The system is used to accumulate profiles and then to transfer them horizontally. It consists of 5 supports with belts running over them fitted with mobile inserts whose position can be changed to accommodate profiles of different diameters. The number of supports can be increased and the distance between them varied to configure the loading magazine to suit the individual needs of the user in terms of length and weight of the profiles to be fed in. Simultaneous forward feed and the belt phasing are guaranteed by a grooved motor shaft that transmits motion to all the supports. A reference stop positioned on the support nearest the machining area allows an initial rough alignment of profiles as they are being loaded in. The bars are fed forwards and if necessary sent in reverse by means of a selector located in the loading area. Technical characteristics Profile detection Installed power: 0.37 KW Minimum permitted profile length: 1,000 mm ( with supplementary supports ) Maximum permitted profile length: 7000 mm Working loading capacity: 1750 mm (9 bars) Maximum permitted weight: 250 Kg PUSH PLUS 8000 NUMERICALLY CONTROLLED BAR FEEDER The PUSH PLUS bar feeder has been designed to push single profiles into work stations after taking them from the STEP IN S magazine. Technical characteristics Installed power: 1.45 KW Maximum permitted profile width: 180 mm Maximum permitted profile height: 180 mm Maximum permitted profile length: 8000 mm Maximum permitted profile weight: 50 Kg Structure It consists of a cross section on top of which a carriage slides, the gripper arm is fitted to the carriage. Horizontal axis sliding and activation This takes place along linear guides, incorporating a high precision, robust and reliable rack with angled teeth, on recirculating ball blocks equipped with an oil scraper and with medium/high preloading. The independent X (horizontal) axis is governed by a brushless servomotor by means of a pinion with helical teeth. The servomotor used not only allows rapid and optimum positioning times but also high speed. Axis reading takes place by rotating transducers. Carriage Made in Ergal (ASTM 7075), this offers at the same time reduced weight, high resistance to load and accuracy in mechanical machining. On request, the carriage can be fitted with two supplementary controlled axes ( horizontal Y and vertical Z) to allow profiles of different diameter to be picked up without any operator action; they slide along high precision, sturdy and reliable round guides, on ball bushings equipped with an oil scraper and with medium/high preloading; their movement, governed by brushless servomotors, takes place by means of high precision recirculating ball screws and preloaded worm screw. The gripper arm has a quick change system. The gripper fitted is recognised by an electronic decoding system. Working area Comprising horizontal and vertical rollers it guarantees optimum profile movement. When the loading magazine (STEP IN) is present, 5 retractable front pushers take hold of the profile, they place it on the horizontal roller table and keep it in contact with the vertical rollers. If necessary the number of vertical rollers can be increased for better profile alignment. The horizontal rollers, just like the retractable front pushers, can increase as the STEP IN S loading magazine supports increase. The profile zero setting along the X (longitudinal) axis takes place by means of a retractable pneumatic stop. MULTISPINDLE MACHINING UNIT The multispindle working unit has been designed to carry out drilling and milling on all four sides of PVC profiles. Structure It consists of two centre plates, one load bearing and one intermediate both in steel and a third centre plate in Ergal (ASTM 7075) to which the electro spindles are fitted. The solution applied guarantees stability and precision during machining as well as considerable advantages in terms of maintenance. Axis sliding movement This takes place along high precision, sturdy and reliable linear guides, on recirculating ball blocks equipped with an oil scraper and with medium/high preloading. Axis drive The independent W (vertical) and V (horizontal) axes are governed by brushless servomotors by means of high precision ground recirculating ball screws and preloaded worm screw. The digital servomotors used allow not only rapid and optimum positioning times and adjustment but also high speed. Axis reading takes place by rotating transducers. Electro spindles The electro spindles fitted to the machine each have 0.8 Kw for machining PVC profiles without metal reinforcement and rotational speeds of up to 24,000 rpm that can be selected by means of two static frequency converters (inverters). The machine is set up to take up to 12 electro spindles. Their arrangement and any orientation necessary on the centre plate will be designed to adapt them to the needs of the specific user. The electro spindles can be equipped with a slide for selecting them during the machining phase (optional). Working area This comprises 2 vices for pneumatically clamping the profiles. Technical information W axis (vertical) stroke 400 mm V axis (horizontal) stroke 400 mm U axis (vice longitudinal) stroke 220 mm Maximum profile dimensions 180 x 180 mm Electro spindle power rating: 0,8 Kw a 24.000 g/min Tool collet: ERG 25 Maximum tool diameter: 16 mm SAWING MACHINE LT 500 Front loading sawing machine with pneumatic control of the blade head angle. Designed specifically to be used as part of an automated production line, it comprises: • Machine base in electro-welded steel and of such a size as to guarantee stability and precision during machining. • Oscillating support in cast aluminium supported at the back to achieve optimum removal of chips and swarf into the lower compartment of the base. • Motor support in cast iron. • Blade head rotation (Y axis) with pneumatic control (on request with controlled axisthrough transmission with a ground recirculating ball screw to give high precision positioning and repeatability) • Front and top clamps. The horizontal supporting table is equipped with: • Fixed table on loading side complete wtih push rollers. • Translating table on unloading side with clamp angled at 45°. The base is alternatively set up to take a box and belt for the removal of chips and swarf. Technical characteristics Tungsten carbide saw blade Ø500 with hydraulic blade feed: adjustable blade exit speed, quick return. Pneumatic control of 45°/90°/135° cutting angles (on request 30°/90°/150° with numerical control). Set up for forced extraction of chips and fumes Integral guard around cutting area Microdrop tool lubrication Set up to take swarf collection drawer Set up to take chips and swarf removal belt Blade power 2.2 Kw (S6). Direct motor – saw blade transmission. STEP OUT TRANSLATING UNLOADING ACCUMULATOR The system is used for transferring and then accumulating profile offcuts which are picked up from the translating unloading table located at the end of the LT 500. It comprises 7 supports on which a belt with a shaped guard runs to guarantee a firm base for the offcuts. The number of supports can be increased and the distance between them varied to configure the bar unloading storage to the individual needs of the user in terms of length and weight of the profiles to be unloaded. Simultaneous forward feed and the belt phasing are guaranteed by a shaped motor shaft that transmits motion to all the supports. Technical characteristics Power 0.37 Kw Minimum permitted length: 250 mm (with optional modules or belts: 110 mm) Maximum permitted bar length: 3000 mm (optional roller table for manual offloading of bars longer than 3000 mm). Working accumulation capacity: 3000 mm. Maximum permitted weight: 5 Kg/m. Complete accumulator and profile detection. Profile drop safety device CONTROL UNIT POWER-C OMEGA 200 NUMERICAL CONTROL POWER-C Industrial control equipment taking care of the mechanical management of all movement devices installed on the machine. Interfaces with the PC by means of Ethernet network connection from which it receives the machining data. Technical characteristics Siemens 40Mhz microprocessor FOM Multitasking Operating System. 8.4 inch graphic LCD Compact Flash reader+ 64 Mb Compact Flash. Alphanumerical touch keyboard with heat-moulded keys. Network card for dialogue with Omega 200. “Trace” function. Dynamic display of machining operations with tool centre path. Program reading via network or from Compact Flash. Integrated tool correction. oMEGA 200 COMMAND UNIT This is the actual work station from where the various production phases of the line are managed and organised. It interfaces with the Power-C through an Ethernet network channel where it sends the machining data while at the same time receiving and displaying in real time the various messages coming from the Numerical Control on the status of the user units installed on the machine. It can be fitted with a laser gun to read the barcode printed on the label of the piece being loaded, through which the system automatically imports from the software all the machining operations to be carried out. Technical characteristics Mobile control console on wheels. Retractable (right and left) shelves, to support mouse, etc. USB optical mouse. USB English keyboard Control panel complete with potentiometer for setting axis overfeed. Directional 17” TFT flat colour monitor with protection and anti-glare glasss oftware installed Windows XP Professional or Vista operating system in English. FomCam Program (see description below) Power Studio for managing manual command blocks and for interfacing with the on line service assistance Production program with the “Machinings” module giving complete piece programming with machining operations Description of some of the main functions Parametric programming. Optimisation of the machining path. Dynamic display of machining operations. Graphic tooling up of the work area. On-screen display of the gripper position directly on the profile section FOM CAM SOFTWARE CADCAM Program, working in Windows environment for managing cutting and machining lines and for graphic definition of the operations to be carried out. Technical characteristics 3D graphic representation of bar and the machining operations entered. Cutting lists read via network, USB memory stick or disk. Graphic simulation of the machining operations carried out on the bar, with true reproduction of the centre plate. Managing profile archives Managing tool archives 2D or 3D CAD creation of accessory/geometry operations (macro) Integration with ProF2 office program OPTIONAL MACHINE ACCESSORIES Description Controlled axes kit for gripper carriage Inclined swarf conveyor belt for multispindle Angled conveyor belt Inclined swarf conveyor belt outside of casing Hose 1 L – exhauster Rear fence Workshop cleaning exhauster kit WORKSHOP AND INSIDE OF CABINET CLEANING KIT Electro spindle with head for comb hinge with three shanks Sound insulated cabin PROF2 PROFESSIONAL software user licence Label printer with automatic application to profile Additional profiles in archive beyond 10th OPTIONAL SOFTWARE ACCESSORIES Description 3D graphic design module Importing geometries defined in CAD by DXF or DWG format Bar positioning in the two areas (dual station) Thread tapping including with comb tools Management of machining lists Management of flowdrills for flow-drilling Automatic identification of the workpiece to be machined by bar code reading system The specifications and illustrations in this technical sheet are only guideline, FomIndustrie therefore reserves the right to make any modifications it deems necessary for technical or commercial reasons at any time and without prior notification.