ECOSPEED Series5-Axes High Performance Machining Centers

02.2

011

- 2,

500

E -

2011

-199

Products:

Dörries Vertical Turning Lathes Vertical Turning Centers

Droop+Rein Portal Machining Centers High Speed Machining Centers

Scharmann Horizontal Machining Centers Boring Mills

Berthiez Vertical Turning Machines Vertical Grinding Machines

Ecospeed 5-Axes High Performance Machining Centers

Service

Headquarters:

Dörries Scharmann Technologie GmbHHugo-Junkers-Straße 12-32D-41236 Mönchengladbach-RheydtTel. +49/2166/454-0Fax +49/2166/454-300www.ds-technologie.dewww.starragheckert.cominformation@ds-technologie.de

Sites, Subsidiaries and Service Centers:

Dörries Scharmann Technologie GmbHProduct line Droop+ReinHofkamp 2, D-33719 BielefeldTel. +49/521/5804-0, Fax +49/521/178006

Dörries Scharmann Technologie Service Center GmbH & Co. KGAm Sülzenbrückener Weg 14, D-99334 IchtershausenTel. +49/36202/77980, Fax +49/36202/779829

Dörries Scharmann Technologie GmbHService Center SouthWannetal 47b, D-88131 LindauTel. +49/2166/454-700, Fax +49/2166/454-701

Dörries Scharmann Technologie GmbHBeijing OfficeRoom 704, Kun Tai Building, No. 10 Chao Wai Da Jie, Chaoyang District, 100020 Beijing, PR ChinaTel. +86/10/65995556, Fax +86/10/65995559

Dörries Scharmann Technologie GmbHMoscow Officeul. Tverskaya 16/2, Building 1, 7. Floor, RUS-125009 MoscowTel. +7/495/933 28 18, Fax +7/495/935 89 62www.ds-technologie.ru

DS Technology (USA), Inc.7861 Palace Drive, Cincinnati, OH 45249, USATel. +1/513/247-2590, Fax +1/513/247-2599sales@ds-technology.com

DS Technology (UK) Ltd.43/45 Phoenix Park, Avenue Close, Nechells, Birmingham B7 4NU, United KingdomTel. +44/121/3593637, Fax +44/121/3591868info@ds-technology.co.uk

Berthiez SAS5, rue Barrouin, F-42029 St. Etienne Cédex 1Tel. +33/4/77923992, Fax +33/4/77923993 www.berthiez.fr, sales@berthiez.fr

Is it your business?

2

C-Frame

Wing Rib

Spar

Stringer

A-shape Frame

3

Is this your cycle time?

Average Cycle Time (2 set ups in one cycle)less than 12 min/m, 12 min/39.4 in

Total Cycle Time (2 set-ups) 27 minutes

Total Cycle Time (2 set-ups) 8 hours, 42 minutes

Total Cycle Time (2 cycles) 4 hours, 15 minutes

Total Cycle Time (3 set-ups) 19 hours, 26 minutes

Material

Length / Width / Thickness

Billet weight

Part weight

Aluminium

5,800 x 1,600 x 100

1,200

30

mm

kg

kg

C-Frame

5,563 x 1,669 x 190

4,123

112.7

mm

kg

kg

Material

Length / Width / Thickness

Billet weight

Part weight

Aluminium

Wing Rib

Material

Length / Width / Thickness

Billet weight

Part weight

Aluminium

6,200 x 350 x 90

350

15

mm

kg

kg

Spar

Material

Stringer length

Aluminium

2,000 – 30,000 mm

Stringer

Material

Length / Width / Thickness

Billet weight

Part weight

Aluminium

900 x 900 x 52

87.6

4.56

mm

kg

kg

A-shape Frame

5

Down the years, Dörries Scharmann Technologie GmbH (DST) has established itself as a proven partner for the aerospace industry. In 1998 DST was challenged with the development of a machine tool concept to achieve the lowest cost per part at an optimum level of investment for monolithic aluminium aircraft parts. This resulted in the innovative and highly efficient ECOSPEED machine series. With the horizontally orientated, parallel kinematic Sprint Z3 machining head at its core, the ECOSPEED series sets the benchmark in its field.

Since market introduction in 1999, more than 50 machi-ning centers employing ECOSPEED technology have been installed at many major aerospace manufacturers world wide and are producing a wide variety of different com-ponents in different sizes.

The ECOSPEED series offers the most advanced techno-logy for machining aluminium aerostructure parts that will ensure future competitiveness for your business. Best reliability and performance installed with ECOSPEED technology with improvement over the years.

DST ECOSPEEDproduct series

Optimum

Over-engineered machinesLow cost machines

Cost

per

par

t

ECOSPEED Series

Contents

Cost at what priceOptimised Productivity

Investment costs

4

Page

6

8

10

12

14

24

Sprint Z3 – DST’s highly dynamic, parallel kinematic head concept.

ECOSPEED – Travelling column machining center with vertical table for large parts.

ECOSPEED F – Fixed column machining center with vertical table for medium sized parts up to 8 m in length.

ECOSPEED F HT – Fixed column machining center with horizontal table for small parts up to 1.25 m in length.

ECOLINER – Travelling column machining center for stringer parts.

Technical data and details

7

Well-proven head concept Sprint Z3

6

Working area

– Cubic working area through linear motion of X-, Y- and Z-axis.

- Conical working envelope with ± 40 degrees of angu-lar freedom.

Advantages

– Motor spindle in cartridge design– Linear ball screw drives with directly connected servo-

motors– No slip rings or rotary couplings required– Standard components are used– No counter balance for Y-axis required

Acceleration / deceleration in all axes

A-/B-axis conical work envelope

A-/B-axis conical work envelope

A-/B-axis

Z-axis

Rotation range

Axis speed

Acceleration

± 40 °

max. 80 °/ sec.

685 °/ sec²

1 g (9.81 m / sec2)

The parallel kinematic concept

Three parallel linear axis drives are mounted radially equispaced in a barrel-shaped headstock. The spindle platform is connected to each drive by means of rigid levers with a simple pivot at one end, and a ball joint at the other end. A high performance motor spindle is mounted to the spindle platform.

The headstock is mounted horizontally and moves verti-cally inside the column. This arrangement offers minimum movable mass resulting in unprecedented dynamic cha-racteristics.

When all three axes are moved equally and simultaneous-ly, the spindle is moved in a straight line in Z-direction.

If the three axes move differentially, the spindle platform will be tilted in the A/B-planes. Synchronized motion of the three Z axes allows the spindle to describe any path within a spherical cone of ± 40 degrees.

ECOSPEED Highlights

Since its introduction in 1999, the ECOSPEED machine with travelling column and its unique Sprint Z3 parallel kinematic head concept, has revolutionized high perfor-mance machining of large-sized aluminium structural aerospace parts, and rendered traditional multi-spindle profilers almost obsolete in this field of application.

Now, based on the experience of over a decade of round-the-clock operation, DST has proven that the ECOSPEED is the most productive solution in its class on the machine market, capable of drastically reducing production costs and time for large-scale manufacturing of structural aircraft parts. At the same time, machining accuracy and surface finish have been considerably improved.

98

Advantages

– Ergonomic horizontal part loading/unloading– Pallet changer for uninterrupted operation– Highly dynamic 5-axis simultaneous machining– High acceleration / deceleration in all axes – Very high material removal rate with direct disposal

via chip conveyor– Extremely high accuracy– Excellent surface quality– Dramatic increase in productivity, virtually

eliminating surface polishing– Highest crash safety– Advantageous price-performance ratio

ECOSPEED F Highlights

ECOSPEED F was developed from the ECOSPEED travel-ling column machine to provide an even more dynamic machine solution for medium sized structural aircraft parts. This was achieved by placing the unique Sprint Z3 parallel kinematic headstock into a fixed column, thereby reducing the moveable mass at the tool.

This arrangement provides the best preconditions for the most precise and fastest aluminium cutting process in structural aerospace machining today.

Advantages

– Ergonomic horizontal part loading / unloading – Twin pallet changer for uninterrupted operation– High acceleration / deceleration in all axes– Highly dynamic 5-axis simultaneous machining– Highest jerk characteristics– Highest material removal rate with vertical chip fall– Extremely high accuracy– Excellent surface finish quality– Dramatic increase in productivity, virtually eliminating

surface polishing– Highest crash safety– Advantageous price-performance ratio

1110

ECOSPEED F HT Highlights

Thanks to modern 3D CAD systems, designers are now able to exploit the physical strength properties of typical aerospace materials by selecting ever more complex geometric shapes, which in turn have lead to a large increase in 5-axis machining content. The ECOSPEED F HT is the highly dynamic, high performance and extremely productive solution to the very demanding machining tasks for small to medium sized parts resulting from this development.

As the name implies, the ECOSPEED F was developed one step further to combine the fixed column concept with a horizontal table group. Since the table group includes a NC-controlled continuous Bt-axis, the ECOSPEED F HT can boast 6-axis capability.

1312

Advantages

– Rotary pallet changer for uninterrupted operation– Highly dynamic 5-axis simultaneous machining – High acceleration / deceleration in all axes– Highest jerk characteristics– Very high metal removal rate– Extremely high accuracy– Excellent surface finish quality– Dramatic increase in productivity, virtually eliminating

of surface polishing– Highest crash safety– Outstanding price-performance ratio

ECOLINER Highlights

A special development of the ECOSPEED travelling column machine with shorter Y-axis, the ECOLINER is specifically designed for machining aluminium profiles – stringers – of up to 30 m length from thin billet material or semi-finished section.

The machine concept uses the unique Sprint Z3 head concept in combination with the lowest moveable mass to achieve the best preconditions for high precision and fastest metal cutting processes.

The machine is rounded off by a highly flexible, fully automatic fixture system which holds the stringer part in its raw and semi-finished condition in both set-ups for front and rear side machining, and also performs the intermediate transfer procedure.

All variances of stringers can be produced on ECOLINER. Machining time is 12 minutes per meter.

1514

Advantages

– Highly dynamic 5-axis simultaneous machining– High materal removal rate with vertical chip fall– Extremely high accuracy– Excellent surface finish quality– Dramatic increase in productivity, eliminating

surface polishing– Highest crash safety– Parts machined in both set-ups in one cycle

Raw part: T-section Al-extrusion

B

H

H1

B1

Stringer length

Stringer width

Stringer height

Profile height

Clamping area

Waste material metal removal

2 – 25 m

150 – 250 mm

30 – 82 mm

21 – 37 mm

11 mm

appr. 90 %

B

H

H1

B1

Spindle capacity, 100 % ED

Spindle torque, max.

Spindle speed, max.

Constant power from

Tool holder according to

Tool clamping force

Spindel technology

FeaturesSpindle

Features Jerk

1716

Spindel 1 Spindel 2

Flange size Ø BTaper size at gage line Ø A

HSK Tool taper shanks

Designation

DIN 69682 HSK-A63

DIN 69682 HSK-F63

DIN 69682 HSK-F80

DST Standard HSK–A 63/80

Ø A Taper size at gage line

48

38

48

48

Tool clamping force

18

11

18

21

kN

kN

kN

kN

mm

mm

mm

mm

Ø B Flange size

63

63

80

80

mm

mm

mm

mm

kW

Nm

rpm

rpm

kN

120

83

30,000

13,800 - 30,000

HSK A 63/80

21

80

46

30,000

16,500 - 30,000

HSK A 63/80

21

kW

Nm

rpm

rpm

kN

Spindel 1 Spindel 2

7.3

7.3

9.3

9.3

13

2.45

1.95

1.95

1.07

1.07

10

20

20

200

200

60

60

80

80

120

22.09

17.53

13.64

7.50

5.36

0

21

38

66

76

mm

mm

mm

mm

mm

sec

sec

sec

sec

sec

9

9

7

7

5

kW

kW

kW

kW

kW

sec

sec

sec

sec

sec

%

%

%

%

%

m/s3

m/s3

m/s3

m/s3

m/s3

Depth of cut Time / pass Number of passes

JerkTime / pocket SavingPower

Others

Others

Others

Spindle 2

Spindle 1

Spindle speed

Number of teeth

Chip load

Width of cut

Feed rate

Example Endmill Ø 32 mm

rpm

mm/tooth

mm

m/min

24,000

3

0.278

32

20

Machines with low jerk capability have difficulties in reaching programmed feed rate.

Conclusion

Velocity Change of position over time -> m/s

Acceleration Change of velocity over time -> m/s²Proportional to drive force in connection with the moved mass -> kg*m/s² = N

Jerk Change of acceleration over time -> m/s³Proportional to change of drive force in connection with the moved mass -> kg*m/s³ = N/s

100 mm50 mm

65 m

m

30

25

20

15

10

5

0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

time (s)

feed

(m/m

in)

jerk 10 m/s3

jerk 20 m/s3

jerk 50 m/s3

jerk 70 m/s3

jerk 100 m/s3

jerk 200 m/s3

Feed-time-chart (s = 50 mm)

Jerk is the significent key to achieving true high performance pocket machining.

Five sides milling and drilling

Two systems are available for integrating angular milling and drilling heads into the machine to expand the range of machining possibilities.

The first system includes a torque support with integra-ted air supply. Small angular drilling heads can be loaded into the spindle and then be positioned at the required angle through the M19 (spindle orientation) function. The selected position is maintained during machining by means of a pneumatically relieved brake. The angular drilling heads can be stored like standard tools in the tool magazine and handled by the automatic tool chan-ger. This variant is available for all machine types.

The second system entails the integration of a fully functional 6th NC-axis, - C-axis – consisting of a torque motor installed around the spindle. This arrangement is capable of receiving not only the small angular drilling heads as described above but also permits the use of a more powerful angular milling head with automatic HSK-A63 /80 tool clamping system. The selected position is maintained during machining by means of the NC control. In combination with a suitably configured auto-matic tool changer and magazine, this feature permits tools be inserted into the milling head as well as into the spindle. The head enlarges the angular work space cone of the spindle by 90 degrees in all directions, thus offering unprecedented accessibility. This system can be implemented on ECOSPEED and ECOSPEED F machines.

Comparison of working envelope

Right Angular Drilling Head, Example

Speed

Torque

Power

Clamping range

rpm

Nm

kW

mm

15,000

10

5

0,5 - 7

C-axis

Speed C-axis

Torque C-axis

C-axis angle

rpm

Nm

° continuous

30

220

360

Right Angular Milling Head

rpm

Nm

kW

15,000

46

20

Speed

Torque

Power

Tool holder according to HSK A-63/80

1918

Fork-type-heads DST ECOSPEED

min

. 2

00 m

m only

60 m

m

typical 200-350 mm 150 mm

Accessories Tool magazine

Accessories Pallet handling systems

2120

Chain magazine

Number of pockets

Tool shank

Tool length, max.

Tool diameter, max.per tool location

Tool weight, max.

40/60/80

250

80

10

pockets

HSK-A 63/80

mm

mm

kg

Rack type magazine WERO

Number of pockets

Tool shank

Tool length, max.

Tool diameter, max.per tool location

Tool weight, max.

129

250

80

10

pockets, min.

HSK-A 63/80

mm

mm

kg

ECOSPEED F HT

Chip to chip

Tool to tool

sec

sec

7

1,8

ECOSPEED F

Chip to chip

Tool to tool

sec

sec

8

1,8

ECOSPEED 2570

Chip to chip

Tool to tool

sec

sec

15,3

2,5

Example of machine system arrangement

Double pallet shuttleload/unload station and buffer stores

Pallet load/unload station

Pallet changer in tilt motionPallet changer stand alone machine

Flexible Manufacturing Systems SINDI Life-cycle-costs

DST Cell Controller

– Well proven and often implemented software solution specifically developed by DST

– Serves to automatically control flexible manufacturing cells with 1 or more machining centers, an automatic pallet transport system, any number of pallet buffer stations and component load/unload stations.

2322

ECOSPEED series machines are equipped with commer-cially available standard guide way, drive and feedback system components, appropriately dimensioned to ensu-re long life cycles with calculable maintenance costs.

The motor spindles are guaranteed for 5,000 operating hours (under S1 [100% DC] conditions). Due to their cartridge design and the simple media connections, spindle exchange can be performed within a few hours. Furthermore, DST’s spindle refurbishment program ensures that equal replacement spindles are always available.

Self-diagnostic systems ensure that maintenance per-sonnel are always up-to-date on the condition of all machine elements, and in combination with preventative maintenance programs, guarantee very high machine availability.

High quality machine tools will repay your invest-ment thru:

– Highest productivity– Highest availability– High accuracy– Calculable life cycle costs– Long service life

Whereas low quality machine tools mean:

– Low productivity– Low availability– Moderate accuracy– Incalculable life cycle costs– Short service life

ECOSPEED

cost

time

Others

Total cost of ownership

Featuring the following standard functions:

– Administration and allocation of: – Workplans – NC-Programs – Tasks – Pallet routing and sequencing

– Optional extended functionality: – Tool disposition – Extended workplans – Extended NC-Program administration – Fixture Management – Task planning and visualization – Unattended operation mode – Display of clamping sketches – Connection to other process equipment

(e.g. CMM, wash station, Tool-Presetters) – Transmission of measurement data – Reporting functions – Data Back-Up-functions

– The cell controller is open for customization.

DST System for INformation and DIagnosis creates transparency and cuts costs

Machine tools are complex systems and they must fulfil stringent requirements. Durable efficiency, maximum availability and the costs incurred are also significantly dependent on correct operation and maintenance.

Modular system for constantly high productivity

Knowing how, where and what:

– Makes procedures transparent– Provides safety– Prevents downtimes– Saves costs

MDE

Diagno

sis

Maintenance

SMS

Help

Vide

o

DST rem

ote di

agnosi

sTrip recorder

Machine diagnosis

Monitoring

Documen-tation of availability

Fault diagnosis

Dynamic maintenance and servicing

Fault messages through email or SMS

Direct access to machine documentation

Video monitoring

Immediate rectification of faults

Malfunction analysis with duration and frequency

On-line data connection

Monitoring through external computer

ECOSPEED from 2570 up to 25200

ECOLINER

Rack type 125Rack type 129

ECOSPEED F 2060 / 2560

Additional information

Pallet changing time

Chip to chip time

Acc / dec in X-axis

Acc / dec in Y-axis

Acc / dec in Z-axis

Acc / dec in A- and B-axis

Rapid traverse / feed in X-axis

Rapid traverse / feed in Y-axis

Rapid traverse / feed in Z-axis

Rapid traverse / feed in Bt-axis

Tool magazine

Pallet

Length (X-axis)

Width (Y-axis)

Payload

Optional

C-axis (spindle 90° ± 40°) 360° continuous

Right angular milling head

Right angular drilling head

ECOSPEED F HT1010

11

7

9.81

9.81

9.81

685

max. 50

max. 50

max. 50

30

Chain type 40/60/80

Technical data

2524

mm

mm

kg

mm

mm

kg

The technical data are standard values which may require adjustment or change according to client or individual requirements.

sec.

sec.

m/sec.2

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

rpm

pockets

mm

mm

Rack type 125

* Values for Type 2570

mm

mm

mm

mm

150*

15*

9.81

9.81

9.81

685

max. 65

max. 50

max. 50

4.91

4.91

4.91

685

max. 50

max. 50

max. 50

7,000 - 20,000

2,000 / 2,300 / 2,500

Rack type 129

ECOSPEED F 2035

210

8

9.81

9.81

685

max. 50

max. 50

max. 50

225

8

9.81

9.81

685

max. 50

max. 50

max. 50

6,000

2,000 / 2,500

5,000

8,000

2,000 / 2,500

6,000

1,000

1,000

1,000

•

mm

mm

kg

mm

mm

kg

mm

mm

kg

184

8

9.81

9.81

9.81

685

max. 50

max. 50

max. 50

190

8

9.81

9.81

685

max. 50

max. 50

max. 50

3,500

2,000

3,000

•••

•••

•••

•••

•• •

4,000

2,500

4,000

X-axis

Y-axis

Z-axis (spindle horizontal pos.)

Z-axis (spindle ± 40°)

Traverse

1,250

1,350

670

370

in B-axis (table) = 360°, continuous

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

Up to 30,000

1,500

670

370

mm

mm

mm

mm

mm

mm

mm

mm

6,300

2,500 / 3,000

670

370

8,300

2,500 / 3,000

670

370

3,800

2,500

670

370

4,300

3,000

670

370

Pallet length (X-axis) +800

2,500 / 2,600

670

370

ECOSPEED F 2080 / 2580

ECOSPEED F 2540

Rack type 129 Rack type 129

sec.

sec.

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

pockets

sec.

sec.

m/sec.2

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

pockets

sec

sec

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

pockets

sec

sec

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

pockets

sec.

sec.

m/sec.2

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

pockets

m/sec.2

m/sec.2

m/sec.2

°/sec2

m/min

m/min

m/min

pockets