Tag Archives: Sinumerik

Sinumerik 828D Basic for Milling and Turning Machines in the Mid-range Job Shop Market

By Bernard and Company Tags: Ad agencies, Drive Technologies, EASTEC, inamics S120 Combi, Motion Control, Siemens, Siemens Industry, Siemens Machine Tool Systems, Sinumerik, SINUMERIK 828D BASIC M, Sinumerik 828D BASIC T, Tim Daro 1 Comment

At this year’s EASTEC Show in West Springfield, MA, Siemens will demonstrate new versions of its popular, compact CNC for the job shop, the Sinumerik 828D.

SINUMERIK 828D BASIC T

The Sinumerik 828D BASIC T is designed to address the needs of shopfloor turning machines.
It combines CNC, PLC, operator panel and axis control for five axes/spindles, including live tooling. Milling and drilling operations on a turning machine, both for face and peripheral surfacing, are therefore possible. In tandem with the new Sinamics S120 Combi drives package, the 828D BASIC T represents a new level of efficiency and virtually maintenance-free operation, as the fans, hard disks and batteries of past CNC generations have been eliminated.

With rugged diecast magnesium front panel on an IP65 enclosure, the BASIC T enables an Ethernet connection, USB or Compact Flash (CF) card program loading. An 8.4-inch color display for easy readability and simple QWERTY keyboard provide fast ramp-up for the operator. Various communication ports in USB, Ethernet, Drive-CLiQ, PLC I/O interface, RS232 C and NC inputs/outputs are standard.

In operation, reliable 80-bit nano accuracy means contour control precision and a better workpiece, every time, while Siemens intelligent kinematic transformations provide the proper orientation of machining plane to work surface.

Though simple command language is provided for operator ease, the BASIC T functions with the highest level of ISO programming language. Established cutting cycles can be utilized with fully Animated Elements for the faster visualization of part production on various levels with combinations of Sinumerik CNC and ISO programming languages possible, as well.

SINUMERIK 828D BASIC M

Similarly, the new Sinumerik 828D BASIC M class features the same quality performance as the T class, but for use on milling machines. Even in complex moldmaking operations, mirror-smooth surfacing and reduced machining times are enabled. Again, in tandem with the Sinamics S120 Combi drives package and Simotics feed and spindle motors, the 828D BASIC T will operate a milling machine at the highest level of performance possible. Superior axis and spindle dynamics within a broad speed bandwith yield quality workpieces, every time.

All the other benefits of the Siemens CNC family, including the Sinumerik Operate graphical user interface platform as well as ShopMill and ShopTurn easy programming are offered in these new 828D CNCs.

SINUMERIK 828D

The Sinumerik 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. This control family is ideal for single-part and small-batch production. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical workstep programming systems, while high-level language programming can be used in conjunction with programGuide to significantly reduce programming times for large-scale serial production.

Also included with this expansion of the Sinumerik 828D family of CNC, modern PC and mobile phone technology are also available for the mid-range machine tool. Extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate data networks.

Through the use of its Easy Message functionality, the Sinumerik 828D family offers production status monitoring by text messaging (SMS). Depending on the recipient’s profile settings, the machine tool can transmit information about workpiece machining status, report on the tool condition currently
in use and send machine maintenance bulletins to a mobile phone, anytime and anywhere. These combined functions are designed to help keep machine downtime to a minimum.

For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.

For more information on this story, please contact:

SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication

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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.

Siemens and Biglia Offer Full Flexibility in New “Quattro” Series of Turning Centers

By Bernard and Company Tags: 1FK 7 G2 series, 1PH8, Ad agencies, Biglia, Drive Technologies, Motion Control, permanent-magnet synchronous motors, Siemens, Siemens Industry, Siemens Machine Tool Systems, Sinamics S120, Sinumerik, SINUMERIK 840D sl, Sinumerik Operate, Tim Daro No Comments

Highlights include two-sided machining and servo drive technology

Recently, Northern Italian machine tool manufacturer Biglia introduced its multi-functional turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC. The mechanical concept, together with the scalable control, provides users with the most diverse standard turning and milling operations. The result is increased flexibility and higher speeds for end users. That quality machine tools are built in Northern Italy is nothing new. And this fact is confirmed again by the “Quattro” series from the machine tool manufacturer Biglia. These machines are multifunctional turning centers that are valued throughout Europe for their high reliability and performance power. The machines are available in different versions from 11 to 15 CNC axes. They are also intended for different turning diameters (45, 52, 65, 71 and 80 mm).

Biglia has equipped its turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC control. The individual machines have 11 to 15 NC axes.

The two opposing spindles form a special feature of the “Quattro” series. This allows the workpiece to be machined from two sides, which reduces the machining time. The second spindle can also be moved linearly in two directions (lengthwise and crosswise). This provides some leeway in the case of additional milling operations, but it can also be used for automatic workpiece unloading. Two turrets, mounted on the y-axis, ensure proper positioning of the necessary tools.

The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.

This innovative machining technology allows the creation of not only rotary but also prismatic workpieces – including polygons. Dealing with everything in one setup not only reduces cycle times, it also enhances accuracy. The machines are developed on the basis of a modular concept that ensures flexible application options – from the universal CNC lathe, to complete machining of complex workpieces with powered tools (c- and y-axis).

Getting it right, from the start

By offering the Siemens Sinumerik 840D sl CNC control, Biglia now wants to expand its previous options and its own market by combining its technologies with that of the Siemens control. “In this project, which is of personal significance to all of us who worked on it and of strategic significance for Biglia, we wanted to do everything perfect right from the start and to get the most out of it,” says Giovanni Delmondo, Business Development Manager for machine tools with Siemens Italy. The result is an all-round successful machine series with a highly modern control that already includes the innovative system expansions of recent months – including increased energy efficiency options offered by the control and drive systems from Siemens.

To illustrate this, Giovanni Delmondo points out that “the fans on the spindles are shut down automatically when they are not required, or certain services such as hydraulics, lubricant supply, or compressed air are deactivated during machine standstill times. This is handled via special screen forms on the control and is extremely simple, using the Run MyScreens function.”

Also notable is the standard energy efficiency solution from Siemens in the Sinamics S120 drives onboard this machine series. This includes automatic power factor correction or regenerative feedback of the energy generated in braking operations, a substantial factor in energy savings.

Performance and scalability

The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.

The centerpiece of the automation concept of these Biglia turning centers is the Sinumerik 840D sl control. This is a universal and flexible CNC system, implemented in the Sinamics S120 design (see Fig. 3). It is suitable for up to 31 NC axes. Whether you are turning, drilling, milling, grinding, laser-machining, nibbling or punching, the Sinumerik 840D sl is suitable for use in the most diverse machining technologies. The CNC control also has PLC (programmable logic controller) functionalities, so that a special PLC can be eliminated, if applicable.

This high-end control from Siemens is ideally suited to medium and complex tasks and production and can be adapted to the task, thanks to scalable hardware. The CNC is also characterized by openness, so the operator interface and also the software present few limits to specific job adaptability. This applies all the way to supplementing the NC core of the control; however, a special license is required for this adaptation.

On the Biglia turning centers, the control was equipped with the Sinumerik Operate user interface, making operation simple and intuitive. Three different methods of parts programming are possible: Classic ISO code programming, programming with the help of the integrated ProgramGuide with graphical support of the selected cycles, and the new two-channel ShopTurn with graphical 3D simulation. The user is led step-by-step through the cycles, whether for simple metal removal, drilling, thread cutting, pocket milling, groove milling or engraving. Complex programming cycles for complex contours are also possible. The “ProgramSync” function for automatic synchronization of the machining programs via two channels ensures a significant increase in machine productivity. The control is equipped with a 15″ monitor and integral keyboard.

Siemens CNC in metalcutting applications.

The Quattro series from Biglia also uses the highly effective personnel and machine protection system provided by the Sinumerik control concept with the Sinumerik Safety Integrated package.

Biglia is also breaking new ground with servo drives. Thus, the new servo motor generation 1PH8 from Siemens is used for the main spindle motors in this series. The linear axes are further equipped with the new 1FK 7 G2 series of permanent-magnet synchronous motors. These motor types from Siemens enable onsite replacement of the encoders without having to dismantle the complete motor. This combination of machine and CNC control in the Quattro turning centers from Biglia provides users with greater flexibility.

For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.

For more information on the this story, contact:

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Gisma Steckverbinder GmbH: Well-Connected

By Bernard and Company Tags: Ad agencies, Drive Technologies, Gisma, Gisma Steckverbinder GmbH, Motion Control, Siemens, Siemens Industry, Siemens Machine Tool Systems, Sinumerik, SINUMERIK 840D sl, Sinumerik Safety Integrated, Spinner, TC77 universal turning machine, Tim Daro No Comments

A variety of complex underwater electrical connector casings are made by Gisma, using Siemens Sinumerik CNC-controlled Spinner lathe technology.

Gisma specializes in the production of underwater connectors typically used in offshore energy generation. Siemens Sinumerik-controlled Spinner CNC machine tools contribute significantly to the success of the company.

Special connectors are required to safely and reliably connect electrical and fiber-optic cables deep underwater. With maintenance more difficult, all of the parts must meet the most rigorous technical requirements in terms of reliability and service life. Products from Neumünster, Germany-based Gisma Steckverbinder GmbH are designed to be fail-safe and to withstand maximum pressure loads, while still operating on the basic “push and pull” principle. In addition to shipyards, the offshore oil and gas industry, and the military, Gisma is now receiving an increasing number of orders from offshore energy companies. Gisma works closely with its customers on all of its developments – most recently on a single-pole, wet-mateable power connector for use in offshore underwater turbines, which was designed to handle operating voltages of 12 kV at 400 A and is guaranteed to be fail-safe for 25 years.

Manufacturing repeatability to the nearest micron

To meet the high standards required in underwater technology, manufacturing accuracy to the nearest micron is required, especially for fiber-optic connectors. In addition, the materials must all be corrosion-resistant. The highest levels of functional safety  are also required to enable the machining of seawater-resistant bronze and stainless steels, along with more sophisticated materials such as duplex and super-duplex steels, titanium and high-performance plastics. The demands placed on the cutting machines and controllers used in the production of these parts are correspondingly high. For many years, Gisma has relied on Spinner milling and turning centers equipped with Siemens Sinumerik CNCs. “The machines rarely fail, mostly because of the high-quality drive and control technology,” says production manager Michael Königsmann. He is particularly impressed by the TC77 universal turning machine from the 800 series, which will be used, among other purposes, to turn the casings for a new high- performance connector measuring up to 3000 mm long. The TC 77 is built on a rigid Meehanite cast iron base with large tempered steel guide rails, allowing a high cutting capacity, along with good damping and rigidity characteristics. It is equipped with a water-cooled motor spindle, which allows precision turning to within a few hundredths of a millimeter, shortly after switching on. The machine also has a counter spindle and features 12 tool stations with driven tools. “This lets us manufacture some workpieces in a single run, whereas previously it would have taken several,” explains the production manager. In accordance with VDI/DGQ 3441, the machine achieves repeat accuracy of 2 µm in the  x- and z-axes.

Consistent CNC strategy since 2000

The sophisticated Sinumerik 840D sl CNC plays an equally important role in reducing manufacturing time. Since the year 2000, Gisma has used only Siemens controllers in its production facility. “By standardizing the controller, we have created an environment where we can deploy our employees flexibly all over the shop floor and operator error  has become a thing of the past,” explains Tobias Frerck, Gisma’s managing director. “We have always had great results with Sinumerik controllers and knew we could rely on our competent regional service partners on those rare occasions when something went wrong.” For newly developed products, production manager Königsmann and his staff usually create the CNC programs on external PCs in DIN ISO and then send them over the network to the most suitable machine. If there is a need to manufacture new connectors based upon an existing family of parts, the required CNC programs can usually be adjusted directly on the machine itself. And, just  as during initial setup, the Sinumerik 840D sl’s fully integrated and user-friendly ShopTurn software comes into its own here. The animated graphical user interface is completely intuitive, meaning that it can be easily picked up even by temporary staff. The Sinumerik Safety Integrated software package provides additional safety when working in setup mode, allowing operators to monitor the production process with the machine door open. Safety mode allows speeds of up to 2 m/min, and the software ensures that the drives stop quickly after a maximum of 1 to 2 mm, should any problems arise. If anything is unclear when an operator is entering data, he or she can push a single button on the operator console to bring up a help menu. Switching to a text-based DIN interface is just as straightforward, for example, when an experienced programmer feels that he or she can more quickly and easily describe a complex contour using a DIN statement. As always, the main focus remains on achieving the highest possible standards in terms of both the manufacturing and the finished product.

For more information on this article, please contact:

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The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.

Spinner Machining Center with Siemens CNC Helping University Researchers See Into Space

By Bernard and Company Tags: 840D sl CNC, Ad agencies, Advanced Technology Research Center, BernardandCompany, IFA, Industrial, Machine tool, Maikalani Institute For Astronomy, Motion Control, Press Release, Siemens, Siemens Industry, Sinumerik, Sinumerik 840D, Spinner, Spinner MC650-5A, Tim Daro No Comments

Machining center used at University of Hawaii Institute For Astronomy to produce one-off diffraction gratings for remote sensing instruments used with telescopes and other research instrumentation

University of Hawaii Institute For Astronomy telescopes are able to see the solar system and into deep space with greater clarity than at any other location on the planet, according to Dr. Ritter.

When you enter the laboratories at the University of Hawaii’s Maikalani Institute For Astronomy (IFA) Advanced Technology Research Center on the island of Maui and hear talk of light years, dark energy and space telescopes, it quickly becomes apparent that this is not your typical machine shop. The machining for instrumentation developed here involves some of the most sophisticated techniques on Earth, which is a pun of cosmic irony, as the workpieces produced here are primarily used to help evaluate happenings in deep space.

The Maikalani facility provides laboratory workspace for Physicists and Astronomers performing advanced metrology and optical fabrication, novel optics design, optical/infrared sensor development and a creative workspace. Maikalani literally means, “knowledge we gain from the cosmos.” As the Lab Director, a world-class physicist, Dr. Joe Ritter explains, “At the IFA, our excellent staff and faculty invent, design and build novel instruments for use in state of the art telescopes. Among other technologies, we are working to develop a novel generalized conformal diffraction grating. Gratings are optical components used to split light into component colors for the study of the chemistry of stars.” Ritter and his assistant John Valliant are also the machinists. They exchange their hats from physicists to milling machine operators, using a Spinner MC650-5A, equipped with Sinumerik 840D solution line CNC, to produce parts from high-conductivity copper and aluminum 6061-T6 grades, among other alloys.

Since the Spinner is used at the IFA exclusively for precise one-off parts, the search for the right machine focused on equipment that had among the industry-highest standards of accuracy and precision. The novel conformal gratings under development at the lab are designed with variable pitch and spacing dimensions to correct optical aberrations and also focus and split infrared light for future deep space spectroscopy instrumentation.

As Ritter explains, “Accuracy is everything in optics. Most of the machining centers I evaluated were in the +/-25 micron (~0.001”) range for accuracy. We settled on a 3+2 axis machine with 100 nanometer precision scales with interferometric remapping on the 840D sl CNC. Because we do experimental fabrication work and optics typically need to be made to micron level tolerances, it was imperative to have a feedback control on the machine tool with a known accuracy and predictable degrees of variation.” As an example, though not suitable for visible light, the optics Ritter discussed required accuracies of a few microns-good enough for infrared optics. Other technologies being developed by Ritter at IFA include novel photonic meta-materials for future space telescopes intended for studying exoplanets and the evolution of our universe.

Dr. Ritter cited the age-old challenge for educational and research institutions, when searching for such precision machinery, namely, budget constraints. In this case, the lab was fortunate, according to Ritter, as they became aware of a demo machine from Spinner, available from Lois Hill and Robert “Mac” McPherson of MacHill Machinery in South Carolina. During the purchase and commissioning, Ritter emphatically noted, “The Spinner technician Herr Siegfried Jungk, who trained us, was exceptionally talented and particularly knowledgeable and helpful. Ritter also noted that the Siemens ShopMill software included with the CNC package, was “…an easy-to-use program for getting the multi-axis machining up and running for basic drilling and facing.”

Sample parts produced on Spinner machine, mostly copper and aluminum, include many that become diffraction gratings used on highly sensitive instruments for deep space exploration projects

While invariably the smart guys in any room, Dr. Joe and John Valliant are not machinists by trade, so they were using both Shopmill and CAD/CAM programs like Mastercam with the highly-specialized G-code generator and post-processor needed to create precision path cuts, then running them directly on the mill to quickly begin cutting, an absolute necessity in their one-off world of custom parts.

“For some optics, the millions of coordinates we use for every workpiece are pushing the control to the limit, but it responds well. Plus, the teach-in functionality of the Sinumerik 840D sl CNC and its software package keep us running very efficiently,” according to Valliant, who worked in the lab as a University of Hawaii-Maui college student and has learned CNC machining on the go. In an environment where 0.1 of a wavelength of light is the desired target for accuracy, this is no small achievement. Valliant adds, “Once you’re comfortable with this machine and the control, the process is very intuitive.”

Photo Credit: Rob Ratkowski

Dr. Ritter, who is constantly pushing the boundaries on novel orbital space telescope designs, notes that the state of Hawaii and the island of Maui in particular have some of the best conditions on Earth for nighttime telescopic observation, as well as the best in the world for daytime solar viewing. The National Science Foundation will soon build the world’s largest solar telescope on Maui. Maui is a little known hotbed of technology development. In addition to solar research and deep space observations, the Institute for Astronomy partners with many nations to push the boundaries of human knowledge, while training future scientists.

Currently, the Institute is engaged in developing technology to make other new scientific discoveries possible. They include the largest camera on earth, new high contrast off axis telescopes, instruments using electronic cameras and spectrographs for the telescopes on Mauna Kea, Haleakala and, in Chile, detectors such as ultra-sensitive mega-pixel infra-red CCD arrays, plus adaptive optics to help overcome the image blurring caused by Earth’s atmosphere. Knowledge gained from the cosmos depends on maintaining Hawaii’s dark skies. Another initiative by Ritter, who chairs the Maui County Outdoor Lighting Committee, includes the development of novel efficient low light pollution outdoor and street lighting to preserve endangered species sea turtles and migrating seabirds as well as to preserve dark skies for Astronomy (see www.EcoScienceLighting.com).

Mac McPherson, the Spinner machine dealer and importer for North America, adds, “We do considerable business with academics and it’s always challenging, owing to the unique nature of their machining needs. In this case, an optic grid pattern with high accuracy was the biggest hurdle. We were able to supply the Spinner demo machine within budget and with the proper tooling included. The lab actually built their own custom fixturing for their work and Siemens helped to develop a special post-processor program.”

“Na Kilo Hoku” means “the watchers of the stars” and the instrument components made here certainly help them do just that — and also gain knowledge from the cosmos for us all.

For more information on this story, please contact:

Joe Ritter, Ph.D
Physicist and Lab Director
University of Hawaii Institute For Astronomy
Maikalani Advanced Technology Research Center
34 Ohia Ku St.
Pukalani, HI 96768
Phone: 808-573-9521
Web: www.ifa.hawaii.edu

Robert McPherson
MacHill Machinery Solutions, LLC
(dealer for Spinner machines)
2245 C-132 Ashley Crossing Drive
Charleston, SC 29445
Phone: 843-873-6888
Web: www.machillmachinery.com

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New Speed Connect Quick Release Mechanism for Siemens Power and Signal Cables

By Bernard and Company Tags: quick release for motion control, Siemens Industry, Sinamics, Sinumerik, Speed Connect No Comments

Siemens Industry, Inc. announced the introduction of Speed Connect, a new quick release mechanism that protects against vibration shakeout on its Motion-Connect^® line of power and signal cables. Motion-Connect^® cables are offered as standard on all Siemens motion control systems.

The Speed Connect release makes installation and changeover, even in very restricted space applications, fast and easy. No tools are required; just a one-quarter turn locks or unlocks the bayonet-style connectors.

All Siemens Motion-Connect^® cables are system-tested to guarantee optimum performance in any motion control system, whether in a Sinumerik^® CNC machine tool or Simotion^® general motion control application. These cables are also compatible with Sinamics^® drive systems and all families of Siemens induction, direct drive and servomotors. Motion-Connect^® cables are fully shielded to prevent EMC noise emissions and protect the motion control system from ambient environmental noise. Motion-Connect^® cables are certified to CE, VDE, UL and UL/CSA standards.

A wide range of cabling with the new Speed Connect quick release mechanism is immediately available. For more information, visit www.usa.siemens.com/motioncontrol.

Watch an operational video HERE.

For additional product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

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Handwheel Mode For Specialized Processing Operations in Locomotive Wheel Manufacturing for SCHÖMA

By Bernard and Company Tags: Ad agencies, BernardandCompany, CNC, Industrial, Industrial PR, Industrial press release, Machine, Machinery, News Release, Press Release, Schoma, Siemens, Siemens Industry, Siemens Machine Tool Systems, Sinumerik, Sinumerik 840, Tim Daro No Comments

Practical Operation

The SCHÖMA machine factory opted for a cycle turning machine with Sinumerik 840D solution line CNC for the manufacturing of individual parts and small batches of locomotive wheels; this machine also features Siemens ShopTurn with Manual Machine function. This hardware and software solution combines the flexibility and benefits of conventional machining with the productivity and efficiency of a CNC and this is what tipped the balance in its favor for one customer.

Christoph Schöttler Maschinenfabrik GmbH (SCHÖMA) is based in Diepholz, Germany. The company specializes in the development and production of diesel-engine locomotives. The model range includes tunnel and shunting locomotives; service, field and narrow-gauge locomotives; handcars, passenger carriages and gang cars. Around 90 percent of the locomotives produced each year at SCHÖMA are destined for use in tunnel construction.

Each construction project brings its own specific requirements and each country through which the locomotives travel has different environmental and safety legislation. SCHÖMA uses a modular system to meet a diverse range of customer requirements and the resulting need for a variety of equipment and product versions. One of the tasks facing the company is working out how to equip the locomotives for transportation by rail on differing track widths. Another requirement is locomotives with driving wheels featuring diameters between 600 mm and 900 mm, depending on local track usage.

The right decision

Faced with even more demanding requirements in terms of production capacity and flexibility, SCHÖMA’s Managing Director, Christoph Schöttler, last year decided to add a cycle-control Seiger Record LC 1400 lathe to his inventory of machines. “We opted for a head turning machine, as we do not need a tailstock to produce driving wheels, axle bearing housings and gear wheels. It is working just as we envisioned, so we obviously made the right decision,” says Schöttler.

SCHÖMA constructs around 120 locomotives each year, which equates to 480 wheels. In addition, there are also repair orders, which increase the workload to between 560 and 600 driving wheels per year. These wheels are produced in two mountings from forged blanks on the cycle turning machine. The first mounting is used to machine the wheel flange on the reverse side and the wheel hub. The shaft locating bore is pre-turned. In the second mounting, the first task is to pre-turn the driving wheel profile, then the rolling circle level and the wheel shaft locating bore are finished.

Careful approach

The cycle turning machine is controlled by a Siemens Sinumerik 840D sl CNC, equipped with the ShopTurn software package with Manual Machine feature. If required, ShopTurn programming can be performed on a separate PC as part of an operator’s work planning, without interrupting the work sequences on the machine. The programs are routed to the machine via the network, where they are called up as required, depending on the workpieces to be produced. The Sinumerik CNC is used for both numerically controlled machining and manual operation with the ShopTurn’s Manual Machine functions. In manual mode with electronic handwheels, the machine behaves just like a conventional lathe with an actual value display.

During face and longitudinal turning, the process operates with the entered feed and spindle speed. The real highlight of the system is that every cycle can be used straightaway, without having to create a custom program. At SCHÖMA, the option for manual intervention is used for setting the zero point or for simple contours. Diameters are determined manually, if driving wheels have been newly profiled or if driving wheel profiles require resurfacing. The wheel profiles abrade as a result of the high loads experienced in heavy-duty operation or on poor-quality tracks or as a result of the driven wheels skidding.

“With a machine that uses only CNC, it is difficult to rework the driving wheels, as it is not possible to determine how much material needs to be removed. With this optional manual mode, however, users can adopt a careful approach. This sums up the ease of control,” explains Walter Horstmann, head of mechanical production and wheel set construction at SCHÖMA.

Siemens ShopTurn with Manual Machine for the job shop

After machine start-up, the basic MANUAL screen is immediately displayed and offers direct access to choosing machining options without having to create a parts program.

Machining procedures such as “taper turning” and “straight line face and longitudinal turning” can be executed immediately. The operator simply selects tool, feed speed, spindle speed and orientation, plus, if required, machining angle, then presses “Start”. The active direction is graphically displayed in the basic screen, using a compass rose symbol. All machining steps such as entry, thread grinding and drilling can also be started in manual mode.

For additional product information and inquirie, contact:

SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.

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