sign in sign up
<<
Home , Facing (machining), Milling (machining), Rotary transfer machine

ROTARY TRANSFER MACHINES HYDROMAT® HC PRODUCT LINE

Precise | Productive | Reliable The FFG Rotary Transfer Platform Flexible Multi- with Hydromat®

Precise, modular and efficient: The FFG group is the The ability to set up working stations horizontally as well as world’s leading manufacturer of rotary transfer machines vertically allows big machining jobs with the highest output and offers the best solutions for workpieces at the high just-in-time. The enormous flexibility of the rotary transfer volume end. machines gives our clients a major advantage in dealing with the growing challenges of today’s global markets: United under the roof of the FFG group: with the rotary 3 The most cost-effective solutions transfer machines of the tradition brands IMAS, Pfiffner and 3 Maximum precision and process reliability in Witzig & Frank, you are always one cycle ahead. 3 High investment security thanks to extensive modularity 3 High reusability thanks to reconfigurable machine systems The program covers all applications for 3 High flexibility and variability (simpler retooling, reduced the serial production of complex metal parts. Rotary transfer setup times) machines are designed for the handling of bar and coil materials, 3 High machine availability or automatic part feeding. They guarantee high-precision 3 Low maintenance costs (TCO) machining of each workpiece, being carried out simultaneously 3 Turnkey solutions on each station. Every rotary transfer machine is specified, 3 Process optimisation built for, and customised to the pieces it will process. 3 Global after sales management

Sequential machiningSequentielle Bearbeitung SimultaneousSi mmachiningultane B onea rotaryrbeitu transferng auf machines: Sequentielle Bearbeitung Simultane Bearbeitung auf Rundtakt-Maschinen: Rundtakt-Maschinen: Q1 Q1

Q2 Q2

Q3 Q3

Q4 Q4

3 4 people 4 Personen 3 Faster  Schneller 4  4P varyingersonen qualities  Schnel Moreler precise 3 4 unterschiedliche Qualitäten3  Präziser Highest profitability 4  4un interfacesterschiedliche Qualitäten  Präziser More productive for you! 3 4 Schnittstellen 3  Produktiver 4  4Schnitt x largers tfootprintellen  Produkti Morever reliable 3 4 Mal Platzbedarf 3  Prozesssicher 4 Mal Platzbedarf  Prozesssicher Höchster Profit für Sie! Höchster Profit für Sie!

2 | Pfiffner The Standard for Series Production The Highest Machining Quality within Seconds

Rotary transfer automatic: Precision in a fraction of a second Up to 8 vertical machining units can be added for transverse In the table, the workpiece will be simultaneously machining and special operations. finish-machined in multiple operating workstations. The heart In addition, further technologies allow the application of honing, of the machine is the indexing table with fixed clamping of the , mounting, press-fitting, clearing, pushing, wobble parts in , jaw chucks or special fixtures for round stock and grinding. All operations are carried out simultaneously, material with diameters from 3 to 52 mm or for cubic parts up which provides extraordinarily short production times. to a maximum of 120 x 120 x 120 mm. In any situation where complex metal parts are required in high 16 horizontal workstations are available for variable machining volumes and at high speeds with maximum precision: operations. FFG offers the best solution.

Machine kinematics of the Pfiffner HC product line

> 2 million

Cold form 1,0 machining

No. of pieces/year 0,5

0,3 Interlinked Standard machines 0,1 machines

Complexity Annual production > 300 000 parts Machining ≥ 4 Workpiece size ≤ 100 mm Ø 52 mm

Areas of application for the flexible Pfiffner rotary transfer machines by quantity and complexity

Pfiffner | 3 Rotary Transfer Machine HC 25-12 / HC 45-12 / HC 52-12 HC 32-16 / HC 45-16

Faster, better, EPICplus Highlights On the Hydromat rotary transfer machines from the Pfiffner HC 3 Easily reconfigurable machine system product line EPICplus, up to 24 machining units can be utilised for 3 100% CNC machine with Bosch MTX control fully-automated and simultaneous operation. 3 Minimal setup times This allows the process sequence to be individually and 3 Modular and configurable unit concept optimally structured. The result: the shortest cycle times and 3 Highest productivity (machine availability) highest output rates at a consistently high quality. The world 3 Lowest maintenance costs leader in productivity.

1 unit 1

2 Inverting unit for machining from 2 sides

3 Indexing table for workpiece transportation 3 4 4 /

5 Unit carrier for stable attachment of units

5 2

A look at the Hydromat machine HC 32-16

4 | Pfiffner Rotary Transfer Machine with Swivel Chuck HC 12-U HC 16-U

5-sided machining for maximum flexibility Highlights of the HC-U product line The types HC 12-U and HC 16-U rotary transfer machines 3 Easily reconfigurable machine system fulfil the highest machining requirements. In addition to the 3 100 % CNC machine with MTX control Hydromat®-specific rotary indexing table, the machines are 3 Minimal setup times also equipped with swivelling hydraulic high-precision indexing 3 Modular and configurable unit concept chucks. The 12 or 16 chucks can be freely indexed: Therefore, 3 Highest productivity (machine availability) machining from 5 sides is also possible without having to 3 Lowest maintenance costs re- the workpiece. 3 Machining from 5 sides in one clamping The hydraulic chucks are specifically adjusted to the workpiece to be clamped. The clamping pressure is hydraulically variably adjustable. As a result, cubic workpieces with edge lengths up to 120 mm or bars with diameters of 52 mm and lengths of 200 mm can be machined without any problems. The HC 12/16-U are ideally suited for cast blanks, profile material and bars.

1 Chuck

3 2 Indexing table for workpiece transportation

3 Support for the inclusion of vertical units 1

4 Unit carrier for stable attachment of units 2

4

A look at the Hydromat HC 16-U

Pfiffner | 5 Investment Security through Modularity The Pfiffner Modular Concept

The Hydromat modular principle The machine control and the new user interface reflect the The structure and equipment of Pfiffner machines are primarily of the machine’s control and operating concept, determined by the workpiece to be machined. The modular which are consistently based on modularity and flexibility. All the concept guarantees high flexibility in the future: The Hydromat® can be individually configured and interpolated via efficient machining units are interchangeable with regard to size and all bus systems. This highly flexible system provides the foundation the stations are individually configurable up to 4 axes. for an efficient setup of the machine during part replacement.

4-fold cross- head Angular head

Swivel unit Angular milling head

Drilling head

Turning head

Toolspindle unit

XY flange CNC

Unit flange (fixed)

6 | Pfiffner Collet

Chuck

Cutting unit

Facing head with single slide

Facing head with twin slide unit

Inverting unit

Unit carrier

Pfiffner | 7 Ready for your Application HC Product Line Loading Variants

from bar

Bar feeder and Bundle loader and saw Dimension: for 3 m to 6 m bar Dimension: for 3 m to 4 m bar Different cross sections possible Loading up to 2 tonnes in a bundle possible Autonomy: approx. 8 - 16 h Autonomy: approx. 3 shifts (24 h) (supporting surface 350 / 500 mm wide)

from blank

Spiral conveyor and load handling Loading robot (6-axis robot) For blanks as bulk material feed Double gripper for a quick loading and unloading, Automatic orientation within the conveyor possible on one station Autonomy: approx. 1 shift (8 h) Ideal for linking multiple machines Autonomy: fully automated process

from wire Machining from the bar, coil, or with automated part feeding As customer needs are always the priority at Pfiffner, each Pfiffner rotary transfer machine is configured and optimised in accordance with individual customer specifications. Together with the customer, we determine the perfect material feeding variant either from bar, From the coil (decoiler) and saw blank or wire for the most economical serial Design incl. wire straightening device production of a complete workpiece family. Round material up to Ø 10 mm As a result, we completely integrate our Autonomy: approx. 3 shifts (24 h) production line into the value chain.

8 | Pfiffner The New Control System Bosch Rexroth IndraMotion MTX Advanced

Innovative, flexible, future-proof Until now, there had been no CNC control available on the The drive-internal safety functions of the IndraDrive drives make market that could control so many axes. The challenge lies in it possible to create a modular safety concept. The intelligent being able to combine decentralized intelligent electric and servo drives and the control cabinet-free IAC Multi Ethernet electro-hydraulic axes in any configuration. control integrated within the valve close the control circuit So far, we had to use multiple CNC control systems in parallel decentrally. using the so-called master-slave process. Within , The efficient control hardware for all axes and the integrated this was extremely time-consuming and expensive. For our PLC reduce cycle times, therefore increasing productivity. At machines, and consequently for our customers, this was no the same time, they simplify operation and reduce the time to ideal technical solution with regard to operability and cycle times. change to new products. In addition, our customers can also With the IndraMotion MTX Advanced, an individual CNC control change the machine configuration themselves. They have the can control up to 99 axes and 25 NC channels. option to independently add or remove the functions of a unit. The CNC control also boasts outstanding processing power The new machine software impresses with its high degree of and a high storage capacity. modularity.

A look at the new compact control cabinet

First control with 99 axes / 25 channels 3 Higher allocation speed 3 Simpler and faster operability and programming 3 Savings of time and money 3 >10% performance increase

Decentralization = flexibility 3 Scalable and modular control system IndraMotion BOSCH MTX control, source: Bosch Rexroth AG 3 Technically expandable to 99 axes 3 Reconfigurable machine system 3 Mechanically and electrically a homogeneous modular system 3 High reusability and therefore high investment security

Everything from a single source: the CNC control as well as the drive technology 3 Long-term product care 3 Long-term reusability 3 Long-term support services 3 Partnership for even higher customer satisfaction Digital axis control valve from BOSCH Rexroth

Pfiffner | 9 Industry 4.0 The Challenge within Production

The fourth Information in the right place, at the right time In recent years, production has been oriented towards the For Pfiffner, this primarily means making use of modern principles of lean production, increased flexibility and therefore comprehensive information and communication technology in the achievement of significant success with regard to productivity order to increase productivity. Requirements such as real-time and supply capability. With Industry 4.0, modern production is capability of production data and simple production system on the cusp of a radical upheaval. As the leading rotary transfer diagnoses can be smartly and intelligently implemented. With machine manufacturer, Pfiffner is ready to take this step into Pfiffner production systems, the “fourth Industrial Revolution” the future together with its customers and implement new is practically within reach! developments.

Data access STOP Minimise unplanned Simple LIVE in real-time downtimes diagnosis

Influence process in Increase in real-time productivity

The Pfiffner concept for Industry 4.0 is the use of the Data The control, drive and sensor data is recorded, processed and Analytics Server from Bosch Rexroth for machines with locally stored in a database via OPC-UA. The evaluated data is IndraMotion MTX. This package solution comprises the machine displayed via web interface. In the end, the data for other IT data collection, an analysis of the overall equipment effectiveness systems (MES, PPS, data analytics...) is made available via (OEE), condition monitoring and a diagnosis logbook. UPC-UA1.

1 Uniform language for the “real-time coupling of machines

10 | Pfiffner Industrie 4.0 Our Approaches for your Benefit and Added Value

Real-time data and statistical analyses

Management Cloud

Supplier

Server

End customer Production management

BIG DATA

Increase in productivity

Compiling and recording data Machine diagnostics 3 Recording and analysis of real-time data 3 Long-term diagnostic 3 Web-based visualisation 3 Visualisation of top 10 error messages 3 Use of standardised interfaces 3 Predictive maintenance

Machine state monitoring Safer remote access 3 Working mode, cycle times and counter 3 Use of proven IoT cloud security 3 Machine availability 3 Safer access via current Internet connection

Pfiffner | 11 Service, Support and Consultation from a Single Source

The great trust that customers have placed in the Pfiffner Spare parts group throughout its over 45-year history is an obligation. 3 Central storage facility with high availability of parts The development of individual solutions is based on the close 3 Competent point of contact for consultation and sales and cooperative partnership with customers all around the world. In addition to the individual equipping of rotary transfer Customer training machines as well as the straightforward support provided 3 Operator training during the conversion of a machine, the fast delivery of spare 3 Maintenance training (mechanical and electrical) parts and short reaction times in the event of machine faults 3 Programming training round off Pfiffner’s scope of offers with needs-oriented gloss. 3 Individual customer training according to requirement profile Thanks to the use of state-of-the-art telecommunications technology, the significance of the teleservice is now even Inspection agreements greater. Cheap and efficient remote diagnoses support the 3 Maintenance and service costs decrease, production quality seamless functioning of the Pfiffner rotary transfer machines. and planning security

An overview of our support services: Turnkey solutions with initial process engineering Service calls 3 Provision of a service call within 24 h of initial telephone Feasibility and chip removal attempts contact 3 Telesupport via VPN for Pfiffner rotary transfer machines Process optimisation, installed base (over 2600 machines in use worldwide) Repairs 3 Qualified repairs with functional tests of units, spindles and Modernisation, installed base (ReVest® & tuning kits) valves at Pfiffner locations (visit www.pfiffner.com for additional information, videos, etc.)

12 | Pfiffner 83% of all customers use more than one Pfiffner rotary transfer machine. (Source: View of the production hall of Rosenberger Hochfrequenztechnik GmbH & Co. KG)

Pfiffner | 13 We are at Home in Many Industries

The possibility of manufacturing highly complex workpieces As a result, Pfiffner Hydromat® rotary transfer machines have quickly, cheaply and at high quantities is a key factor for been successfully used within numerous different quality- success. oriented industries.

Application examples:

Cycle time: 9.6 sec. Cycle time: 10.5 sec. Material: Sint C30-E Material: 9SMnPb28

Cycle time: 13 sec. Cycle time: 12.5 sec. Material: ST52-3 Material: 1.4301

Cycle time: 8.5 sec. Cycle time: 9.5 sec. Material: AlSiMg Material: AlSiMgMnT6

Cycle time: 12.5 sec. Cycle time: 10 sec. Material: 1.4301 Material: 38SMn28

14 | Pfiffner Cycle time: 12.3 sec. Cycle time: 11.7 sec. Material: 1.4307 Material: 1.4301

Cycle time: 4.5 sec. Cycle time: 4.0 sec. Material: CuCrZr Material: MS58

Cycle time: 5.6 sec. Cycle time: 8.0 sec. Material: Material: 1.4301 Hexagon 11SMnPb30

Cycle time: 9.3 sec. Cycle time: 7.5 sec. Material: 11SMn30+C Material: 9SMnPb36K

Pfiffner | 15 Endless Possibilities

The proven technology of the Pfiffner Hydromat® rotary transfer ensure maximum precision and allow shorter setup times machines allows highly profitable and complete machining through duplicate settings. Universal application areas of all serial parts, from the simplest to the most complex. The employing modular machining stations support the application possibilities are limitless. Intelligent procedures development of challenging and future-oriented solutions.

Sawing off a bar part Simultaneous pilot drilling and cross drilling

Simultaneous drilling Deep- and milling

Threading cutting Turning an inner contour

Face turning and Cross drilling, internal chamfering deburring (spoon deburring)

16 | Pfiffner Inverting Inclined cross drilling

Simultaneous turning Threading milling and drilling

Recessing Milling a slot or contour

Hexagon wobble broaching Hexagon punching or milling

Pfiffner | 17 18 | Pfiffner Overview Hydromat® HC Product Line

Efficient drives Ready for the future 40% of the total power The Pfiffner I4.0 solution provides consumption is taken up by our customers with an overview industry. 65% of this is of the state of the machine and consumed by motors. Through an improved planning capability improved energy efficiency of for maintenance and repairs. the speed-regulated drives, this Condition monitoring is not only consumption can be reduced used to reduce downtime times, by up to 50%. A further benefit but also to guarantee process is the flexibility to meet new quality. requirements.

100% CNC Everything under control Minimal setup times Rotary transfer machines have Pfiffner sets the course: Setup Shorter product life cycles and never been this flexible before. mode and diagnostics displays increasing part diversity require Being able to react quickly to are available at all times for a a rapid retooling process. changing requirements provides fast and targeted error analysis. Thanks to the consistent modular you with the decisive competitive As a result, your Hydromat® will principle and innovative configura- edge. be working in perfect sync and tion software, your Hydromat® will A safe investment in the future! with maximum precision at a be fully operational again in a very record time. short time.

HC 45-12 HC 12-U HC 25-12 HC 32-16 HC 52-12 HC 45-16 HC 16-U

Bars, round ø 25 32 45 52 - Workpiece size Blank, cubic mm 35 x 35 x 50 50 x 60 x 60 50 x 60 x 60 50 x 60 x 60 120 x 120 x 120 Workpiece length mm 100 150 170 | 150 170 200 | 150

Clamping stations Number 12 16 12 | 16 12 12 | 16 Rotary indexing table Indexing time s 0.5 0.7 0.7 0.7 1.0

12 16 12 | 16 12 12 | 16 Number Horizontal Vertical Number 6 8 6 | 8 6 6 | 8 Machining units Spindles/axes 18 / 99 24 / 99 18 | 24 / 99 18 / 99 18 | 24 / 99

X axis mm ±8.5 ±15 ±15 ±15 ±30 Travel paths Y axis mm ±12.5 ±30 ±30 ±30 ±30 Z axis mm +100 +120 +120 +120 +120

Dimension L x W x H m 8.9 x 3.3 x 2.9 8.9 x 3.3 x 2.9 8.9 x 3.3 x 2.9 14 x 4.8 x 3.0 5.7 x 4.0 x 2.9 Standard layout Machine weight t approx. 4 approx. 6 approx. 6.5 approx. 7 approx. 8

Loading direct from the bar with loading magazine, up to 6 meters | from coil | load blank via load handling or robot

Pfiffner | 19 K.R. Pfiffner Fax Tel. CH-3427 Utzenstorf Sonnmattstrasse 28 K.R. PfiffnerAG(Headoffice) FFG Europe&Americas premium technology within FFG. for stand They Group. Friend Fair global of the opportunities and strengths the from benefit entities group, these independent an truck, aerospace, machine building, machining, general railway industry, industries. While being engineering and heavy energy and automotive the for suppliers solutions systems and equipment innovative and reliable as known well are and manufacturing industrial in to progress the contributed 1798, substantially have Since brands &Frank. these Witzig and Tacchella SMS, Sigma, machine brands VDF Boehringer, Hessapp, IMAS, Jobs, MAG, Meccanodora, Modul, Morara, Pfiffner, Rambaudi,Sachman, renowned of the knowhow the and technology, manufacturing and grinding, turning, of milling, range abroad with industry tool machine American and Swiss Italian, German, the from players major unite Americas the and Europe in entities FFG The &Americas FFG Europe About Subject totechnical changes|AsatJuli2017 Sterling Heights,MI,US +41 326663555 +41 3266635 Port Huron,MI,US Fax Tel. DE-78658 Zimmerno.R. Axtbuehl 2 K.R. PfiffnerGmbH FFG Europe&Americas +49 7419288155 +49 74192880 Sprockhoevel, Eislingen/Fils, DE Zimmern o.R.DE Goeppingen, DE T Rottenburg, DE aunusst O Augsburg, DE Neuhausen a.Rhf.,CH Che f fenburg, mnitz ein, DE Lyon, FR , DE [email protected] Utzenstorf, CH DE DE Mariano Comense,IT Thalwil, CH Cassine, IT Pia cenza Kecskemét, HU , IT Moscow, R U Ahmedabad, IN B a Pune, IN ngalo Chennai, IN r e , IN Neuhausen a.Rhf. Zimmern o.R. Taunusstein Offenburg Sprockhoevel Utzenstorf Thalwil www.pfiffner.com T a S i h p a e S ngha h, Tokyo, JP eoul, KR Beijing, Changchun, TW i , C Rottenburg N

C N

C N Eislingen/Fils Goeppingen Chemnitz Augsburg

PF2601(01DE)en/1100/09.17