODER mm 0.015

REPEATABILITY FOR X, Y & Z AXES WITH ROTARY ENCODER mm ± 0.005

ACCURACY AS PER ISO 230-2

POSITIONING FOR X, Y & Z AXES WITH ROTARY ENCODER mm 0.01

REPEATABILITY FOR X, Y & Z AXES WITH ROTARY ENCODER mm ± 0.003

MOTORS

SPINDLE POWER 30 MIN. / CONT. (FANUC ) KW 18.5 / 15

FEED MOTOR X, Y & Z AXES (FANUC) NM 30 / 30 / 30

 Special features
ADDITIONAL FEATURES ORDERED BY M/S HSCI
HOLLOW SHAFT ENCODER (HEIDENHEIN MAKE) FOR ROTARY TABLE FOR FINER ACCURACY
OF ±7.5 ARC SECONDS
HYDRAULIC INTERFACING FOR FIXTURE CLAMPING WITH 3 ROTARY JOINTS ONE ON EACH
PALLET & ONE AT THE PALLET CHANGE ROTARY AXIS
SPINDLE SPEED OF 100-10000 RPM WITH 18.5 / 15 KW SPINDLE POWER
SPINDLE CHILLER UNIT

HIGH PRESSURE COOLANT THROUGH SPINDLE SYSTEM (30 LPM AT 50 BAR) WITH WANNER
PUMP AND HYDRO CYCLONE (NIKUNI MAKE) FILTRATION SYSTEM
SCRAPER TYPE CHIP CONVEYOR WITH DRUM TYPE FILTRATION FOR CAST IRON &
ALUMINUM CHIPS (ALONG Z-AXIS) (FILCON MAKE)
COIL CONVEYOR
SEAT CHECK FOR FIXTURE (CKD MAKE)
MIST SEPERATOR (LOSMA MAKE GALILEO 2000 MODEL)
TOOL BREAKAGE SENSOR (NON CONTACT TYPE) RENISHAW MAKE A-5450-1000 TRS-2 KIT,
AIR REG, + CONDUIT:
2 NO'S OF IFM MAKE 7000 SERIES (DIGITAL) PRESSURE SWITCHES FOR HYDRAULIC & 3 NO'S
OF SMC MAKE ISE SERIES PRESSURE SWITCHES FOR PNEUMATIC.
SPINDLE RUN OUT SENSING ATTACHMENT (TOSEI MAKE)
LINEAR SCALE FOR X & Y AXES
BALL SCREW COOLING X, Y & Z AXES
ADDITIONAL FEATURES - MECHANICAL

GUARDING TO ACCOMMODATE MACHINE WITH ROTARY TABLE

UPPER /LOWER LIMIT BY A FLOAT SWITCH FOR COOLANT LEVEL

CONCEALED TYPE CARRYING HANDLE FOR ENCLOSURE (WHEREVER POSSIBLE) FOR

MAINTENANCE PURPOSE

OIL SKIMMER (UPT MAKE WITH BONIFIGLOLIO MOTOR)

SAFETY SWITCHES FOR ALL DOORS WITH BY PASS IN THE ELECTRICAL CABINET

AIR GUN FOR CLEANING COMPONENTS OUTSIDE THE MACHINE

SEAT CHECK BY-PASS SWITCH INSIDE THE CABINET
OPERATOR CONTROL PANEL - FANUC MAKE
MANUALS – 3 SETS

TOOL BOX ( SPANNER, KEYS ETC.,) TO BE PROVIDED AND TO BE MOUNTED ON THE

MACHINE

SMC PNEUMATIC ELEMENTS

HYDRAULIC HOSES - GATES MAKE
HYDRAULIC FITTINGS - HYLOCK MAKE
PRESSURE GAUGES - DP MAKE [UNIT- MPA, METAL BODY,GYL. FILLED,]
PNEUMATIC VALVES - SMC MAKE VQ7 SERIES [COIL VOLTAGE - 24 V DC]

PNEUMATIC CYLINDERS - SMC MAKE [SHOULD BE COOLANT PROOF ITS IN COOLANT EXPOSED AREA]

AIR TUBING - SMC MAKE TU SERIES

PNEUMATIC FITTINGS - SMC MAKE
PNEUMATIC FITTINGS - SMC MAKE
TIMING & V-BELT - GATES MAKE
ROTARY JOINT - DEUBLIN MAKE
BEARING - FAG FOR SPINDLE MAKE CAN BE USED
NEEDLE BEARING - IKO / NTN MAKE
CAM FOLLOWER - IKO / NTN MAKE
BALL SCREW - TSUBAKI MAKE
LM GUIDEWAYS - SCNEEBERGER MAKE
OIL SEALS & O-RINGS - SIMIRIT / NOK MAKE (STANDARD) / EQUIVALENT MAKE (SPECIAL)
FLOW SWITCH - IFM MAKE
ACCUMULATOR - HYDAC MAKE
OIL / COOLANT LEVEL GAUGE - VIDYUTH MAKE

COUPLINGS - MAYR MAKE.

Machine configuration CMh-500
Machine Base

The base is a thick wall logically ribbed completely enclosed structure to absorb torsional and flexural forces
induced during machining. This structure is stress relieved twice, once before rough machining and another
before finish machining in order to retain the geometrical accuracies throughout the life of machine. It also
ensures high performance and reliable operation.
X -Axis longitudinal SLIDE

X-axis
y -Axis vertical SLIDE

Y axis
z-axis Slide

Z Axis
FEED SYSTEM FOR AXES
VERTICAL SLIDE ( Y - AXIS )
The vertical slide which carries Headstock body made up of close-grained cast iron.
The weight of the vertical slide is continuously balanced by high torque axis motor.
CROSS SLIDE ( Z - AXIS )
The cross slide which carries LM guide-ways for longitudinal slide (X axis) is made up of close grained
S.G.IRON Grade 600/3. The slide moves on the L.M. guide ways mounted on the base.
LONGITUDINAL SLIDE (X - AXIS)
The x axis slide includes column movement.
The slide will move on the L.M. guide ways mounted on cross slides.

All the axes slides - vertical slide (y-axis), longitudinal slide (x-axis) and cross slide (z-axis) are provided with
independent feed systems which consists of high precision ball screws with optimally preloaded re-circulating
double nut and AC servo motor. The ball screws are directly coupled to AC servomotors through torsionally rigid
coupling. This type of feed system gives infinitely variable feeds and position setting. The precision ball screws
used will give a low total lead error over their full travel length. To cut down the idle time during positioning a
rapid traverse rate of 40/40/40 m/min has been provided.

The ball screw mounting bearings are lubricated by means of oil. All the ball screws are fully and securely
protected against chips and coolant by telescopic covers provided over the slide ways.
HEAD STOCK ASSEMBLY

The spindle is directly coupled to AC servomotor.

SPINDLE
Play free mounting of work spindle with precision bearings specially lubricated for life, ensures minimum
heat generation.
Torsionally rigid & robust work spindle mounted on high precision preloaded angular contact ball bearings.
Wide range of spindle speed ensures most economic rate of metal removal on work.
No maintenance is required, as the special life lubrication is provided in the completely enclosed spindle
body. There is no necessity for maintenance or adjustment of the bearings.
Absolute protection of the bearing from penetration by dirt and coolant by a special labyrinth design.
The spindle and its mating parts are precision ground/lapped.
The spindle head is located is optimally spaced guides of Y-axis which ensures smooth metal removal with high
repeatability.
The spindle head is provided with orientation facility so as to stop it at one fixed position enabling correct tool
change.
TOOL CLAMPING SYSTEM (FOR BT-40)

The tool is clamped securely by a draw bar mechanism, mechanically pulling the tool
retention stud with the help of disc spring stacks. The fast operating jaws of the
automatic power draw bar system provides powerful fail-safe clamping of the tool. The
jaws are closed due to the sliding over of the controlled wedge due to the disc spring
force exerted on the power draw bar. Tool de-clamping is done by a Hydraulic cylinder,
which unlocks the tool holder as the jaws are opened.
Spindle speed and torque characteristics MODEL α15/10000iT
Effective Axes movement range

Rotary table
Rotary table
Rotary table
Machine setting and parameters selections
Z-axis

Rotary table
PROCEDURE FOR REFERENCING THE AXES OF MACHINES WITH
ABSOLUTE ENCODER

STEP 1
1. SET THE PARAMETER 1815#5=1(Absolute Pulse Code) FOR X,Z & Y AXES.
a. SET 1815#5=1 FOR M/C WITH ABSOLUTE ENCODER
b. SET 1815#5=0 FOR M/C WITH LIMIT SWITCHES

STEP 2

1. MOVE THE Z-AXIS (COLUMN) IN THE +VE DIRECTION

TO REACH THE POSITION AS SHOWN IN above figure
y-axis

STEP 3

1. MOVE THE Y AXIS (HEADSTOCK) IN THE +VE DIRECTION TO REACH THE POSITION
AS SHOWN IN THE FIG

STEP 4

1. NOW SET THE PARAMETER 1815#4=1(APZ) FOR ALL THE 3 AXES(Z,X & Y).
2. SWITCH OFF THE MACHINE & SWITCH ON.
y-axis

Rotary table
x-axis

Rotary table
ATC ASSEMBLY

4
Technical specification of ATC-A63/BT 40 H version
 ATC ASSEMBLY

The unit comprises of a chain type tool magazine with an independent arm drive unit. Arm drive unit is
mounted on an independent bracket fixed to the magazine frame.
The tool magazine is powered by a servo motor for fast magazine rotation and precise positioning of tool pot
for tool change operation.
A tool pot shifting mechanism grips tool pot and shifts it towards arm drive unit during tool change operation.
Arm drive unit then changes the tool through twin arm.
The ATC consists of 4 basic sub units:
1. Tool Magazine
2. Arm drive unit
3. Tool pot shifter
4. Gripper arm
.
1. Tool magazine

Tool magazine is in the form of a chain, comprising of 40 sliding tool pockets. The
magazine is rotated by a servo motor through a reduction Gear box (Gear ratio
1:30), ensuring fast rotation and precise positioning of tool pot for tool change.
Tool pot shifter then grips tool pot and moves it towards Arm drive unit for tool
change operation and moves the pocket back into chain after tool change
operation. Servo drive Gear box, Tool pot shifter & Tool ejection are designed as
independent units. They can be easily fitted and taken out thus ensuring ease of
servicing
Tool Pot Sliding movement
During tool pot shifting operation grippers fixed to the pneumatic cylinder grip the tool pot. Another
pneumatic cylinder then shifts the tool pot from the chain towards the Arm drive unit for tool change
Operation.
Arm Drive Unit

1. Motor 2. Flat Cam 3. Globoidal Cam 4. Follower Plates

5. Gripper Arm 6. Roller Follower 7. Proximity Switches
 Arm Drive Unit

Arm Drive Unit is an Independent unit with a twin arm.

Tool changer Arm movement is obtained as a combination of two movements :
Axial and Angular : These movements are generated using a Globodial Cam (2)
and a Flat Cam (3). Cams are driven by an Electric motor (1) through a reduction
gear train. One revolution of cam shaft completes one Tool change cycle.
This Gear Box is designed to Rotate the cam shaft at 1:33.03 ration for 225 Arm
@50Hz. One revolution of cam shaft takes 1.4 seconds @ 50 Hz for CD 225 Arm. Tool
change cycle involves synchronized actions of ‘tool release’ and ‘tool clamp’ from the
machining centre spindle.
Proximity switches (7) help in synchronizing these actions, though the use of machine
PLC (Programmable Logic Control).
Cam Displacement Diagram
Apc & rotary table ASSEMBLY

APC Assembly

NC rotary table
Apc ASSEMBLY

Rotary table

APC Assy
rotary table
Rotary Table specification
N.C Rotary table is a precision equipment designed for long life and sustained
accuracy. N.C Rotary table can be used as accessory to precision CNC milling or
machining center. NC Rotary table is assembled with best quality precision parts
which ensures longer life and accuracy. NC Rotary table enables the working
efficiency and it is cost effective.
N.C. ROTARY Table supplied by UCAM
Foundation Layout as per m/s honda
Thank you