Heller h series 4-axis machining center

HELLER solutions: Knowing how it works.

CONTENTS Our quality pledge: Made by HELLER 4 H series: For high output 6 Machine concept: Structure and basic layout 8 Machining units: Optimised precision 10 Tool management: Comprehensive know-how for your tools 14 Workpiece management: High accuracy and process stability 16 Chip disposal: Perfect answers for your requirements 18 Operation: Proven and perfected 20 Control: Programming in the familiar system environment 21 Maintenance: Optimised life cycle costs in an instant 22 Energy efficiency: Maximum savings with package bundles 23 Options: Typical extra quality from HELLER 24 Automation: Solutions for higher efficiency 26 HELLER Services: Ensuring maximum productivity 28 HELLER product range: Productivity over the full spectrum 30 This brochure is intended exclusively for advertising does not constitute an integral part of a contract, a guarantee, or an offer. We reserve the right to make interim modifications to technical data, specifications, or equipment and do not accept any liability for errors or misprints. The illustrations used may contain options subject to a surcharge. © 2017 Gebc Heller Maschinenfabrik GmbH

H series F series C series HF series 5-axis production machines with and 5-axis milling/turning centres for Horizontal 5-axis machining centres without pallet changer complete machining with fifth axis in the workpiece

Our quality pledge MADE BY

HELLER e H series H series Flexibly configurable 4-axis machining centres The basis for quality and precision for each HELLER solution is a simple principle: HELLER machines produce HELLER machines. Our machining centres 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. H series H series FOR HIGH OUTPUT The compact and powerful machining High-grade standardized series, which can Proven and perfected operation and cost- centres are ideal for a large range of parts nonetheless be individually configured optimized maintainability and materials. From individual part through to large series production. From light alloy Machine sizes from H 2000 to H 16000 with Technical added value included in the basic machining to heavy-duty cutting. pallet sizes up to 1,250 x 1,600 mm and a scope of machines maximum pallet load of 8,000 kg Designed for stable processes with adapted speeds, fully loadable even at the thresholdChip disposal for highly productive applications, configurable to customer requirements from a wide range of options H series I S J 2 Maximum load on a pallet/table kg

Machine column Tool changer H 2000 H 4000 H 4500 H 5000 H 6000 Línear guideways Pallet changer λ Machine bed Every HELLER machine essentially comprises main components f H 2000 6000: NC rotary feed table traverses in the Z-axis driven by developed using the Finite Elements Method. These include a two ball screws. machine bed optimized for stiffness and a mass-reduced column H 8000 16000: NC rotary feed table traverses in the Z-axis driven by for high dynamics. At the same time, the vibration-optimized a central ball screw. machine structure ensures the best surface quality during For all machine sizes: Optimised force flow and thermo-symmetrical machining and long tool life. design H 2000 6000: Unrestricted chip evacuation below the tool spindle. H 8000 16000: Optimum chip removal by 3 spiral conveyors H series BASIC LAYOUT

Machine column H 8000 Tool changer H 10000 H 14000 H 16000 Pallet changer Extremely rigid cast iron machine bed bears the X and Z axes Tool changer: Fast and precise even with high tool weights and moments of weight X-axis designed as a cast iron column Use of highly accurate linear guides and absolute coded measuring systems glass measuring scales, rotary encoders Spindle growth compensation as standard Pallet changer: Highly-accurate even under high load shown here H series Spindle units HIGHEST PRECISION Made by HELLER machining units are among the core component spindle cooling always with precision cooling unit for maximum of the machining centres that determine performance. This includes temperature stability

efficiency, accuracy, quality, and precision. Additional spindle growth compensation as standard High process stability through rigid guide slides from one cast Extraction of the IC coolant from the spindle for fast chip-to-chip times, Robustly designed connection from the spindle neck to the guide slideseasy work area and tools High precision from dynamically stiff, short machining unit design anEstablished solution for the main spindle replacement thanks to the sophisticated water-cooled spindle neck HELLER Zero Spindle system Options Attachment head support MSK offers a larger support basis for Heller facing slide as a full axis, integrated into the NC-controller, for supporting attachment heads and improves rigidity contour and facing work Ф H series

spindle units ideally equipped for the most demanding tasks H 2000 . H 4000 . H 4500 H 5000 H 6000 H 8000 H 10000 H 14000 H 16000 Speed range rpm kW Tool holding fixture 5K/H5K-A/BT HELLER facing slide HELLER attachment head support MSK HELLER attachment head additional clamping . Acc to price list Standard

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Tool management Comprehensive know-how for your tools Chain-type magazine Tool changer Options Chain-type magazine with tool holders Perfect interplay between tool changer Tool break monitoring during machining for mounted on both sides in the double chain for and chain-type or rack-type magazine - for effective process reliability optimized traversing dynamic short chip-to-chip times and follow-on tool provisioning during machining Tool loading parallel to machining on selected Compact dimensions with high packing density magazines for tools Tools always precisely positioned for the tool change due to the traverse attachment acting Tool shank cleaning as a link between the chain-type magazine and Rack-type magazine the tool changer; with the rack-type magazine, Tool coding Rack-type magazine with highly-dynamic loadethris function is performed by the loader for tool provisioning Measuring probe with radio or infrared technology Short loading times thanks to optimized operating strategy Bridge mounted tool  Length mm  Weight Moment of weight2 Nm Loading during machining

Adjacent places free/all space4ce sO boscecrvuep liimedited tool length Standard unavailable 2 > relative to the tool gripper groove for H 2000 Option Optional values HZP= During machining 5 > for machine sizes upwards of H 8000 6 Observe overall load capacity H series Workpiece management

High accuracy and process stability Pallet changer Optimized power grip due to fork shape of the swivel traverse for total loads of up to 8t Total load up to 16 t with slide/swivel pallet changer Air nozzles on the swivel traverse for chip clearance Optional cleaning of functional surfaces at rotary table and setting station with maintenance function NC rotary feed table For demanding 4-axis machining operations with worm gear drive for optimised dam- ping, without compromising rigidity Highly reliable tilting moments thanks to compact design Rotary table clamping with oil-hydraulically actuated diaphragm brake High tangential and rotary milling torques Rotary table positioning through direct path measurement with absolute rotary encoder Air blast ensures cleanliness at pallet supports, pallet locks and coupling points for media transfer Pallet alignment via sword and full index for consistent clamping and alignment quality Optionally available Media interface for hydraulic workpiece clamping to 60 bar, 200 bar, or 200 bar with proportional valve technology Workpiece setting station Friction-locked 4 x 90 indexing at the setting station with foot release Optional automatically rotating NC setting station with automatically actuated setting station doors Optional pneumatic location check, un- clamp or positioning check available Optionally available Media interface for hydraulic workpiece clamping at the work- piece setting station to 60 bar or 200 bar Chip disposal Perfect answers to your needs Chip conveyor and coolant unit Cooling lubricant high pressure to 50 bar or Optionally additional coolant cooler for even 70 bar higher process reliability through thermal Expandable with scraper conveyor or hinge stability band conveyor - depending on machining Internal coolant supply with up to 7 pressure process requirements stages programmable in the NC program Coolant units in paper band filter or vacuum High coolant unit tank volumes delivering high rotation filter technology volumetric flows H series Work area Various flushing nozzles for wet machining for keeping workpiece and work area clean as H 2000 - H 6000: Unrestricted chip evacuation- standard on below the spindle and central conveyor for fast chip removal and increased productionAdditional flushing of the machine bed H 8000 - H 16000: Optimised chip disposal Easy to clean thanks to good access to the work from the work area by 3 spiral conveyors area Continuous self-cleaning effect of the moved Air and flushing gun as standard concertina covers by stainless steel louvres Extraction of lubricants from the work area is optionally available H series Operation Proven and perfected

Operation Workpiece setting station Tool setting Optimized availability thanks to more reliable and more convenient operation Short distance to the center of the setting Tool setting at the magazine when spindle is running Optimally accessible operating stations Automatic setting/desetting sequence for Optionally available: User-friendly operating panels Optionally with screen blow-off device on the main operating door Control panel is ergonomically integrated in the guard panels Easy-access doors to the setting station with linear guide H series Control Programming in the familiar system environment Sinumerik 840D solution line Trust is good Control is even Functions for practical use and Fanuc 31 i-B better Convenient programming with HELLER Highly user-friendly HELLER 1PM Integrated Process Monitoring technology cycles boring, milling, measuring process, collision and tool break monitoring Operating modes 2 and 3 included in standard Order management/management of multiple machining Integrated pallet and program management RDS Remote machine diagnostics, including alternative strategy program restart after unit tool break User-guided setup functions CDS Condition Monitoring Tool requirements planning Milling technology package Automated setting/desetting sequence H series Maintenance Optimized life cycle costs in an instant The concentration of supply units and maintenance points at just a few locations ensures quick and easy inspection and operation A quick response HELLER spare parts service equates to the shortest possible production interruptions in an emergency 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 milling spindles can be quickly replaced thanks to HELLER's tried and proven Zero spindle system 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 of up to 30 Use of 1E2 motors with up to 5 less current 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 time 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 in addition to HELLER BLUE supply, switch off tasks, the more important an adaptive or sleep mode for further function units such as demand-regulated current consumption of the Booster technology in accordance with the periphery and main units, to be able to optimize coolers, pumps, lights, chip conveyors, drive, pressure amplification principle ensures low- various operating points. seal air and other options noise, energy saving high-pressure provisioning while simultaneously minimizing heat admission into the hydraulic system H series Options TYPICAL EXTRA QUALITY FROM HELLER Tool break monitoring during machining Air nozzles on the swivel traverse, pallet support, pallet lock, and coupling points for media transfer ensure optimized process reliability Tool cleaning for chain-type magazine and rack-type magazine chain-type magazine including cartridge flushing, rack-type magazine with brush and flushing options Measuring probe for radio or infrared technology HELLER additional milling head support MSK, also with additional clamping HELLER facing slide for turning operations at a machining centre HELLER Zero Spindle principle for fast main spindle replacement Spindle growth compensation as standard for guaranteed machining accuracy H series Automation SOLUTIONS FOR HIGHER EFFICIENCY H-series machines are productivity centers: They work highly accurately and effectively, remain extremely reliable even under constant load, and can be flexibly adapted to new tasks. 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. The results are maximized effective machining time, optimized throughput, and increased production output. Pallet and tool automation system Rotary pallet magazine We offer automation solutions that perfectly match your requirements and that are constantly being refined. The corresponding cost and safety benefits of these concepts are passed directly Semi-automated loading with balancer onto you. The offer ranges from simple pallet magazines to pallet rack systems through to flexible robotic cells for complete workpiece handling. H 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: 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 making the resources available fit again qualify your employees to work on a HELLER offering you an extensive range of standardized production life, we look at all relevant aspects machining - offered by the HELLER Academy. optimization packages. Through these packages, of retrofitting: We also offer basic and advanced courses in HELLER always provides the right answer to the following areas: your optimization requirement, in adapting to new production the following are at:status check and disassembly _ Operation Overhaul of the basic machine Programming Machining unit Overhaul of the assemblies Maintenance. Media supply Conversion of the controller Measuring probe Upon request, HF also providessmlr,oflyr.training on - your own Process optimization bling premises. In this case, the contents of this Guard panels/machine frame Replace covers and guards premium training program will be adapted specifically to the needs of your company, and Software/control Acceptance at factory prior to delivery cover all HELLER specialist areas technology, control technology, and machine technology. Workpiece management The result is always an almost new machine Tool management with higher productivity and safety. The benefit Increased energy efficiency same guarantees and rules of warranty or service availability as a new machine. 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 package. It 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 H series HELLER product range PRODUCTIVITY OVER THE FULL SPECTRUM The H series: 4-axis horizontal machining Pallet loading: to 750 kg F series The F/C series: 5-axis complete machining

FP 4000 CP 4000 FP/FT 6000 CP/CT 6000 X/Y/Z 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: 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 SWEDEN SLOVAKIA FRANCE POLAND Värnamo Vráble Paris Poznań 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 Pune BRAZIL Bangkok

Belo Horizonte, Sorocaba SINGAPORE Singapore