TREVISAN DS1200/450C Horizontal Machining Center

The base of the machine consists of a stress-relieved welded steel structure, engineered to maximize rigidity while incorporating open areas for efficient chip and coolant flow away from the working environment. The column travels along the top of this machine base on re-circulating crossed roller bearings along the precision ground linear ways, driven by the CNC controlled AC servo motor and precision ballscrew mechanism. The standard feedback system is by servo motor pulse coder, with the option of employing Heidenhain linear glass scales for even higher accuracy and repeatability. One (1) set of leveling plates and bolts is included in this offer.

The rotary table consists of a Meehanite cast iron structure housing a hydrostatic rotary system with a hydraulic locking function. The table can be rotated by electronic handwheel or CNC command to any indexing position or programmed to move continuously at a specified speed in either direction. The very large rotary table is supported by a massive Meehanite cast iron housing and hydrostatic bearings. The movement is powered by a brushless AC servo motor and accuracy and repeatability of this B axis movement is guaranteed by the Heidenhain rotary encoder feedback system. The rotary table travels along the top of a rotary table base on re-circulating crossed roller bearings along the precision ground Z axis linear ways, driven by the CNC controlled AC servo motor and precision ballscrew mechanism. The standard feedback system is by Heidenhain encoder mounted on the end of the ballscrew, with the option of employing a Heidenhain linear glass scale feedback system for high accuracy and repeatability. The standard rotary table is supplied with a single fixed table top, but this can be modified to automatically receive pallets from a variety of optional pallet changer systems.

A sophisticated rack and pinion system propels the massive column along the X axis in a zero backlash situation. This is achieved by employing twin servo motors and a precision ground rack. The column consists of a stress- relieved welded steel structure, which is fed longitudinally on re-circulating crossed roller bearings along the precision ground linear ways by the CNC controlled AC servo motors. The standard feedback system for the X axis is by Heidenhain encoder mounted one of the the servo motors, with the option of employing Heidenhain linear glass scales for even higher accuracy and repeatability.

This massive headstock travels up and down the middle of the column on re-circulating crossed roller bearings along the precision ground Y axis linear ways by means of the CNC controlled AC servo motor and precision ballscrew mechanism. This vertical movement of the head is also hydraulically counterbalanced when in motion and clamped when stationary. This headstock has two spindles, each having a separate spindle motor and uniquely different features.

The high torque big diameter facing head is integrated into the headstock above the ram spindle. The “U” axis diameter adjustments of the contour slide are controlled by CNC command. The slide has two tool mounting positions for diameter flexibility, and tools are loaded automatically from the tool magazine to one of the two mounting positions. This can be used for single-point facing, boring, turning and threading operations. Standard tooling is employed at any programmed diameter to rough and finish complex internal and external profiles. Extra large tools can be loaded automatically from a tool rack, such as very long and heavy boring bars. The speed is fully programmable with constant surface speed control as on a conventional CNC lathe. Incredibly high torque can be produced through the optional headstock gear box. Standard flood coolant comes from the nozels at the top of the headstock, but as an extra option, coolant is supplied through the facing head and any of the tool holders directly to the tool insert, which greatly improves tool life and surface finish.

A robust quill protrudes from the lower half of the headstock with a built-in high speed spindle to power milling, drilling, reaming and tapping operations. This spindle is driven by an independent high torque motor which is also used to control the indexing of any head attachments. This quill also has a built in “U” axis drive to control the diameter of any smaller contour heads loaded from the tool changer or storage rack. A servo controlled "W" axis drives the quill linear movement and during the tool change procedure the quill is automatically positioned and locked. Coolant is supplied through this ram head and any of the tool holders directly to the tool insert. This ram type spindle enables the machine to perform the smaller single point turning, boring and threading operations, as well as the standard machining centre functions.

This tool changer and tool magazine are mounted on the side of the column thus enabling tool changes to be performed at any position along the X axis. The tools are exchanged automatically by means of the two hand hydraulic manipulator. The TG2000 tool holder system was specially developed by GT Trevisan and has a unique patent. Any previous tool is removed and stored into whichever magazine it came from, after which a tool automatically selected from the magazine is moved to either of the two high torque head positions or to the ram spindle. The magazine will always take the shortest path to find the next tool, and searching can be performed during machining operations. A TG2000 178 mm tool holder base is supplied as standard for each magazine position.

The cabinet containing the electrical and electronic system is independent from the machine and connections are established by means of a heavy duty overhead ducting system. The interface between the CNC control and the Trevisan machine has been specially engineered by system by Trevisan Macchine Utensili S.p.A..

The hydraulic system consists of a variable displacement pump mounted on the hydraulic tank and high pressure oil is directed by means of hydraulic valves to facilitate tool unclamping, chucking, indexing, and also to power the “Y” Axis counter balance system.

The central lubrication system feeds oil to all machine slideways, ballscrews and bearings at a rate and interval specified by control parameter and is monitored for system failure and low oil level.

The coolant is pumped from the large coolant reservoir through a filtration system and various heavy duty pipes to the two spindles and distributed through the centre of the ram and through various coolant nozzles at the top of the integrated turning and boring spindle. The system includes set of safety shields and it is recommended that a trough with a top grill is installed, at the customers expense, around the machine to collect and return the coolant. An optional feature is available to supply this coolant through the integrated facing head and its tools, directly to the cutting insert, thus greatly enhancing the surface finish and tool life.

This touch probe system will be used for automatic datum setting and for work piece coordinate measurement. It will also enable automatic offset adjustment before final machining.

This high pressure coolant system takes used coolant from the main storage tank and then by means of a sophisticated filtration system all particles larger than 20 micons diameter are removed before the coolant is pumped at high pressure through the ram.

With this headstock gear box both spindles have greatly enhanced cutting torque, especially the integrated turning and boring spindle with a gear ratio of 1:72. This feature enables automatic selection of either high speed or high torque.

With this option included a second rotary workstation can be retrofitted later to meet growing capacity demands.

The rotary table consists of a Meehanite cast iron structure housing a hydrostatic rotary system with a hydraulic locking function. The table can be rotated horizontally by electronic handwheel or CNC command to any indexing position or programmed to move continuously at a specified speed in either direction. The rotary movement is powered by a brushless AC servo motor and accuracy and repeatability of this B axis movement is guaranteed by the Heidenhain rotary encoder feedback system.

The rotary table travels along the top of a rotary table base on re-circulating crossed roller bearings along the precision ground Z axis linear ways, driven by the CNC controlled AC servo motor and precision ballscrew mechanism. The standard feedback system is by Heidenhain encoder mounted on the end of the ballscrew, with the option of employing a Heidenhain linear glass scale feedback system for high accuracy and repeatability. The standard rotary table is supplied with a single fixed table top, but this can be modified to automatically receive pallets from a variety of optional pallet changer systems.

The table can be rotated by electronic handwheel or CNC command to any indexing position or programmed to move continuously at a specified speed in either direction. The rotary movement is powered by a brushless AC servo motor and accuracy and repeatability of this rotary movement is guaranteed by the Heidenhain rotary encoder feedback system.

A 6-jaw self-centering chuck is mounted on the rotary table. Three jaws are for centering the workpiece and three for hydraulic clamping. The internal diameter of the chuck will be 900 mm, with an external diameter of 1500 mm.

This tool changer and tool magazine is used for manipulation and storage of indexing, facing and speed booster head attachments and other standard tool holders. The tool changer and magazine are mounted in the centre of the 'X' axis slideway, adjacent to the storage rack. The tools are exchanged automatically by means of the two hand hydraulic manipulator. Any previous tool is removed and stored into whichever magazine it came from, after which a tool or attachment is automatically selected from this magazine and clamped into the ram spindle. The magazine will always take the shortest path to find the next tool, and searching can be performed during machining operations. This tool changer and magazine will return to a safe parking position while the machine is performing other operations. A TG2000 128 mm tool holder base is supplied as standard for each magazine position.

This head indexes automatically at intervals of one degree for milling, drilling, tapping and reaming at irregular angles in difficult machining positions. This indexing head with integral extension is loaded automatically from the accessory rack to the headstock and is driven by the ram spindle. Any tools mounted on 128 mm TG2000 tool holders in the static tool magazine can be loaded and unloaded automatically with regard to this indexing head.

This head indexes automatically at intervals of 2.5 degrees for milling, drilling, tapping and reaming at irregular angles in difficult machining positions. This indexing head can be loaded directly to the ram spindle nose or to the ram extension adapter from the column mounted tool magazine. This indexer only uses manually mounted fixed tooling.

This facing head can be loaded directly to the ram spindle nose or to the ram extension adapter from the column mounted tool magazine. A single tool is manually mounted on to this type of facing head.

This facing head is loaded directly to the headstock and driven by the ram spindle. This accessory has a long reach and also a 128 mm TG2000 tooling interface for automatic tool changing.

This extension accessory is loaded automatically from the tool rack to the ram spindle to give a tool or attachment greater reach. Tools or attachment can be loaded and unloaded automatically.

This storage rack can have mounting positions for an indexing head, a facing head, a ram extension and a speed booster. These accessories are automatically loaded and unloaded at this storage rack.

This storage rack has a storage position for the very long gun drill. This tool is automatically loaded and unloaded at this storage rack.

The pallets driven along a floor mounted railway track by CNC servo motor and positioning encoder, with a conductor rail for power supply connection. Loading and unloading is performed by hydraulic geared motor and chain driven system. The storage rack is a steel construction consisting of horizontal beams and necessary brackets to support the pallets. Safety guards micro switches and photocells are mounted at strategic positions to comply fully with any CE regulations. The computer numerical control is housed in a ventilated metal cabinet, and the software delivered with the system is licensed not sold. The standard system has one loading and unloading station with a second station available as an additional option quoted on request. The system has three operating modes :- fully automatic, MDI, and maintenance mode.

The item has the following options :

Travisan engineers will install and commission the entire machine, and training will be provided before installation at the Trevisan factory in Itally.

Travisan engineers will install all four DS1200 machining centres and the chosen pallet shuttle. After commissioning of the flexible manufacturing cell, full tuition will be given during the final two week period before hand over and the commencement of full production.