Spindles / Options

CMS' working units: type TP & ATC

CMS' linear spindles, type TP, shown to the left, are designed to be placed in line, side by side, for the simultaneous machining of several pieces with a limited number of tools. The type TP unit can mounted with other TP heads on the same Z carriage or with other types of working units on 3 axis milling machines. Depending upon the application and machine typology, up to 9 TP heads can be placed side by side with up to 8.5 kW (11.4 hp) power each at 18,000 rpm, S1 rating, maximum 24,000 rpm, air-cooled. Minimum center distance between two adjacent TP heads is 240 mm (9.44"). Each working unit is mounted on an independent insertion slide with micrometric vertical adjustment (for machine offset of the various heads). TP is available with quick release tool change, angular transmissions and copying ring capability.

CMS' type ATC working unit, Automatic Tool Changing, shown on the right, can be equipped in several ranges of spindle power and toolholding magazines for 3 axis CNC machining centers. Each ATC unit has a pneumatic insertion slide with double movement for tool change and release positions. An ATC can be placed side by side with other ATC heads on the same Z carriage, or with other types of working units, power 12 kW (16 hp) at 10,000 rpm, S1 rating, maximum 18,000 rpm, with ISO30 / HSK63F connection, liquid cooled, 8-place onboard toolchanging disc, pneumatic auxiliary slide with double movement. ATC is also available with ceramic bearings, up to 15 kW power (20 hp), S1 rating, at 12,000 rpm, maximum 24,000 rpm and with 4th axis device capability for spindle rotation of various aggregates, and up to a 16-place onboard toolholder magazine.

CMS' working unit: type TX3

CMS' tool changing unit, type TX3, shown on the left, can be equipped with different types of electrospindles, tool magazines and Z strokes, either 500 mm or 700 mm (19.68" or 27.56") and up to 4 TX3 units may be mounted side by side to work completely independently via CNC control on a 3 axis milling machine. TX3 can also accommodate the following accessories on the same Z carriage of the TX3 unit (on an independent insertion slide): various drill blocks, saw blade group, single-exit horizontal electrospindle either fixed or CNC-controlled. TX3's spindle power is 12 kW (16 hp) at 10,000 rpm, S1 rating, maximum speed 18,000 rpm, with ISO30 / HSK63F connection, liquid-cooled, 8-place onboard tool changing magazine. TX3 is also available with ceramic bearings, up to 15 kW power (20 hp), S1 rating, at 12,000 rpm, maximum 24,000 rpm and with 4th axis device capability for spindle rotation of various aggregates, and up to a 16-place onboard toolholder magazine.

On the right can be seen TX3 with a 9+4+4 drill block unit with dust collection shroud (to the left of the TX3 head) and on the right of the TX3 head is a barcode labeling device to print and apply labels as required prior to the start of the machining cycle.

CMS' working unit: type PX5

CMS' working unit, type PX5, is a 5-axis, universal (bi-directional) head with automatic tool changing, power 12 kW (16 hp) at 12,000 rpm, S1 rating, maximum 24,000 rpm, with pneumatic brakes on B/C axes for automatic insertion when either of these axes is not being interpolated by the CNC mill, HSK63F connection, liquid-cooled, +/- 120° B axis rotation, +/- 270° C axis rotation.

In the photo to the left PX5 is shown mounted on CMS' ARES 5 axis milling machine, or alternately on a POSEIDON, in which case it comes with a standard 8-place tool rack, located onboard and under the bridge for fast tool changing. It is available optionally with a 2nd 8-place rack under the bridge, and PX5 on POSEIDON may also be equipped with a 16-place rack located at the side of the work envelope, and as an option for either ARES or POSEIDON a 24-place tool changing disc located to the side of the work envelope. PX5 is shown with a clamshell style dust hood for 5 axis work, which opens (as shown in the picture) to permit tool changing or to pick up and work with an aggregate.

In the photo to the left PX5 is shown mounted on either FXB or MBB, in which case it comes standard with a 16-place onboard tool changing magazine, located to the front of the working unit, with CMS' patented 5-axis dust collection hood with rotating manifold on the C axis. In this version PX5 may also be equipped with the following accessories mounted on the same Z carriage: various drill block groups, blade group, single-exit horizontal electrospindle, either fixed, CNC-controlled, or in combination with a 2nd PX5 unit mounted on separate carriage and working independently under CNC control or with a TX3 working unit. In the picture a drill group, with dust collection shroud, is also shown with its pneumatic slide down and in the working position, while the PX5 is up and could also be changing a tool while the drill group is working, masking the tool change time.

CMS' working unit, type TUCU

CMS' working unit, type TUCU, is a universal (bi-directional) head with automatic tool changer, located at the side of the working unit, available with either vertical stroke of 770 mm or 1200 mm (30.31" or 47.24"). TUCU is characterized by high power, stiffness and its special C axis version, which has an electrical ring-type manifold to allow its rotation over 360°, continuously, and for all necessary support systems including, liquid, air and CMS' patented 5 axis dust collection system, +/- 110° B axis rotation, 360° C axis continuous rotation, power 13 kW (17.4 hp) at 12,000 rpm, S1 rating, maximum 18,000 rpm, liquid-cooled, with pneumatic brakes on B/C axes for automatic insertion when either of these axes is not being interpolated by the CNC mill, HSK63/E connection, 16-place automatic tool changing disc. TUCU is also available in an optional maximum 24,000 rpm version.

In the photo to the left TUCU is shown with its 5 axis dust shroud open and ready to change tools, or work with an aggregate. The photo to the right shows TUCU's structure with dust collection system, and the dust hood closed and ready for work.

CMS' working unit, type R4

CMS' working unit, type R4, 5-axis, is a universal (bi-directional) 4-spindle revolving unit, having the fastest possible tool changing time - since the time for a tool change is the time to rotate to the next required tool - with pneumatic brakes on B/C axes for automatic insertion when either of these axes is not being interpolated by the CNC mill. Each revolver station can be equipped with electrospindles of various performance characteristics, among the following: - 8.5 kW (11.4 hp) electrospindle at 18,000 rpm, S1 rating, maximum 24,000 rpm; - 6.6 kW (8.9 hp) electrospindle at 9,500 rpm, S1 rating, maximum 12,000 rpm; - 4.4 kW (5.9 hp) at 4,500 rpm, S1 rating, maximum 4,500 rpm, with CMS tool holder connection for ETS25, ETS32, ETS40 collets, air cooled, +/- 210° B axis rotation, +/- 270° C axis rotation.

R4 is also available with quick tool release connections for its standard electrospindles, a 2nd converter for handling 2 electrospindles at the same time, providing instant startup of the next spindle while the other is slowing down and stopping, or a tool changing electrospindle, in place of a standard spindle, with ISO30 connection, 7.5 kW (10.1 hp) at 12,000 rpm, S1 rating, maximum 24,000 rpm and equipped with a 6-place tool changing magazine mounted at one end of the beam.

CMS' working unit, type KX5

CMS' working unit, type KX5, 5 axis, is a powerful universal tool changing head, with pneumatic brakes on B/C axes for automatic insertion when either of these axes is not being interpolated by the CNC mill, +/- 110° B axis rotation, +/- 300° C axis rotation, with a 16-place, lateral pick-up tool changing magazine placed to the side of the work envelope. The KX5 working unit is used on CMS' POSEIDON class 5 axis milling machines and its 15 kW and 28 kW spindles are used in CMS' Torque5 working unit on its CRONUS class machines.

In the photo can be seen 2 KX5 working units, mounted on the same POSEIDON bridge completely independent under CNC control, capable of full flood machining in heavy, high speed aluminum processing applications. KX5 may come equipped with different style dust hoods for dry 5 axis machining, and for combination requirements, it's possible to combine a dust hood with oil mist or full flood machining requirements, or both.

KX5 asynchronous electrospindle, AC15_24 - HSK63E connection, ceramic bearings, 15 kW (20.1 hp), 12,000 rpm, S1 rating, 12.1 Nm, maximum 24,000 rpm, liquid cooled

KX5 synchronous electrospindle, SC28_18 - HSK63A connection, ceramic bearings, 28 kW (37.5 hp), 4,300 rpm, S1 rating, 63.0 Nm, maximum 18,000 rpm, liquid cooled *

KX5 synchronous electrospindle, SC28_24 - HSK63A connection, ceramic bearings, 28 kW (37.5 hp), 4,300 rpm, S1 rating, 63.0 Nm, maximum 24,000 rpm, liquid cooled *

KX5 may also be equipped optionally with a joint for air or liquid passage through the spindle and the tool cutting body shaft (only for SC28_18 and SC28_24), or accelerometer hardware for vibration control on the electrospindle, or also CMS' patented 5 axis dust collection system with rotating manifold.

* NOTE: Synchronous motor spindle control provides the opportunity to use the spindle shaft in a 6th axis mode for precise rotation of a device to a particular angle, for example the rotation of a "touch probe" to a precise angle about the spindle armature axis for qualification and verification purposes.

CMS' working unit, Torque5

CMS' working unit, Torque5, 5 axis, universal tool changing head, with pneumatic brakes on A/C axes for automatic insertion when either of these axes is not being interpolated by the CNC mill, liquid-cooled, 16-place lateral pick-up tool changing magazine placed at the left side of the work envelope, with direct high precision encoders, accuracy tested at CMS. +/- 110° A axis rotation, +/- 300° C axis rotation.

Torque5 has several dust hoods for dry 5 axis machining, and for combination requirements, it's possible to combine a dust hood with oil mist or full flood machining requirements, or both. In the picture to the left Torque5 is shown with a clamshell style dust hood, in the picture to the right Torque5 is shown with an accordion style dust hood, which is collapsed in its upper position and can be extended to its working position via m-code as needed. In the photo to the center a picture of Torque5's linear motor, with cut away, is shown.

CMS' Torque5 working unit uses today's high end servomotor performance technology, in which Torque5's direct drive motors may be conceived as linear motors in a rolled-up form, consisting in an outer stator whose electrical windings are used to create the magnetic field needed to transmit the required torque to rotate the inner rotor, having permanent magnetos placed about its circumference.

Torque5's direct drive motors, its rotational system drives, are permanently excited synchronous servomotors with the following advantages:

• Very fast rotational movements
• High dynamics
• High static stiffness
• No inherent wear parts
• High torque
• Elimination of backlash
• High end positioning accuracy

Torque5's technical characteristics are as follows:

• Torque in continuous service: 480 Nm – liquid cooling
• Torque maximum: 1200 Nm
• Velocity maximum: 36,000°/min., 100 rpm (188 m/min. at 300 mm)
• Acceleration max.: 2500°/sec^2 (13 m/sec^2 at 300mm)
• Error of rotation axial and radial: 0.01mm (0.00039")
• Torque of locking brake: 1000 Nm
• Support bearings: Precision slewing axially - radially with rollers Rigidity at reversal: 21.4 KNm /mrad

Troque5 synchronous electrospindle, SC28_18 - HSK63A connection, ceramic bearings, 28 kW (37.5 hp), 4,300 rpm, S1 rating, 63.0 Nm, maximum 18,000 rpm, liquid cooled *

Torque5 synchronous electrospindle, SC28_24 - HSK63A connection, ceramic bearings, 28 kW (37.5 hp), 4,300 rpm, S1 rating, 63.0 Nm, maximum 24,000 rpm, liquid cooled *

Also available with asynchronous electrospindle, AC15_24 - HSK63E connection, ceramic bearings, 15 kW (20.1 hp), 12,000 rpm, S1 rating, 12.1 Nm, maximum 24,000 rpm, liquid cooled

As with CMS' KX5, Torque5 may also be equipped optionally with a joint for air or liquid passage through the spindle and the tool cutting body shaft (only for SC28_18 and SC28_24), or accelerometer hardware for vibration control on the electrospindle, or also CMS' patented 5 axis dust collection system with rotating manifold.

* NOTE: Synchronous motor spindle control provides the opportunity to use the spindle shaft in a 6th axis mode for precise rotation of a device to a particular angle, for example the rotation of a "touch probe" to a precise angle about the spindle armature axis for qualification and verification purposes.

HSK toolholders for optimum cutting performance

Part of the overall chain of essential considerations, and equally important to spindle design performance, is the spindle's tool holding system, and, in consideration of which, CMS supplies the standard range of HSK toolholders for its working units, noted for their:

• ability to work well at higher speeds, essential for today's aerospace and advanced materials applications
• dual surface location design, which engages the spindle's nose with a 1:10 mounting taper ratio, as opposed to the traditional cone taper of 7:24
• diminished susceptibility to changes in accuracy due to unequal surfaces' heating as seen with traditional cone taper tools and their receiving shaft
• improved holding of the tool at higher speeds due to the beneficial effects of centrifugal speed, which forces the gripper tighter to the internal wall of the hollow of the toolholder and consequently into the spindle nose seat
• resulting high level of functional stiffness CMS' standard HSK toolholders are provided with a wide selection of collet diameters with ring nut for securely locking the cutting tool into the toolholder. In addition, CMS also provides the Tribos HSK toolholder system for applications requiring even higher levels of precision, and extended tool length runout control, which benefits from its tool shaft 3 point compression holding methodology and virtually eliminates runout and the attendant problems of vibration - even more pronounced with tools working at extended lengths from the nose of the spindle, and is noted for its:
• run-out accuracy of less than 0.003 mm (0.0001")
• suitability for high speed applications, tested up to 205,000 rpm
• tool changeover time: within 20 seconds, removing and replacing the tool in the toolholder body
• extended clamping range with interchangeable sleeves and tool extensions
• maintenance-free design
• axial length adjustment ability
• stability at high speeds improved tool life, benefiting from nearly zero runout

In the picture to the left is seen the standard HSK toolholder with collect and ring nut, and in the picture to the right is seen the Tribos HSK toolholder with 3 point compression holding methodology for the tool shaft.

Cutter cooling/lubrication - dry, oil mist or full flood versions

Depending upon the machining process, type of machine, and combination of cutter cooling/lubrication requirements, CMS provides its working units in dry, oil mist or full flood versions.

In the photo to the left a KX5 working unit with full flood capability is shown cutting heavy plate in a high speed aluminum machining process via a CMS CNC mill. The photo to the right shows an aluminum cutting application supported with oil mist to cool and lubricate the cutter. The same system that delivers the oil mist may also be run "dry" using compressed air to cool the tool while cutting, as well as helping to remove chips from the cutting path, avoiding "chip recutting" and cutter overheating.

Working unit dust hood options

Depending upon the work to be done, number of axes and machine type, CMS has a variety of dust hood options available for its working units specifically designed for use in 3, 4 or 5 axis applications:

• Clamshell style - for straight forward applications where tool length is more or less constant and not excessively long, with a more or less tight opening and brush at its extremity, allowing for a simple hinged retraction and opening of the dust hood for tool change, or even to work with an aggregate.
• Accordion style - where it’s possible to allow for somewhat longer tool lengths, and variation of projected length from the spindle nose, to accommodate several different tool lengths, having a somewhat larger opening and brush at its extremity. Automatic "dust hood" changing system - for applications where tool length requirements vary greatly, which makes it possible to have specific dust hoods in an "automatic dust hood changer" for specific types of tool lengths and to provide the optimum efficiency for each situation, where the hood is changed out prior to the tool being changed out, followed by the next tool and next hood, as required.

In addition, CMS provides "high velocity vacuum pump" systems for a higher air velocity, with deeper vacuum draw, depending upon the application requirement.

In the photo to the left is seen CMS' clamshell style hood on its PX5, 5 axis working unit. In the central photo is seen CMS' accordion hood on its Torque5 unit in the "retracted" position for tool change or work with an aggregate on a 5 axis milling machine. In the photo to the right the Torque5 unit is seen with its dust hood fully extended to work with a tool of somewhat longer projection from the spindle nose.

EPS foam milling tools - integrated dust collection capability

Developments in the use of EPS foam as a substrate in mold and model making, over which a curable paste is applied and later machined to a finished surface, has turned out to be an important technological advance, but extracting and collecting the dust while machining proves very difficult.

For machining EPS foam with one of our 5 axis milling machines, CMS provides an effective alternative to other traditional dust collection methods. In this photo is pictured CMS' special EPS foam machining tools with integrated dust collection capability. The cutting tools are connected directly to the dust collection system, are longer–providing the benefit of being able to reach into deep recesses, a typical need in model making–and larger in diameter, making roughing and milling operations at high speed much easier. EPS dust is drawn through the tool shaft's hollow body, moves out through a rotating manifold at the spindle nose into the facility's dust collection system, and is as effective in 5 axis applications as it is in 3 axis, and eliminates the need of a dust hood.

Tool storage - onboard disk rack versions

Tool storage is another important consideration based on number of tools required, tool weight and frequency of change. In this photo two variations of CMS' rack storage system are shown. To the left is a standard 8-place, stiff spring loaded, tool grip rack positioned onboard the bridge for fast, 5 axis tool changing on your CNC mill, which can be doubled, if needed, with an additional 8-place rack on the bridge. To the right is another version of the 8-place rack, but designed for much heavier tools, requiring a positive pneumatic release command for the tool grips. Both rack styles also include a CNC controlled cover plate to keep dust from collecting in the head of the toolholder. For additional tool capacity requirements, depending upon the machine version, it's possible to supplement the rack with a 16 or 24 place disc carousel.

Tool storage - large format machines

Shown in this photo is CMS' standard 16 place toolholding rack placed to the side of the work envelope for large format 5 axis milling machines. When a tool change is required the toolholding rack extends out into the work envelope from under its protective dust cover and following tool change retracts to its storage position under the cover. It may also be supplemented with an additional 16 place rack or a 30 place CNC controlled disc carousel.

Tool storage - disc carousel

This photo shows CMS' 24-place tool storage CNC controlled disc carousel. The disc carousel provides compact, rapid access, dust protected storage for many additional tools. When a call for a tool change occurs, the doors open, following which the carousel extends into the work envelope, and the disc rotates to the requested tool position. There are several versions of disc carousel available depending on the CNC mill machine type: 16 and 30 place.

Rail and pod/clamping systems

CMS provides a wide range of rigid, heavy duty, rail and pod/clamping systems for each of its families of milling and machining centers. Rail and pod/clamping systems are an important element in part holding methodology when vacuum surfaces are insufficient, parts are oddly shaped, intermediate processing moves may be required, or elevated part holding pressure is necessary for processing operations. Depending upon the overall combination of processes a particular machining center may need to handle, it's also possible that the rail and pod/clamping system might be equipped with a special vacuum table permitting it to do double duty, supported by the rail and pod/clamping system.

Rail and pod/clamping systems are available in:

• manual setup versions, in which the operator, assisted by readout scales, moves the rails and pod/clamps to the variously required positions for work and locks them into place
• semi-manual setup versions, in which the operator, assisted by LED readout and verification scales, moves the rails and pod/clamps, and - as the correct position is being acquired the LED flashes orange, green when it is acquired and red, if it is passed - then locks them into place. automatic setup versions, in which the CNC executes the setup instructions as per its program, moving the rails and pod/clamps to the specific required positions for each element - with the possibility of additional moves being carried out during the processing cycle, if required, which, as true for all special requirements, should be discussed during the project phase - and then locks them into place.

Rails may be of various widths, typically 1500 or 2000 mm, and on them may be placed various vacuum operated pods, references, loading/unloading support bars, as well as pneumatically activated clamps and vices.

In the picture to the left is seen 3 manually set rails with clamping devices rigidly holding an aluminum extrusion for its heavy processing requirements, in the picture to the right is seen a special aerospace fixture used in a larger POSEIDON 5 axis milling machine, in a pendular work cycle, and equipped with CNC controlled setup of rails, vacuum pods, support rails and reference points.

FTS - CMS' CNC controlled Flexible 3D Table Solution

In this photo, courtesy of DAHER - SOCATA, CMS' special FTS (Flexible Table Solution) is shown. FTS provides aerospace manufacturers with the flexibility to hold oddly shaped surfaces, as for example today's new composite material surfaces, which need routing, drilling and trimming, along with other special needs, like paint removal and conductivity testing for metal surface bushings. FTS makes it possible to "fixture up" 3D surfaces regardless of height variations, surface contours, varying angles of surface contact, surface size and reference requirements and to provide quick, accurate and just-in-time setup production capabilities.

FTS works in conjunction with the CNC's controller and the machine's 5 axis working head to present, as requested by the controller, each specific support pod needed, raise it to the correct height, at which point its height position is rigidly locked into place by FTS, following which the working head makes whatever required B&C axis inclination of the pod is needed, then securely locks this position into place. During the same setup cycle, FTS will also place, where required, referencing devices, which are inserted into its pods, designed to provide for this double function, furthering extending its flexibility.

Making FTS even more flexible is the fact that an FTS unit can be provided in each working zone so that nonstop (pendular) work cycles can take place, and surfaces, even of different types, can be produced on each FTS unit at the same time. FTS' methodology is unbeatable for overall speed of setup, flexibility for reference requirements and absolute control of each location in space.

In the picture to the left FTS is shown in the process of setting a pod at its required height and inclination under the working unit's CNC control, in the picture to the right FTS is shown supporting a composite wing surface with each pod at its required height and angle of rotation, providing the surface's optimum holding condition and true position in space.

CMS' patented "ring pressing device" for stacked aluminum sheet cutting

Another of CMS' important innovations is its patented "ring pressing device" for stacked aluminum cutting (or other non-ferrous or sheet materials), shown here. CMS' "ring pressing device" is a significant advance over previous traditional methodologies, which resulted in drilling, screwing or riveting stacks of aluminum sheets together to a waste board, routing groups of nested parts from the stack, breaking out the parts after machining and then manually removing the "micro tabs" left over from the machining process, often resulting in a slower, less accurate, reduced quality outcome.

CMS' patented "ring pressing device" can be used on several of CMS' families of 5 axis CNC milling and machining centers. The "ring pressing device" works with stacks of aluminum sheets 12 mm in height. The cycle has two phases. In the first phase the "ring pressing device" exerts a lower pressure on the stack and carries out the majority of the machining work to be done, including drilling holes and routing the path around the parts. During this phase several "micro tabs" are left along the path in predetermined locations to hold the parts to the sheet. During the second phase the "ring pressing device" is directed to return to each of these locations and the "ring pressing device" is fixed at that location, exerting a high pressure, while the machining head is free to move +/- 20 mm within the "ring" and so remove the "micro tab", resulting in a perfect part, no excess manual breaking-off of tabs or cleanup work later, and no preparation before work for the hundreds of excess holes, screws or rivets required to hold it all together.

The "ring pressing device's" work is supported by CMS' special high velocity vacuum pump system, providing for optimum chip removal during the machining cycle, which would otherwise naturally contribute to surface scratching. The "ring pressing device" is also designed for easy removal when not needed.

In the picture to the left the "ring pressing device" is shown holding a stack of aluminum sheets and waiting for a tool change to begin its machining cycle, in the picture to the right is shown a stack of 8 sheets which have been already cut and the resulting high quality edge finish.

CNC application of curable paste to EPS substrates for mold and model makers

Among the important advances for mold and model makers, reducing cost, inventory of raw materials and lead time, is the opportunity to use EPS foam as a substrate upon which can be applied a curable paste and, which after curing, can be machined to a finished surface. Having already produced the program to machine the EPS foam surface with CMS' special machining and dust extraction tooling, it's a simple step to re-post the information to work with the special equipment needed to apply the curable paste. CMS provides the integration so that both the machining and paste application technology can be done with the same machine. Such integration is particularly helpful on large surfaces without intricate complexity, such as boat hulls, decks, wind blades or molds and models of various types and, as well, benefits from the precise CNC control of the depth of the paste avoiding waste and extended curing time.

In the picture to the left paste is being applied to a vertical deck surface, without "sagging" or "drooping", in the picture to the right paste is being applied to a horizontal curved wind turbine blade surface and in both pictures the paste blends well with itself, but does not "sag" or "droop" and the paste will be ready for machining in about 24 to 36 hours.

Hotwire cutting of EPS foam - integrated into a machining center

Certain processing applications in EPS foam can benefit from cutting with "hotwire" technology, as opposed to machining the same edge or surface. Hotwire cutting can provide a quick, accurate, finished cut over a large surface in a greatly reduced time, providing a finished edge on both sides of its cut at the same time, whether straight edges or even edges nested within each other.

In another special application, CMS provides hotwire cutting capability integrated into one of its standard 5 axis CNC milling and machining centers, which is capable of picking up a special frame on which the "hotwire" is mounted and driving the "hotwire" cutter through large or smaller blocks of EPS foam, vertically, horizontally, or in combined complex movements. For applications benefitting from "hotwire" technology, cut time is tremendously reduced, dust is eliminated, and finished cuts are immediately obtained.

In this picture the "hotwire" is shown moving in a "saw-tooth" fashion vertically through the edge of a large block of EPS foam... imagine the dust generated and the time taken to obtain this same edge with conventional machining.

Integration of Robots with machining centers, work cells or lines

Many of today's processing applications may benefit from some aspect of robotic integration, either by manipulation of a part or panel, or by the performance of some secondary process in tandem with the machining center. CMS offers and integrates robotic devices into its 5 axis CNC machining centers, work cells and lines. Robotic integration, flow of information and commands, and determination of safe interfacing between the operators, machine and robot in their work together is carefully considered and engineered into the final project.

In the photo, as part of a final preparation for an acceptance test, seen without the barrier protection in place at this point, a robotic device is shown picking up a full sheet with a vacuum grid end-effecter and is ready for loading it onto the machining center's work table.

Integration of Ultrasonic cutting technology

In addition to other methods for trimming and cutting honeycomb materials, CMS also provides high frequency ultrasonic cutting capabilities, which can be integrated into a standard machining center.

In the picture to the left is seen an ultrasonic device mounted into the working unit's spindle with short knife type cutter, and in the picture to the right is seen an ultrasonic slicing cutter in the process of trimming a honeycomb part.

CMS' smooth flatwork steel table

Seen in this photo is CMS' basic smooth flatwork steel table with a grid of anchoring points for fixtures, waste boards or molds, as shown on an ANTARES 5 axis CNC machining center. The smooth steel flatwork table is built upon CMS' robust substructure for solid, vibration-free cutting and is designed so that waste can be brushed or blown to the back of the table across its smooth surface and into a declined recess at the back for easy removal later, or evacuated through the dust collection system. Or as in the case of the ANTARES, the waste can be disposed of when the waste drawers, 2 each located underneath it in the front and back of the machine, are removed.

Aluminum plate, gridded work surfaces with steel T-slots

CMS offers solid plate aluminum work surfaces in several versions. In this photo, to the left, is shown CMS' thick aluminum plate work with gridded surface, designed to work with vacuum gasket, accessible through an array of holes in the table, sealed with removable threaded bolts with o-ring. This table may also be supplied with, recessed, inlaid steel T-slots providing for rigid heavy anchoring requirements, as shown in the photo to the right.

Aluminum table - reference hole array, vacuum access and grid sectioned

Shown in the photo is an aluminum table with reference hole locations, large spaced grid work, and vacuum access at grid intersection points. This heavy table is designed to work with a full flood application, quick precise pattern placement via pin and hole reference array, and to provide vacuum to the patterns and fixtures, which have been sealed off via gasket and located above the vacuum access intersection points.

Full flood cutting table versions

The photo shows a full flood table version. The table is the previous one discussed and in this picture can be seen the double vacuum hose connection providing the table with 2 vacuum work zones, which can be controlled independently via m-code. In addition the table has been provided with a complete guard and catch rim all the way around it to control and direct the cutting fluid to a filtering and recirculation unit. This is an example of CMS' special fabricated work tables, which are produced and equipped based upon the project requirements, and which can also be provided with the complete chip collection and disposal system, cutting fluid capturing, filtering and recycling equipment as well.

APC tables, Automatic Pallet Changing

CMS also provides APC tables, Automatic Pallet Changing, on many of its 5 axis CNC machining center versions. APC tables represent an important capability in processing options. APC tables make it possible to carry out nonstop (pendular) work cycles, external to the work zone, increasing output capacity and assuring operator safety during production, while increasing access around the table and making it easier to unload/load work from 3 sides, as opposed to just the front of the table, or change out the pattern, fixture or mold for a different one. APC tables can also be "slaved" so that they work together, increasing available work surface, as well as their flexibility.

In this photo a large set of APC tables is shown, capable of supporting heavy weight, distributed in a non-uniform placement on the table, with an array of reference pin location holes for fast, accurate fixture or template placement. In addition at the front of each APC table is a set of compressed air and vacuum connections for work which requires these capabilities during processing operations with a pattern, fixture or mold, or for manipulating mechanical devices, such as clamps, vices, or connection to vacuum pods.

Cast iron tables

Cast iron's properties, including its ease of casting and machining, resistance to wear, deformation and oxidization, have long made it a desirable choice as a work table, among other industrial applications. CMS provides a complete range of cast iron tables, based on process requirements, in various lengths, and widths, including T-slots, and according to the various DIN levels of surface precision, as required. As with CMS' fabricated tables, cast iron tables may be placed on the floor or in the floor, subject to discussion and clarification of all engineering details.

In this photo a large, heavy, cast iron table is shown with T-slots running in both directions.

Vacuum flow through belt table

CMS' vacuum flow through belt is another table option available on its MBB series of 3 and 5 axis CNC machining centers useful for acrylic, plastic or other sheet material applications and makes possible flow through processing operations. The vacuum belt brings sheet material into the machining center's work zone, where it is aligned and, at which point, the vacuum system, according to the sheet size, activates the most efficient vacuum zone arrangement to hold the sheet. The vacuum is drawn through venturi spread across the entire surface of the belt to increase and deepen the effect of the normal vacuum. The vacuum belt has a "stiffness" which supports the sheet in work, while at the same time provides a natural sealing surface to the bottom of the sheet. During processing any chips that block the venturi further increase the depth of vacuum and at the end of the cycle the chips are removed from the venturi as the belt moves by a brush cleaning device located at the end of the machine on the belt's return trip.

The process cycle is designed so that the cutting tool only passes a few thousandths of an inch beneath the sheet being cut. That being the case, the vacuum belt has a long life, and is such as to be more cost effective than resurfacing and replacing waste boards. To ensure that the belt is not inadvertently damaged by incorrect information from operator input, or wrong tool loading, the machining center is provided with a "touch probe" to determine tool length and automatically enter this value into the controller's tool offsets before beginning work.

In the photo to the left can be seen the flow through vacuum belt as it appears at the end of the 3 axis milling machine with brass venturi across the surface of the belt. In the photo to the right is seen an MBB CNC mill with flow through vacuum belt and an unloading belt station placed to the end of it.

CMS' Tool Presetting and Axis Alignment Device (TPD) - contact probe

CMS' Tool Presetting and Axis Alignment Device (TPD), a compact touch probe, has proven particularly useful in 5 axis applications with its multiple capabilities for:

• Verification of the B and C axes' rotational accuracy prior to commencement of machining, helpful for compliance requirements or implementation of operator "due diligence", eliminating surprises resulting from an inadvertent, non-communicated, head crash and avoiding the production of bad product.
• Automatic correction of B and C axes' alignment, following the failure of axis verification the TPD also functions to correct and realign the B and C axes and with the new axis information make the adjustments needed to the controller, following which, with the reboot of the control, the new information becomes active.
• Length and radius measurement, in addition TPD also functions as a tool presetting device, which makes it possible to acquire data for tool length and radius. A cycle is executed, selecting a tool, and a simple probing of the tool's length on top of TPD's disc obtains its length measurement; and for the tool's radius, a routine spins the tool backwards on the side of TPD's disc at about 100 rpm to check and acquire the radius permitting the controller values to be updated.
• Tool wear compensation, in the same way, TPD can also be used to check for tool wear and make the necessary updates to the current controller data so that all values are currently compensated correctly. Tool integrity check, as part of a cycle or prior to commencement of a cycle, TPD can also be used to make sure that the cutting tool has not been broken.

If the tool fails the integrity check, it's possible to combine this with a command to change out the broken tool to another predesignated tool already available in the tool rack.

CMS' laser tool presetting device - non-contact probe

CMS' laser tool presetting device proves useful with its multiple capabilities for:

• Non-contact methodology, the laser presetting device provides a convenient "non-contact" probing device applicable for all tool data acquisition purposes.
• Length and radius measurement, as with the contact version, the laser presetting device makes it possible to acquire data for tool length and radius. A cycle is executed, selecting a tool, and a simple probing of where the tool tip crosses the laser light determines its length measurement, while for the tool's radius, a routine spins the tool backwards to the side of the laser light at about 100 rpm and acquires its radius, following which the controller values can be updated.
• Tool wear compensation, the laser can also be used to check for tool wear and make the necessary updates to the controller. Tool integrity check, as part of a cycle or prior to commencement of a cycle, the laser presetting device can also be used to make sure that the cutting tool has not been broken and, upon failure during a tool check, to request the change out of a broken tool with another predesignated tool already available in the tool rack.

Spindle mounted, wireless, contact probes

CMS provides spindle mounted, wireless, contact probes, which can be placed in the tool changer rack to serve a variety of process requirements:

• Probing of a model or part to determine its location in space and to update the program information relative to its real position, so that the program is executed based upon the probing results of a real location in space, reducing setup time, and improving accuracy
• Probing to verify information on a produced part and overlay it to the programmed information to check correspondence Probing to gather geometric information for modeling purposes

Laser scanning devices for data acquisition used with data manipulation

CMS also provides laser scanning devices for data acquisition. Such laser scanning devices provide rapid acquisition of large amounts of data, which can be sent to external software programs for manipulation and program adjustment just prior to the execution on the CNC program. For example, in this picture a POSEIDON 5 axis milling machine has picked up a laser scanning device in order to scan the surface of a fiberglass boat deck. When the fiberglass component is removed from its plug, it is subject to spatial distortion, since the component is nothing but a shell and even when incorporated into the boat's final structure, will still have some give. Determining where various features actually are in space is important prior to trimming the deck. Not only is it probable that the deck is not located in space where expected, but also that the distance from one wall to another is not as expected, or that an opening which needs to be machined will have some surface dimensional distortion associated with it. The laser scanner is driven by a preliminary CNC program to scan the important areas to be machined; spatial surface and feature data is captured and sent to external software, which manipulates the data, and sends the updated program information to the CNC machining center so that a perfectly trimmed part can be obtained.

Label printing and application systems

CMS provides label printing and application systems to carry out part labeling requirements for full nested sheet processing, either prior to entering the machining center, and so masking the time for the labeling operation, or as part of the processing cycle with the following capabilities:

• label definition: number, content and position of labels definable for each panel
• label size: from 19 mm to 118 mm (0.75” to 4.64”) wide by 20 mm to 120 mm (0.79” to 5.90”) long
• printing technology: heat transfer or direct heat
• printing resolution: 203 dpi
• printing speed: 8"/second
• memory: 1 MB SRAM + 1 MB Flash to load fonts, logo, and label information
• choice of printable fonts, bar codes according to unified formats, and images in pcx, bmp, img formats. average time for printing and application of label: 3 seconds

Linear Scales - high precision accuracy systems

Linear Scales - Measuring Systems technology in accordance with the AMOSIN Measuring Principle, and particularly significant for longer length machine strokes:

Based on the proven AMO technology of length and angle acquisition where high precision graduations, whose structures etched photolithographically in steel, are scanned, this next generation measuring system incorporates newly developed inductive sensors and an integrated electronic evaluation circuitry (ASIC).

As a next generation measuring system it opens up a wide range of applications from demanding high quality machine tools or measuring machines to handling systems or special installations for metal, advanced materials and composites machining applications.

As purely inductive operating devices, AMOSIN systems achieve high degrees of accuracy up to ±5µm/m. Yet they are nevertheless extremely resilient to environmental influences such as solid particles, composites, oil, and so forth and feature extremely high shock resistance and vibration strength. The coefficient of elongation of the measuring scale is identical to that of steel (~11 ppm) with the result that expensive temperature compensation facilities are unnecessary. Its high degree of accuracy is primarily attributable to the manufacturing process of its sturdy steel measuring scale and its outstanding sensor signal with sinusoidal accuracy deviations of up to only 0.1% (harmonic content as a measure of the attainable interpolation accuracy within one grating pitch). In contrast to magnetic measuring systems, the AMOSIN measuring principle has no magnetic parts (neither as part of the measuring scale nor the scanning head) and is therefore completely insensitive to all types of electromagnetic interference fields.

Main properties:

• insensitivity to all types of dust
• insensitivity to magnetic interference fields
• high accuracy and resolution
• high traverse speed
• easy installation
• integrated reference mark, also distance-coded protection level: IP67 (without pressurization)

Precision and repeatability - CMS assures the positioning precision and repeatability of the axes through the use of precision checking devices. Axis verification is made by using Renishaw LASER and BALLBAR measuring systems and usually carried out according to the VDI-DGQ 3441 rules, or other standard which may be agreed upon.

Full flood cutting systems - cutting fluid filtration and chip take away

For full flood cutting systems, CMS' CNC milling and machining centers can be provided with an automated complete fluid recovery, filtration, and recirculation system, along with chip separation and disposal capabilities.

This photo shows part of one such system, in which the recovered fluid, which has been separated from the chips, is being separated from its small remaining particle components through a filter medium. Just before the filter medium reaches its saturation point, its weight is sensed and the filter medium is indexed forward and disposed of at the end of the machine, while the filtered cutting fluid is ready to be recirculated. The other parts of such a complete system may incorporate chip recovery capabilities, with mesh take away conveyor belts, which provide a first stage chip/fluid separation and then carry the chips away for disposal, either as part of an automated system or when manual cleaning takes place at a later time during the shift.

Steel flatwork table - dust management

This photo shows CMS' standard steel flatwork table, designed for the placement of fixtures, molds or various devices with an array of threaded holes for locating and rigidly anchoring them to the table. The standard steel flatwork table is also designed with ease of cleanup in mind, so that dust, scrap, and chips that fall down, remain on the table until the operator is ready to move them out of the way, when either a quick push with a broom or compressed air spray moves the waste to the back of the machine, into a declined, and recessed, holding area out of the way, where it can be easily removed at cleanup either by shoveling it out or pushing it toward a dust extraction opening. Dust and waste is left in the most convenient place until it's ready to be removed, not handled more than necessary and easily gathered up for removal or pushed to one of the dust collection openings for extraction along the back (one of these is seen opened in the middle of the, declined, recessed area to the back of the machine).

Dust extraction provisions

Along with the dust management of the steel flatwork table is the provision for dust extraction. As seen in the prior photo, along the back of the declined, recessed holding area, there is a series of extraction openings available, to which the production plant's dust extraction system can be connected. This improves the overall ambient conditions as the air flow is downward and to the back of the machine.

In the same way, as seen in this photo of an ARES 5 axis CNC machining center, an optional series of dust extraction openings is available at the front of the machine located at the foot of the table, making it easy to sweep up unextracted dust and waste into the dust collection system, and providing for a double downward extraction from both the front and back of the work envelop, for which the hookups are located on the outside back of the machine.

CMS' downdraft dust collection system

In this photo CMS' downdraft dust collection system is connected to an ARES CNC mill with APC tables. The downdraft system is placed along the back and both sides of the APC table and is specially designed to enhance the dust collection system's draw by the use of small parallel openings in the downdraft collection system. In this way, the movement of air being pulled down and past the 5 axis machining head is spread throughout the work envelop regardless of the orientation of the head while machining.

Total enclosure - ARES

The next step in dust control is coupling the downdraft dust collection system with CMS' total enclosure. The total enclosure closes the machine from the top, delimits the airflow and restricts any particulate from leaving the work envelop into the ambient. The total enclosure is also provided with internal lighting and acoustical sound deadening wall insulation, reducing noise emitted to the ambient. With both of these working together, air flow is guided from the top of the enclosure and pulled downward throughout the envelop toward the downdraft extraction openings, by which the dust and particulate, even from difficult to collect 5-axis machining situations, is trapped into the airstream and moved to the dust collection system, resulting in a cleaner operation and safer work environment.

CMS' total enclosure for its POSEIDON and CRONUS class machines

In this photo is seen a total enclosure for one of CMS' POSEIDON class 5 axis CNC machining centers. The enclosure fully encapsulates the entire machine including its vertical height and provides a complete, totally safe, very clean, and impressively finished machining center. As well as providing complete dust collection control for aggressive, dust generating, 5-axis machining applications, safe from any release to the ambient, with control of the door openings, multiple operator console positions, sound dampening, and internal lighting coupled with skylights for natural light entrance, this total enclosure also provides for fire suppression and may optionally be equipped with a powered retractable roof for overhead loading and unloading requirements.

In the photo on the left the total enclosure is seen from the outside with its powered doors on one end opened, double operator console, acrylic glass windows for natural light, and dust collection piping along its outside. In the photo on the right, the total enclosure is seen from within with its bridge and Z axis mast to the far end.

CMS' alternate folding roof total enclosure

CMS' alternate folding roof total enclosure is shown. The folding roof enclosure is based on an accordion principle, by which a section of folding roof, lockable and unlockable by machine control and powered to be moved away from its fixed end position, when required, is connected to one side of the bridge from each end of the machine. The folding roof, being mounted at the height of the bridge, is outside of the machining envelope, yet not above the machine's shoulder structure, making it possible to extract air from a greatly reduced volumetric space, as well as providing for easy mounting locations for internal lighting.

As the bridge moves back and forth, the folding roof alternately collapses and expands without ever allowing particulate to leave the working envelope and escape into the ambient. At the same time, if loading or unloading requirements from overhead exist, a command from the control console of the CNC mill directs one or the other of the powered roof sections to move from its end point and permit loading or unloading from overhead.

In the photo to the left can be seen the folding roof several meters from the end of the machine, as well as the internal lighting along the top at shoulder level. In the photo to the right the roof can be seen having arrived at its fixed end position.

CRONUS - showing its total enclosure, folding roof system

This photo shows a CRONUS 5 axis CNC machining center with its total enclosure folding roof system open and expanded to the far end of the machining center. The bridge, with its mast, is also shown extending above the folding roof. In the photo to the left the machining center is shown with its doors open and in the photo the right its doors are closed, completely enclosing the machining center and providing a dust free ambient, while at the same time still providing the ability to open a section of the folding roof and perform loading or unloading operations when needed.

NOTE: the folding roof system may be installed on CMS' ARES class 5 axis CNC machining center, as well, also providing for a complete total enclosure.