Heller f/c series 5-axіѕ milling/turning centres
Heller f/c series 5-axіѕ milling/turning centres
CONTENTS QUALITY PLEDGE: HELLER 4 F/C SERIES: Sustainable production 6 MACHINE CONCEPT: Structure and basic layout 8 MACHINING UNITS: Innovative spindle technology 10 TOOL MANAGEMENT: Fast, precise, flexible 14 CHIP DISPOSAL: Perfect answers to your needs 18 OPERATION: Proven and perfected 20 CONTROL: Ideal solution for complete machining 21 MAINTENANCE: Optimized life cycle costs in an instant 22 ENERGY EFFICIENCY: With package offers for maximum savings 23 OPTIONS: Typical extra quality from HELLER 24 AUTOMATION: Solutions for more efficiency 26 HELLER SERVICES: Ensuring maximum productivity 28 HELLER PRODUCT RANGE: Productivity over the full spectrum 30
F/C SERIES H series HF series Flexibly configurable 4-axis machining centers Horizontal 5-axis machining centers with fifth axis in the workpiece
Our quality pledge MADE BY ρь; с series F series C series 5-axis production machining 5-axis milling/turning centers with and without pallet changer for complete machining
The basis for quality and precision for each HELLER solution is a simple principle: HELLER machines produce HELLER machines. Our machining centers evolve within a worldwide production network that manufactures to the high HELLER quality standards. We develop and produce ourselves all components that ensure the reliability, accuracy, and quality of a HELLER machine. Especially when it comes to the daily availability of your HELLER, we consider the deepest vertical integration paramount. Therefore: Made by HELLER, a quality seal on which you can rely.
F/C SERIES F/C series SUSTAINABLE PRODUCTION Powerful machining centers for 5-axis complete machining. Table concept for optimally accessible table loading suitable for a large part and product range with small batch quantities F series for 5-side machining and simultaneous 5-axis machining Sound HELLER process experience ensures maximum output with optimized C series for milling/turning jobs Combined Processing with a 5th axis limit the tool and a fast rotating NC table Robust machine design, combined with powerful spindle technology Pallet changer concept for productive high-volume machining, connection to pallet automation systems possible Increases productivity, time, and cost savings due to complete machining in one setup
F/C SERIES MACHINE CONCEPT STRUCTURE AND BASIC LAYOUT FT 6000 FP/CP 4000 FT 8000 Machine column Tool changer Tool changer Linear guideways Pallet changer Machine bed
Every HELLER machine essentially comprises main components F/C 4000: NC rotary feed table traverses in the Z-axis driven by two developed using FEM methodology. These include a machine bed ball screws. optimized for stiffness and a mass-reduced column for high F/C 6000 16000: NC rotary feed table traverses in the Z-axis driven dynamics. At the same time, the vibration-optimized machine by a central ball screw. structure ensures the best surface quality during machining and For all machine sizes: Optimized force flow and thermo-symmetrical long tool life design F/C 4000: Unrestricted chip evacuation below the tool spindle. F/C 6000 16000: Optimum chip removal by 3 spiral conveyors
F/C SERIES BASIC LAYOUT FP/CP 6000 FP/CP 8000 FP/CP 10000 FP 14000 FP 16000 Machine column Tool changer Linear guideways Pallet changer Machine bed Extremely rigid cast iron machine bed bears the X and Z axes Tool changer: Fast and precise even at high tool weights and tool moment of weight X-axis designed as a topology-optimized cast iron column Use of highly accurate linear guides and absolute coded measuring Powerful and precise machining units in the Y-axis essentially with system glass measuring scales, rotary encoders spindle growth compensation as standard Pallet changer: Highly accurate even at high loads for maximum productivity
F/C SERIES SPINDLE UNITS INNOVATIVE SPINDLE TECHNOLOGY F series C series Broad range of between 4 swivel heads and and 4 tilting head units Turning and milling with the 5th axis in the tool available Vertical, horizontal and positioned turning with A/C and B axes High cutting performance thanks to extremely rigid machining units Producing precise outer and inner contours Speeds of up to 16,000 rpm Repeatability and precise positioning of the tool thanks to Torques to 822 Nm with tilting head and to 1,146 Nm with swivel head K-T tool shank Ideally suited for heavy-duty cutting of cast iron, steel, and titanium To additionally rigid and repeatability due to spindle lock the volume cutting of light alloys swivel head Tilting head Thermally stable and compact design with swivel head geometry Compact tilting head geometry with rigid spindle mounting with water cooling A swivel range from sub-equatorial to -120 Short distance between swivel head mounting tool holding fixture for high stability and rigidity Optional A-swivel range extension from to -120 Rigid cast iron guide slides A-axis driven by 2 swing motors and a braced power train C swivel range from to -190 Energy and media routing through the tilting head jaws Optional C-swivel range extension Spindle growth compensation as standard from to -200 tool shank 40/63 or from to -190 tool shank 50/100 Energy and media routing through the center of swivel head Spindle growth compensation as standard Options Attachment head support M5K offers a larger support basis for Facing slide as a full axis, integrated into the NC-controller, for contour and supporting attachment heads and improves rigidity facing work HSK A-100 F/C SERIES SPINDLE UNITS IDEALLY EQUIPPED FOR THE MOST DEMANDING TASKS FP 4000 CP 4000 FP/FT 6000 CP/CT 6000 FP/FT 8000 CP/CT 8000 FP/CP 10000 FP 14000 FP 16000 Speed range rpm 5 16,000 5 16,000 5 10,000 Torque > F/C Nm 80/68 80/68 116/- Power F/C kW 40/34 40/34 46/- Tool holding fixture SK/HSK-A/BT Facing slide HELLER attachment head support MSK S6 40, duty cycle 10 minutes Standard
for C series with HSK-T holder and spindle - unavailable lock Π Optional 3> not for C series for D Andrea tools F/C SERIES SPINDLE UNITS IDEALLY EQUIPPED FOR THE MOST DEMANDING TASKS
Tool management Fast, precise, flexible Chain-type magazine Tool changer Options Chain-type magazine with tool holders For short chip-to-chip times and follow-on tool Tool break monitoring during machining for mounted on both sides in the double chain for provisioning during machining effective process reliability optimized traversing dynamics setting during machining for selected Tools always precisely positioned for the tool magazines Compact dimensions with high packing density change due to the traverse attachment acting for your tools as a link between the chain-type magazine and Tool shank cleaning the tool changer; with the rack-type magazine, this function is performed by the loader Tool coding Rack-type magazine Rack-type magazine with highly-dynamic loader Tool changer essentially with NC drive for Tool measurement Measuring probe with radio or infrared technology for tool provisioning ting and swiveling Tool measurement Short loading times thanks to optimized operating strategy
FP/CP 4000 FP/CP 6000 FT/CT 6000 FP/CP 8000 FT/CT 8000 FP/CP 10000 FP 14000 FP 16000 Tool holding fixture Bridge mounted tool Percent of weight 70 70 Loading during machining Adjacent places free/all spaces occupied For F/C 6000 only in combination with swivel Standard - unavailable relative to the tool gripper groove head units Option optional values Observe overall load capacity HZP= During machining 800 mm in combination with tilting head units F/C series Workpiece management Workshop or production machine Table concept Optimized access to the work area via the three- 6 part work door for optimal tool handling Table with large clamping surface With mechanical or hydraulic workpiece clamping Ideal for workshops with small batch quantities and frequently changing machining tasks Pallet changer concept 1 Optimized for the workpiece automation of 4-axis and 5-axis machines combined with one other in productive machining Optimized power grip due to fork shape of the swivel traverse for total loads of up to 8 t Total load up to 16 t with slide/swivel pallet changer Air nozzles on the swivel traverse for chip clearance Protects the interfaces from mechanical damage caused by pallet indexing Optional cleaning of functional surfaces at rotary table and setting station with maintenance function Friction-locked 4 x 900 indexing at the setting station with foot release Optional automatically rotating NC setting station with automatically actuated setting station doors Optional pneumatic location check, unclamp or positioning check NC rotary feed table variants Worm gear drive for optimized damping, without compromising rigidity As directly driven rotary table at up to 1,000 rpm CP 4000 Imbalance detection integrated into the controller during machining Highly reliable tilting moments thanks to compact design Rotary clamping device with oil-hydraulically ac- tuated diaphragm brake Rotary table positioning through direct path measurement with absolute rotary encoder Optionally-available Media interface for hydraulic workpiece clamping to 60 bar for F and C series, F series has additional 1200 bar or 200 bar with proportional valve technology Chip disposal Perfect answers to your needs
Chip conveyor and coolant unit With scraper conveyor or hinge band conveyor - depending on machining process requirements Coolant unit in paper band filter or vacuum rotation filter technology Cooling lubricant high pressure with 50 bar, optionally with 70 bar Internal coolant supply with up to 7 pressure stages programmable in the NC program High coolant unit tank volumes delivering high volumetric flows Optional additional coolant cooler for even higher process reliability through thermal stability F/C series Work area Size 4000: Unrestricted chip evacuation below the spindle and central conveyor for fast chip removal and increased production Machine sizes 6000 to 16000: Optimized chip disposal from the work area by 3 spiral conveyors Continuous self-cleaning effect of the moved concertina cover by stainless steel louvers Extensive flushing nozzles for wet machining for keeping workpiece and work area clean as standard Additional flushing of the machine bed Easy to clean thanks to good access to the work area Air and flushing gun as standard Optional extraction of lubricants from the work area F/C series Operation Proven and perfected Table concept Pallet changer concept Automatic setting/desetting sequence for incre- ased process reliability and short idle times One arm philosophy: Short-stroke doors canOptimum access to operating stations be operated by one arm Control panel is ergonomically integrated into Control panel at the setting station with the guard panels Optional: Convenient operating terminal at integrated media guns the tool loading position Tool setting Simple connection to all standard automation Best-possible access to the work area systems Tool setting at the magazine when spindle is running Optimally-designed guard panels Optionally with pane blow-off device at the main operating door Smooth running doors to the setting station Linear-guided, smooth running doors, hence with linear guide optimal access during loading Short distance to the center of the setting station for convenient handling Optionally-available: User-friendly operating panel F/C series Control ideal solution for complete machining For perfect 5-axis machining: For combined processing: Sinumerik 840D s1 Sinumerik 840D s1 Highly-accurate speed and acceleration control Highly-accurate speed and acceleration control Variable adjustment to individual requirements with good accuracy Variable adjustment to individual requirements with good accuracy and surface finish and surface finish Operator interface SINUMERIK Operate for efficient programming graphical cycle support and operation Remote diagnosis via HELLER RDS Comprehensive cycle package as standard Integrated balancing functionality User-friendly setup functions FIC series Maintenance All function-relevant systems and components are quickly and easily accessible Easily removable guards and positioning designed for maintenance purposes guarantees access by a single action The main spindles can be quickly replaced thanks to HELLER's tried and proven Zero 5pindle system The concentration of supply units and maintenance points at just a few locations ensures quick and easy inspection and operation Optimized life A quick response HELLER spare parts service equates to the shortest possible production interruptions in an emergency cycle costs in an instant Energy Efficiency With package offers for maximum savings
HELLER BLUE HELLER BLUE basic HELLER BLUE coolant Energy-efficient packages that Basic supply for all H, F, and C series A frequency converter ideally adapts the volume guarantee you an energy-saving flow of the high-pressure coolant pump and Use of IE2 motors with up to 5 less current of up to 30 hence also the energy consumption to your consumption machining requirements Regenerative drive systems, servomotors that Individual switch-off of individual consumers make efficient use of the entire speed range and HELLER BLUE chill after a programmable specified time output-reduced valves have been standard at Flexible control instead of ON/OFF circuit Heller for many years. Methods for optimizing HELLER BLUE supply the topology of structural components beds Just like the coolant pump, the central cooler and columns have also been consistently in Nueseeds-driven compressed air shut-off can also be controlled via a frequency converter for a number of years. in line with machining requirements Constant media and filter monitoring supported Thus enabling rigidities to be increased and thin uninterrupted machine operation The current consumption is significantly reduced mass of moved components to be optimized. by a new compression technology The new HELLER BLUE energy-efficient packages HELLER BLUE smartsupply allow - depending on the machining situation - HELLER BLUE hydraulics further potentials to be systematically switch off/on of all consumers The more universal and versatile the machining High pressure on demand 1 an additional to HELLER BLUE supply, switch off tasks, the more important an adaptive de- or sleep mode for further function units such as mand-regulated current consumption of the pe- Booster technology in accordance with the coolers, pumps, lights, chip conveyors, drives, riphery and main units, to be able to optimize pressure amplification principle ensures low- seal air and other options various operating points. noise, energy saving high-pressure provisioning while simultaneously minimizing heat admission into the hydraulic system F/C series Options TYPICAL EXTRA QUALITY FROM HELLER F/C series Tool break monitoring during machining Measuring probe with radio or infrared technology Tool cleaning for chain-type magazine and rack-type magazine chain-type magazine incl. cartridge rinsing, rack-type magazine with brush and flushing options HELLER Zero Spindle principle for fast main spindle replacement HELLER attachment head support MSK Facing slide with special tools D Andrea for turning operations or machining center Spindle growth compensation as standard for guaranteed machining accuracy Air nozzles on the swivel traverse, pallet support, pallet lock and coupling points for media transfer for optimized process reliability Laser tool measurement for F series and as a combination of lasers scanner for C series Swivel range extension F/C series Automation SOLUTIONS FOR HIGHER EFFICIENCY F and C series machines are productivity centers: They work highly accurately and t Overhead gantry loader effectively, remain extremely reliable even under constant load, and can be flexibly adapted to new tasks. f Fully automatic loading via mobile robot The same is true for our automation solutions. They have been designed to optimize your Pallet rack system production process and maximize added value. f Pallet and tool automation system The results are maximized effective machining time, optimized throughput and increased production output. f Rotary pallet magazine We offer automation solutions that perfectly match your requirements and that are const a nRtolytary pallet magazine being refined. The corresponding cost and safety benefits of these concepts are passed directly on to you. [t Semi-automated loading with balancer The offer ranges from simple pallet magazines to pallet rack systems through to flexible robotic cells for complete workpiece handling. F/C series HELLER Services ENSURING MAXIMUM PRODUCTIVITY Especially when it comes to global competition, maximum productivity is now considered to be the key success factor in machining. Achieving maximum productivity hinges on the interplay between several aspects: besides optimizing production, especially the reduction of unplanned downtimes and increasing machine availability. That's why HELLER machines and HELLER Services simply belong together. HELLER Services guarantees optimized machine availability for many years through its worldwide presence, fast reaction times and qualified support. You benefit from a comprehensive range of services: Φ F/C series HELLER Optimization Packages HELLER Retrofit HELLER Training new productivity To increase the performance and productivity A multitude of practical training sessions that of HELLER machines in your facility, HELLER is To make available resources fit again for thequalify your employees to work on a HELLER offering you an extensive range of standardized production life, we take care of all relevantmachine - offered by the HELLER Academy optimization packages. Through these packages, aspects of retrofitting: We also offer basic and advanced course HELLER always provides the right answer to the following areas: your optimization requirement, in adapting to new production the following areasstatus check and disassembly operation
Overhaul of the basic machine Machining unit Programming Overhaul of the assemblies Media supply Maintenance Conversion of the controller Measuring probe HELLER services can also provide Overhaul of the control cabinet and new cabling customized, individual training on your own Process optimization premí this case, the contents of this Replace covers and guards premium training program will be adapted Guard panels/machine frame at factory prior to delivery specifically to the needs of your company, and software/control cover all HELLER specialist areas technology, The result is always an almost new machine control technology and machine technology. Workpiece management with higher productivity and safety. The benefit to you: A retrofit machine is covered by the Tool management HELLER TPS the modular service package To provide you with optimal support as you maximize your productivity, HELLER has developed the TPS Total Productive Services modular service comprises various service packages, which integrate seamlessly into your production system always allowing for your maintenance strategy. You decide which of the three packages is the best solution for you: Performance Package: Maintenance Package: Full service Package: Annual manufacturer inspection Annual manufacturer maintenance All inclusive HELLER product range PRODUCTIVITY OVER THE FULL SPECTRUM The H series: 4-axis horizontal machining Pallet loading: to 4,000 kg The HF series: Productivity in 5 axes H 16000 HF 3500 HF 5500 X/Y/Z: 2,400 x 1,600 x 1,600 mm X/Y/Z: 710 x 750 x 710 mm X/Y/Z: mm Pallet: The MC series The RFK / DRZ /RFN series: Highly-productive Production of crankshafts batch manufacturing and camshafts
MC 20 RFK DRZ RFN X/Y/Z: 800 x 750 x 800 mm External and internal milling of crankshafts Crankshaft chasing External milling for camshafts Table: Ø 520 mm Table loading: 500 / 800 kg Process modules and special solutions: productivity across the full range
CBC MPC TRS VCM Wenzler Coating cylinder bores of automobile Head Changer System Stand-alone machine for transfer lines, Vertical chamber machine with 5 axes for engines for multi-spindle machining processes rated for high volumes the machining of structural components
F/C series SWEDEN SLOVAKIA FRANCE POLAND Värnamo Vráble Paris Poznan SWITZERLAND ITALY SPAIN Niederbüren Verona Barcelona RUSSIA USA
Moscow Troy, Michigan
CHINA ENGLAND GERMANY Beijing, Changzhou, Chongqing, MEXICO Redditch Goslar, Hattingen, Shanghai Nuremberg, Nürtingen, Querétaro Saarbrücken, Salem INDIA - THAILAND BRAZIL Pune Bangkok
Be10 Hor zon te, Sorocaba SINGAPORE Singapore
