okuma america corporation productivity proposal 11-27-12 m560-v (12k) w-thinc proposal page 1 of 21...
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Revision: 11-27-12 M560-V (12K) w-THINC Proposal Page 1 of 21
Okuma America Corporation
Productivity Proposal
GGEENNOOSS MM556600--VV ((1122KK))
Vertical Machining Center with
.
Applicable Model and Versions:
M560-V with OSP-P200 THINC control system
Standard Specification
Spindle Taper NT40 Big Plus
Spindle rpm 50 - 12,000
Spindle Horsepower (Max/Continuous) 30/25 HP
Tool changer - Number of Pockets 32 Tools
OKUMA Thermal Technology TAS-S and TAS-C
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GENOS M560-V Introduction
The OKUMA GENOS M560-V CNC is the vanguard of the proven Okuma vertical machining centers. The M560-V adopts a powerful new double column structure to offer the most machining in the least floor space. The latest innovations in thermal countermeasures have been incorporated to offer the best performance available today. The OKUMA M560-V is equipped with a high speed; high power 40 Taper 12,000 rpm spindle with a 30/25 HP VAC liquid cooled integral motor. This model incorporates a high-speed 32-position automatic tool changer and 1574ipm (X/Y) rapid traverse, resulting in a powerful production capability. Control is by Okuma's own patented OSP THINC with Hi-Content control system which includes the patented OSP absolute position encoders which do not require a zero return.
A thumbnail of the M560-V Standard Specification:
Travels: X: 41.34” Y: 22.05” Z: 18.11 OSP-P200M THINC control system
T-slot table: 51.18” x 22.05” Okuma control, motors, encoders and drives
12,000 rpm, 30/25 HP integral motor spindle – standard
15” LCD w 3D color animation
CAT 40 Big Plus 40 V-flange specification
40GB Hard Disk – 512 MB DDR
Spindle jacket cooling system MACMAN machine utilization monitoring
Oil air mist spindle bearing lubrication Thermal Active Stabilizer technologies TAS-S and TAS-C standard.
1,575 IPM, rapid feed X, Y. ( .6, .65 G) 8 Sets of external m codes
Z-axis rapid & max. feed-rate: 1,259 IPM
MACMAN machine utilization monitoring
32 tool ATC magazine 1.2 sec. T-T; 3.2 sec. C-C*
60 gal roll-away twin 0.5 hp coolant syst. Twin chip channel (insulated) with coil
conveyors. See Control P200M Proposal for control
features and specification. Preparation for 1,000 psi coolant
through spindle
Okuma Care, 24-7 support + 2 year warranty. First year parts and labor, second year parts.*
*See warranty statement for details.
The M560-V continues Okuma’s fundamental commitment to total system engineering of its machine tools. This means ALL Okuma design and manufacture of machine, motors, drives and controls and including the industry leading Okuma Care (24-7) support program. This level of integration and support is an Okuma Trademark. Your single source. Thank you for considering Okuma products.
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CONSTRUCTION
M560-V Orientation
FAST FACTS ABOUT M-V Compact footprint - service at front and rear Install the machines closer side to side Double column rigidity - less overhang Total enclosure every model Thermal deviation countermeasures Symmetrical design Insulated chip channels Insulated cross rail Center mounted screws and ball nut Heat generation clear of machine No hydraulic unit Spindle motor re-circulating cooling - new design Bearing jacket re-circulating cooling Oil mist lubrication spindle bearings - new design TAS-C and TAS-S standard (thermal technology) Faster axes at higher G force Cast in ball screw brackets Heavier X and Y guideways Service at front and sides Easy access ATC - faster ATC Centralized grease lubrication Rear chip ejection - ATC shutter included as standard Okuma THINC Control System
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CAPACITY MAXIMIZING FLEXIBILITY AND SPEED
Work Range Okuma has one of the largest work envelopes in its class. This provides the flexibility to handle a wide range of work-pieces. Axis Travel Inch Metric
X-Axis Ram saddle L/R 41.34 in. 1050 mm
Y-Axis Table - Front / Rear 22.05 in. 560 mm
Z-Axis Ram Head U/D 18.11 in. 460 mm
Table Capacity
Table size 51.18” x 22.05” 1300 x 560mm
Max. table load 1980 lb. 900 kg Spindle nose to table top 5.91” 24.02” 150 610 mm
Floor to table top 31.50” 800 mm
Axis Orientation
GENOS M560-V work range
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Spindle Head bearing support - rigidity & finish
Dual oil jacket for motor and bearings - thermal stability.
Ceramic angular contact ceramic ball bearings
70 mm bearing ID
Oil-air mist bearing lubrication - life - stability
Spring clamping – electro pump release
CAPACITY MAXIMIZING FLEXIBILITY AND SPEED
Power and Torque Main Spindle Drive
The M560-V utilizes a 30 HP VAC motor-spindle drive system. The unique Okuma spindle drive accurately controls input commands and continuously monitors actual performance.
The wide range spindle motor develops 29.5 HP at 4,000 rpm, 20.1 HP at 720 rpm and a maximum torque of 146 foot/pounds is available from 50 to 720 rpm.
The spindle design allows the flexibility of feeds and speeds needed to cut work-pieces of steel, aluminum, stainless steel, high-temperature alloys and exotic Materials. The spindle motor design produces less vibration and power loss at the tool tip yielding excellent surface finish and impressive metal removal rates.
Axis Thrust
X, Y and Z-axis
The X, Y and Z axes are driven by Okuma brushless motors and servo drives. Ample Z-axis thrust is critical for drilling, boring and plunge milling operations especially tools with indexable inserts.
The M560-V has allowable thrust as follows: X-axis: 1323 lbf, Y-axis: 1323 lbf, Z-axis: 1784 lbf,
Dual spindle sleeve, symmetrical cooling
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CAPACITY BALANCED SYSTEMS – CONSISTENT PERFORMANCE
ATC and Tooling capacity
32-Tool Magazine
The M560-V tool changer is simple, reliable and extremely productive. The standard tool changer has a capacity of 32 tools, held in a cast iron carousel magazine. Rotation of the tool magazine is powered by an Okuma servomotor, with position monitored and controlled by an Okuma absolute encoder. This design eliminates sub-arm and its mechanism, stepping motors, and clutches. Spindle orientation for tool change is accomplished by the Okuma spindle drive and magnetic pulse generator on the spindle unit, which accurately orients and holds the spindle in position. Big Plus tooling capability enables additional tooling rigidity provided by tool face to spindle nose contact. Standard Cat 40 tools can also be used as required. Automatic Tool Changer
The simple, reliable Okuma M560-V tool changer provides an impressive tool change time of 1.2 seconds T-T (tool to tool) 3.2 C-C (chip to chip)*. Using the standard CAT V-flange, it will handle tools weighing up to 17.6 pounds, 3.54 inches in diameter with tools adjacent, and up to 11.81 inches in length. Larger tools, up to 4.92 inches in diameter, can be handled if adjacent stations are open.
32 tool ATC magazine
Tool capacities
Maximum tool sizes
Boring bar offset See op maintenance manual for further details regarding tools
With tools adjacent
No tools adjacent
Okuma PREX motor
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Machine without covers
T-slot table
The powerful bed construction which supports the rigid table.
RIGIDITY & CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES
Machine Construction Design and Construction
There are eight main components of the M560-V vertical machining center.
Bed (w/twin column) Table Crossrail ATC Ram saddle CNC Systems Spindle head
Materials
These components are produced from high tensile strength (40,000#) alloyed cast iron which is carefully stress relieved. The bed casting is designed with reinforcing ribs for increased stability and load carrying capacity. The column utilizes a reinforced box construction to increase stiffness, resist vibration and minimize deflection during high thrust loads. Saddle & Table Support
The machine saddle is designed to provide full support of the machine table in the Y axis movement. Good machine design and fitting allows for exact perpendicularity of the spindle head. The machine table, holding the work piece, is supported by the fixed saddle and bed and is capable of supporting full table load while holding alignment Extra width in the saddle design prevents the table from overhanging the bed. The column and bed are joined at the column flange to produce alignment bed, column, & saddle tolerances of 0.00020” or better in full travel of the X, Y, and Z axis.
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View of table showing protective covers and chip
channel [opt. auto tool length offset]
2-cam ATC, powered by OSP servo
Cross rail, ram head saddle and spindle head
CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES
Crossrail, Saddle & Spindle Symmetrical dual column construction
Robust power train provides for long term reliability
Heat deviation eliminated from crossrail
Symmetrical box structure offers balanced expansion
Insulated cross rail keeps heat away
Low moment of guideway construction
Cast-in ballscrew brackets - rigidity
1575/1259 ipm rapid X,Y/Z
Quiet operation 72dB at operator station*
* at the operator station under full rpm and full rapid test conditions.
Table
Inch T-Slot
Table dimension: 51.18” x 22.05”
Maximum table load: 1,980 lbs.
Robust power train provides for long term reliability
Suitable for powered fixture applications
2 – cam ATC
NC Servo driven system
High power and reliability drive
ATC – step tracking by encoder
Magazine position tracking by encoder
Robust construction assures durabilty
17.6 Lb. Tool x 11.81 inches x 3.54 in.
4.92 in large Tool – no adjacent tools)
1.2 Seconds T-T, 3.2 C-C, enabled by servo + CAM*
New design eliminates the sub-arm design
Low maintenance, long grease interval. Cycle times are incremental and under nominal conditions
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M560-V “Cast-in” ballscrew brackets offer the highest rigidity
RIGIDITY & CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES
Axis Drives Ball Screws
Powerful, robust high precision ball-screws generate sideway movement to all three axes of the M560-V. The ball screws are based on unique Okuma designs and exacting performance standards. They are directly coupled to special Okuma axis drive servomotors. Contrary to commercial drive systems, the custom Okuma servomotors precisely match the electrical and mechanical prerequisites of the M560-V performance requirements. An essential element in the drive system is the unique Okuma absolute position digital feedback encoder connected directly to the shaft of each Okuma servo drive motor. The Ballscrews are precision mounted on the exact center of any controlled axis and are preloaded at the end of the ball screw opposite the drive system. The precision ball screws are supported by a twin set of thrust bearings mounted in ball screw support brackets at each end of the ball screw. Preload is set during machine construction by careful hand sizing and fitting. Once set, the preload is maintained by a twin set of ball screw mounting brackets supporting both ends of the screw. The ball screw mounting is designed for both tension and compression for thermal compensation and control of ball screw growth.
Ball Screws X Y Z Diameter in (mm) 1.57 (40) 1.57 (40) 1.57 (40) Pitch In (mm) .79 (20) .79 (20) .63 (16) Allowable thrust lbf (N) 1,323 (5,880) 1,323 (5,880) 1,784 (7,840)
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Okuma dual-supported ballscrew Mass centered ball screws. (Typ )
Okuma HSR NR NRS
Vertical Stiffness
100 % 200% 140%
Horizontal Stiffness
100 % 70% 140%
Guideway illustration
45
CONSTRUCTION ROBUST SYSTEMS SUPPORT SHORT CYCLES
Ball Screws Powerful, robust high precision ballscrews generate slideway movement to all three axes of the OKUMA M560-V. The ball screws are based on unique Okuma designs and exacting performance standards. They are directly coupled to special Okuma axis drive servomotors. Contrary to commercial drive systems, the custom Okuma servomotors precisely match the electrical and mechanical prerequisites of the M560-V performance requirements. An essential element in the drive system is the unique Okuma absolute position digital feedback encoder connected directly to the shaft of each Okuma servo drive motor. Preload is set during machine construction by careful hand sizing and fitting. Once set, the preload is maintained by a twin set of ball screw mounting brackets supporting both ends of the screw.
Guide ways
Centrally Lubricated oversize NRS type linear guideways are employed on X, Y and Z-axes. The class is selected as one size above that indicated by manufactures design specification. The NRS designation is a guideway design with greater uniform stiffness than competing designs.
Automatic continuous grease lubrication Substantial sealing and way protection
offer precision over a long period Wear by friction is negligible Design life span of 10 years 1575 ipm rapid traverse rates for X & Y. 1259 ipm
for Z. Excellent positioning and repeatability
Note: See additional axis drive data in section 2 – (Specifications)
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ACCURACY & REPEATABILITY MAXIMIZING LONG TERM QUALITY
X, Y and Z axis Accuracy The rigid machine structure coupled with a high response positioning system provides the following machine performance: Positioning accuracy of +/-0.00016" ( 0.004 mm) for all three axes, full stroke. Repeatability of 0.000060". ( 0.0015 mm) with ball screw pitch error compensation employed These positioning guarantees are based laser measurements of a single, uni-directional, rapid traverse move of the slide to a programmed position along the X, Y, and Z Axis of 3.94”. For repeatability inspection each Axis is moved 3.94” from the starting position, for repeatability tests. This measurement is repeated seven and the difference between the largest result and the smallest result is the repeatability of X, Y, and Z axes.
Geometry Inspection Laser alignments and positioning accuracy checks are among the over 200 quality tests performed on every M560-V. Lead screw and backlash compensations are measured during final inspection and maintained in the Okuma OSP THINC control to insure and guarantee the above stated accuracy definitions. Inspection data sheets accompany each machine tool showing target data and actual data of 35 machine geometry inspections.
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Centralized grease station
Guideway and ball screw grease
Typical X, Y and Z
Self-contained tool unclamp Electric pump cylinder
. Motor and spindle Spindle oil air mist cooling unit (8k min-1)
Pneumatic Panel
FLUID SYSTEMS MAXIMIZING LONG TERM VALUE
Machine Lubrication
Long interval maintenance
The M560-V is lubricated with a manual lubrication system. The ATC, all ballscrews and all linear guides are lubricated by the system. The two lubrication manifolds are centrally located for convenience, where the entire machine can be serviced.
The M560-V is a manually lubricated machine, grease lubrication need occur only after every 200 hours. No tramp oil separator is required since there is no oil contaminating the coolant, there are no moving parts in the less complex system and the grease has a higher resistance to viscosity breakdown due to temperature increases.
Machine System Lubrication
X,Y, Z ball screw / nut Central system - grease
Guidways Central system – grease
ATC mechanisms Central system - grease Gear box - oil
Main spindle bearings Oil-air mist lubrication
Ball screw bearings Sealed
No hydraulic unit Reduced energy consumption Reduced heat generation – better accuracy
Clean environment Specialized Hydraulic fixtures may require discrete power unit(s)
Cooling Systems Main spindle bearing housing – re-circulating oil
Main motor spindle housing cooling – re-circulating oil
Spindle bearings – oil air mist
Main electrical control enclosure – heat exchanger
Heat generating units mounted for good convection flow
Pneumatic Machine applications:
Supply required: 71 psi, 500 NL. Spindle bearing oil - air mist
ATC air blow
Chip air blow at spindle
ATC shutter
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Roll-away coolant system and chip tank
Chip channels to rear of machine
Insulated twin chip gutters – to rear tank
5 coolant nozzles at spindle
Front view with optional lift-up chip conveyor and bucket
Coolant tank shown
With optional side lift-up chip conveyor
FLUID SYSTEMS MAXIMIZING LONG TERM VALUE
Chips and Coolant Basic Coolant Supply 60 gallon (230 litres) Roll away reservoir and chip recovery tank with settling partitions and screen filtering (A lift up chip conveyor is optional) Chip channels Seamless channels to rear – Machine front is clear
Slanted way covers and APC casting apron shed chips to flush channels which send chips to the rear.
Chips, tanks, conveyors and coolant
Included as standard twin coil system to rear of machine.
Spindle nozzle coolant 0.33 Hp pump and 6 gal (22-26 liter) / min.
5 adjustable nozzles surrounding the spindle Optional rear chip conveyor available
For machining operations where large quantities of chips are produced, an optional lift and drop chip conveyor is appropriate. Several types are available selectable based on material application.
Available through spindle options: Through spindle coolant 215 psi Through spindle coolant 1000 psi Interface and coupling for 1000 psi included as standard
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GUARDING AND ENCLOSURE
Easy Access
The operating area of the machine is totally enclosed and has a low friction sliding front door with observation window. Construction permits easy entry for workpiece loading/unloading and easy access to the tooling.
SAFETY
Safety Features
The M560-V is equipped with a variety of safety devices to prevent accidents and injuries. However, it is strongly advised that operators use the machine carefully and not rely solely on these devices. Complete safety precautions are found in the operation manual.
Programmed soft limits are used to provide each axis with stroke end limits.
Limit switches on X, Y and Z-axes provide each axis with a hard-wired limit.
Extreme axis limits use rubber cushions for dampening the contact before motor overload
occurs.
Emergency stop push button, slide hold push button, and alarm indicator on operational panel.
Fluid levels are interlocked
Full enclosure guarding with standard access door interlock for complete chip and coolant
containment.
Operators sliding door with interlock and excellent work area lighting
Measured 72 dB level at the operator station under full rpm and full rapid test conditions.
Interlocked pallet load station for correct pallet orientation
ATC Magazine access door interlock
Warning / Alert signage
Safety Documentation
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USA STANDARD SPECIFICATIONS MACHINE WEIGHTS AND MEASURES
TRAVEL INCH METRIC
X-axis travel (Ram saddle right/left) 41.34 in. 1050 mm
Y-axis travel (table traverse F/R) 22.05 in. 560 mm
Z-axis travel (spindle up/down) 18.11 in. 460 mm
Spindle nose to table upper surface - (T-slot) 5.91 - 24.02 in. 150 - 610 mm
TABLE
Table size 51.18 x 22.05 in. 1300 x 560 mm
Table top surface to floor height - T-slot 31.50 in 800 mm
Table load capacity – T-slot – USA std. 1980 lb 900 kg
SPINDLE INCH METRIC
Spindle speed range – USA Std. 50 – 12,000 rpm
Tapered bore NT40 (BIG PLUS)
Spindle diameter at front bearing 2.76 in 70 mm
Spindle bearing lubrication Oil air mist
Number of spindle speed ranges infinitely variable
M560-V Table and T-slot
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USA STANDARD SPECIFICATIONS MACHINE WEIGHTS AND MEASURES
ATC & MAGAZINE INCH METRIC
V-Flange and Taper CAT40 (BIG PLUS)
Pull stud CAT – Special
Tool magazine capacity - USA Standard 32 tools
Tool selection Random
Tool Change Times
Tool –Tool* 1.2 seconds
Chip – Chip* 3.2 seconds
Max Tool Diameter
Max. Tool diameter. with adjacent tools 3.54 in 90 mm
Max. Tool diameter. Without adjacent tools 4.92 in 125 mm
Max tool length 11.81 in 300 mm
Max tool weight 17.6 lb 8 kg
Magazine feed rate* Adjacent pot 0.7 sec
10 pots 3.0 sec * cycle times are incremental and under nominal conditions
FEED RATE
Rapid traverse rate: X,Y 1,574 ipm @ 0.6, .65G 40 meters / min. @ 0.6, .65G
Rapid traverse rate: Z 1,259 ipm @ 0.48G 32 meters / min. @ 0.48G
Max Cutting federate X, Y, Z axis 1,259 ipm 32 meters / min.
Jog Feed Rate 0.04 – 1,259 ipm 1-32,000 mm
AXIS DRIVE
Ball Screw Diameter X, Y 1.57 in 40 mm
Ball Screw Pitch X, Y 0.787 in 20 mm
Ball Screw Diameter Z 1.57 in 40 mm
Ball Screw Pitch Z 0.629 in 16 mm
Available Axis Thrust
X 1323 lbf 5880 N
Y 1323 lbf 5880 N
Z 1784 lbf 7840 N
Screw Mounting Pre-tensioned
Drive Connection Direct Motor Coupling
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USA STANDARD SPECIFICATIONS MACHINE WEIGHTS AND MEASURES
MOTORS AND ELECTRICAL INCH METRIC
Main spindle drive motor
Power (10 Min. / cont.) 30/25hp 22/18.5 kW
Torque (10 min./ cont.) 146.2 / 107 lbf.ft 199 / 146 N-m
Axis Servos
X – axis brushless drive motor 5.3 hp 4 kW
Y – axis brushless drive motor 5.3 hp 4 kW
Z – axis brushless drive motor 5.3 hp 4 kW
ATC – servomotor 2.7 hp 2.0 kW
Electrical Supply AC 200 V +/- 10%, 50/60 Hz, 3 ph
COOLANT SYSTEMS
Coolant System (Max capacity) – USA Standard
Reservoir – Roll-away tank 60 gallons 230 liters
Flood pump power ( to nozzles) 0.33 hp 0.25 kW
Pump Volume 9 gal / min. 22/26 liters / min
Pump Pressure 30psi (est) MPa
Distribution 5 directional nozzles at spindle
OTHER FLUID SYSTEMS CAPACITY
Spindle Head Cooling Unit – FC2 3.96 gal 15 liters
ATC oil 2.1 gal 8 liters
Pneumatic required minimum pressure 70 psi 0.5 - 0.7 MPa
Oil Air spindle lube Unit - 0.53 gal 2.0 liters
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USA STANDARD SPECIFICATIONS MACHINE WEIGHTS AND MEASURES
ACCURACY INCH METRIC
Positioning
X , Y, Z – USA standard specification 0.00016 in 0.004 mm
Over full stroke – with ball screw pitch error compensation employed.
Repeatability – with ball screw pitch error comp
X , Y, Z 0.000059 in 0.0015 mm
CYCLE PERFORMANCE
Spindle Acceleration
rpm Acceleration seconds Deceleration seconds
0 > 1200 0.08 sec 0.08 sec
0 > 8000 1.32 sec 1.1 sec
Spindle Orientation 1200 rpm 0.31sec
8000 1.39 sec
Positioning X 400mm 0.73 Y 400mm 0.72
Z 400mm 0.88
ATC Time T-T 1.2 sec
C-C 3.2 sec
Magazine 10 pots
3.0 sec
OTHER INCH METRIC
Machine Height 108 in 2,746 mm
Floor Space 97 x 122 in 2,470 x 3,100 mm
Machine weight 16,000 lb. 7,300 kg
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USA STANDARD SPECIFICATIONS
Floor Plan of M560-V showing Optional Chip Conveyor
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USA STANDARD SPECIFICATION M560V (12K)
OOKKUUMMAA MM556600--VV CNC Vertical Machining Center With THINC Control System
Base Machine Price
1. M560-V with OSP P200M CNC Controller and USA standard specifications
Standard Specification - OAC USA Standard
1 Axis stroke, X1050, Y560, Z460mm 1 set
2 Main spindle, 12,000min-1 (199N-m) 1 set
3 Main spindle motor, 22/18.5kW 1 set
4 TAS-S 1 set
5 TAS-C 1 set
6 Spindle big plus 1 set
7 Tool shank CAT40U 1 set
8 Pull stud bolt CAT type CAT40U 1 set
9 32 ATC 1 set
10 In-machine chip conveyor, coil type 1 set
11 Chip conveyor (Concep 2000) interface - electrical only 1 set
12 Chip pan 1 set
13 Prep. For through spindle coolant, 7.0MPa (1,000 psi) 1 set
(including through spindle air blower)
14 External M-code 8 sets 1 set 15 Pull stud bolt CAT40 (through tool coolant type) 20 sets 16 IEC standard 1 set
17 Preparation for transformer 1 set
18 Manuals 1 set
19 OSP P200M 3D-E kit 1 set
20 Inch/metric switchable (1 set)
21 API (1 set)
22 Okuma standard color (door is Crystal silver ) 1 set
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PROPOSAL SUPPLEMENT
M560-V Available Options.
Machine Options Control Options Prep for rotary table. Collision Avoidance Software (CAS)
Rotary table (model to be defined) Super Nurbs
Lift up chip conveyor – hinge type 5 Axis control spec
Lift up chip conveyor drum type (Mayfran) 5 axis machining
Through spindle coolant 217 psi Caron adaptive control
Through spindle coolant 1,00 psi Machining Navi Mg
Transformer One Touch IGF including real 3D
Chip air blow thru spindle I-MAP
Shower coolant Common Variables 1000 sets
Work wash gun Program branch
Tool breakage detection Program message function
Auto gauging by Renishaw Cylindrical side face machining
Auto door open close with light curtain Inverse feed function
3 D tool compensation
DNC Function (T3, B, DT)
Warm up function
External program selection
Robot Interface Type D
M560-V Not Available Options. Alternative spindle power or taper specifications Table options Alternative tool magazine sizes Abso scales High column Ball screw spec change
Shuttle type 2 APC