Ops-Ingersoll Edm Eng

8/20/2019 Ops-Ingersoll Edm Eng

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The Road

EDM

GANTRY 400GANTRY 500GANTRY 800GANTRY 1200GANTRY 1500GANTRY 2000

> More Productivityby more efficient EDM


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>The nature as Paradigm

The CourseIn the Mould and Die Industry, improving

your efficiency is the only way to secure

your future and your strategy. The

management task requires a comparison

of all the possibilities with the best

technical solutions. We, as a supplier of

technical-systems and equipment, see

our duty and task to develop machines

so that you will be able to reach your

goals.

Our EDM-program features a wide range

of applications, excellent technics and

intelligent possibilities for process-engineering.

That is the way to improve your

productivity.

“Go for performance”

Erosion (lat.:erodere = to gnaw off) is the

geological process of removing weathered

stone-material, that creates textures and

sculptures over millions of years.

The technical principle “spark-erosion”

(EDM = electrical discharge machining) is an

erosion-production-process which relies on

electrical discharge procedures between the

electrode and the conductive workpiece. These

opportunities and results of the process are

fascinating to the ambitious technician, just like

the nature paradigm.


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OPS-INGERSOLL is positioned as the

specialist in the market, with expertise in

the total range of machining workpieces.

The combination of HSC and EDM,

our OPS-INGERSOLL-MoldCenter,

was developed and is the positive proof

of the evidence. The GANTRY-concept is

covering the EDM requirements from

small to large. Herewith we are confident

to raise your process-efficiency funda-

mentally.

The direction is obvious, let’s go the

course together.

Your Partner

Rainer Jung, President

GANTRY 400

GANTRY 500 and 800

GANTRY 1200

GANTRY 1500 and 2000

Control

High-Lights

Technical Data

Options

MoldCenter / Automation


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Plug and Play!

Set-Up, Fill-In, Erode!

And this with highest accuracy on

smallest floor space!

This is possible with our GANTRY 400.

When you got to machine workpieces

with limited dimensions, the GANTRY 400

is the ideal base of operation for efficient

processes, and also offers intelligent

automation technology.

GANTRY 400

GANTRY 400Axis-Travel: X / Y / Z

400 / 300 / 300 mm

Work tank dimensions: L / W / H

650 / 500 / 340 mm

Control

High-Lights

Technical Data

Options


Operator friendly machining

with efficient handling

Miracle in floorspace-saving

Highest accuracy at minimum space


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With the 500th GANTRY 500 machine

which was built in 2006, the machine

has proved an allrounder for over a

decade.

Due to the “GANTRY-style” regarding

accessibility and retrofitting of auto-

mation, this makes this machine to be

“one of a kind”.

GANTRY 500


525 / 400 / 450 mm


750 / 650 / 420 mm

GANTRY 500 and GANTRY 800 – Precision-machines which “sta

Maximum accuracy due to rigidity and temperature-stability

High-Speed-Jump for fastest machining with excellent image-preciseness

Top performance, by the use of modern generator-technology

More versatility for new applications through modular upgrading

All possibilities and wide scope for automation


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The requirements and the workpiece-

dimensions are getting more complex

and demanding.

For this configuration we have con-

ceived the GANTRY 800. The machine

only needs slightly more floor space

than the GANTRY 500, but has the

double working-area. This makes it to

a real “Capacity-Miracle”.

GANTRY 800


550 / 850 / 450 mm


800 / 1100 / 480 mm

crowd”

Best quality for machining and consequently for your final product

Highest productivity by saving manufacturing-time and better cost-benefit-relation

Absolute reliability of processing with defined reproducibility

Best future- and planning-reliability for your investment

Optimised flexibility as an assumption for more customer orientation

Control

High-Lights

Technical Data

Options



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GANTRY-EDM in big size

Large axis-travel-ways by smallest footprint

Large fluid-tank, lowering totally into the base

Machine in GANTRY-style

Weight of electrodes 1– 100 kg, automatically exchangeable

Axis-Travel: X / Y / Z

1000 / 1500 / 650 mm


1270 / 1770 / 680 mm

The GANTRY 1200 is unique for its

various possibilities. The experiences

of the “large-scale-machines” and the

vitality of the “small-machines” are

combined in the GANTRY 1200.

The machine moves fast with large

workpieces through “high-axis-travel-

speed” and “High-Speed-Jump” (HSJ).

At the same time the machine is

conceived for large machining in the

“Big-mould-manufacturing”.

GANTRY 1200

GANTRY 1200


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Generator, fire-extinguisher, cooling-unit and electrical-control-cabinet

are integrated into the supply-unit

Fluid-level is maintained automatically, means no fill- or drain-time

Best accessibility for loading, set-up and for inspection

Ideal for complete and partial machining of workpieces

Control

High-Lights

Technical Data

Options


Axis-Travel: X / Y / Z

GANTRY 1500: 1050 / 2050 / 1000 mm

GANTRY 2000: 1550 / 2750 / 1000 mm


GANTRY 1500: 1520 / 2520 / 945 mm

GANTRY 2000: 2020 / 3220 / 1350 mm

As a result of experiences over decades

for the design, manufacturing and

application of large EDM-equipment,

OPS-INGERSOLL is your qualified part-

ner in the “Large-mould-manufacturing-

industry”.

With GANTRY 1500 and GANTRY 2000

we offer future-oriented and inflective

solutions for large EDM-tasks and

-challenges.

GANTRY 1500/2000

GANTRY 1500/2000


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CONTROLOPS-INGERSOLL expects to increase

the efficiency of your production.

Control, power-unit and innovative

ideas like HSJ are consequently “under

review” regarding these requirements.

The 64-bit-PC-NC-control supports the

capability of the “GANTRY” even to fulfil

complex duties with high discharging

performance, small electrode-wear,

homogeneous surfaces and to accom-

plish dependable long-lasting-accuracy.

Essential facts of the control:

Windows-operating-system

Adaptable to all common CAM-systems

MultiProg Technology-Selection

Shop-floor oriented operator-guidance

Easy to learn, due to dialog-text


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multipulsePRO

A new dimension in sink-EDM. With

multipulsePRO you will reach an

improvement of electrode-wear specific

for graphite-electrodes of up to 60%,

and even better metal-removal.

With this you will benefit the full poten-

tial of your GANTRY machine, and reach

shorter process-times.

MultiProg

Programming with PC

As complex as any machining-task may

be, with MultiProg the programming will

be very easy.

The input of the most important para-

meters is sufficient and MultiProg calcu-

lates the necessary number of electrodes

for an optimized EDM-result, determinesthe complete EDM-technology from

roughing to the final-step.

Whether you have single- or multiple-

cavities, tunnel-gating, ribbed- or

freeform electrodes, made out of copper

or graphite, whether you have to

machine tool-steel or even exotic

materials, for every task there will be

the right solution in “MultiProg”.

multipulsePRO/MultiProg

00%

80%

60%

40%

0%

20%

Wear Others Wear OPS-INGERSOLL

Graphite Copper

Current Result 2006

Less wear,up to 60% with graphite

Customer conclusionsconcerning multipulsePro:

Experiences up to date extremely positive

Very good process-stability

Better wear results

EDM-Times, especially with graphite, definitely reduced

EDM-secondary effects are mostly eliminated

Wear change due to multipulsePRO

MultiProg, Programming with PC


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With the GANTRY-type-series from

OPS-INGERSOLL you tap the full poten-

tial out of the quality, as well as the

efficiency-gain of EDM and utilize for

your manufacturing.

Each machine of the model-range

features in principle:

● Enormous dynamics by best

possible rigidity

● Long axis-travel-ways at

minimum footprint

● Thermo-symmetrical bodywork

for long-life-accuracy● Operator convenience

The constructive base for all these

features is our approved and conse-

quently further developed GANTRY

method of construction.

High-Lights

OPS-INGERSOLL C-axis

Integrated into the Z-slide the high-performance C-axis is a standard outfit of all

OPS-INGERSOLL EDM-machines.

Rotation-properties, potential moment of inertia and positioning-accuracy

accomplish the highest requirements, which must be made available by the C-axis

for EDM. Even heavy and wide overhanging electrodes are held in exact position.

The high dynamic direct-drive allows the EDM-process in multiple axis.Every standardized electrode-clamping-system can be adapted.

GANTRY-style-construction

The OPS-INGERSOLL GANTRY-style-construction is providing a high rigidity of all

machine-elements and results in minor deformation compared to C-frame-structures.

This tight machine-concept is characterized by large axis-travel-ways and easy

pick-up electrode-exchange.

Mega-Filter

As a standard feature of the machine, a special cartridge-

filter is developed especially for EDM requirements. The

filter-surface is 10 respective 20 m2 (40 m2 for the big

machines) and the filtering-principle is that the fluid is

running from the inside to the outside, and maintains anextremely long lifetime.

The exchange of the filter-elements is done via a quick-

disconnect-coupler and works clean and fast.


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Technical Data

GANTRY 500 GANTRY 800 GANTRY 120GANTRY 400MachineMachine weight kg 5,100 4,400 6,200 12,000Generator weight kg 200 200Power input kVA 10.3 9.1 9.1 17.4Fuse protection A 25 25 25 25Voltage/Frequency V/Hz 400 / 50 400 / 50 400 / 50 400 / 50

Work tankType Rise and fall tank Rise and fall tank Rise and fall tank Rise and fall tank, filled mClear dimensions (L xWxH) mm 650 x 500 x 340 750 x 650 x 420 800 x 1,100 x 480 1,270 x 1,770 x 6Dielectric fluid level, max. mm 300 375 450 640programmable/automatic

Work headmax. head load kg 50 100 200 300Distance electrode-clamping mm 105 / 405* 135 / 585* 135 / 585* 150 / 800*chuck to work table min./max.

Integrated C-axisRPM (adjustable) 1/min. 1 – 20 1 – 20 1 – 20 1 – 20Angle positioning degree 0.001 0.001 0.001 0.001Loading capacity manual kg 50* 50* 50* 50*electrode changeLoading capacity automatic kg 10* 15* 15* 25*electrode exchangeMovement kg/m2 0.4* 0.4* 0.4* 0.4*of inertia, max.Torque Nm 120 120

Work tableSurface (L xW) mm 550 x 470 730 x 630 760 x 1,000 1,640 x 1,140Load capacity kg 500 1,000 2,000 7,500

Travel waysX / Y / Z inside mm 400 x 300 x 300 525 x 400 x 450 550 x 850 x 450 1,000 x 1,500 x 650work tankY (by electrode changing mm 675 1,180 1,945position)

ControlPC-NC-dialog 64 bit 64 bit 64 bit 64 bitType of drive Digital AC-servo-drive Digital AC-servo-drive Digital AC-servo-drive AC-servo-driX,Y, Z rapid traverse mm/min. max. 10,000 max. 2,000 max. 2,000 max. 6,000Digital display (selectable) mm 0.001 or 0.0001 0.001 or 0.0001 0.001 or 0.0001 0.001 or 0.0001

Dielectric supplyFilter unit Cartridge (integrated) Cartridge (integrated) Cartridge (integrated) Cartridge (integratFilter surface m2 10 10 20 20Dielectric fluid, total volume ltr 320 400 800 2,800

Electrode changerType Pick-up rotary disk Pick-up rotary disk Pick-up rotary disk Pick-up linear magazPositions (Option) 20 20 (30) 20 (30) 13 (30/50)Combi-magazine positions optional 2/14Electrode weight– Single electrode kg 10* 15* 15* 25– Total weight kg 40* 60* 60* 150

GeneratorType Switching mode, resistorless Switching mode, resistorless Switching mode, resistorless Switching mode, resisMachining power, max. A 70 70 70 70 / 100

Additional features

Automatic lubrication Standard Standard Standard StandardChiller, cooling power kW 2.5 3.9 3.9 8CO2-fire-extinguisher,DIN 14497, size kg 6 6 10 20

* Note: The values stated are max. values which may vary according to the clamping system used. Technical modification


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GANTRY 1500 GANTRY 2000

30,000 42,000

30 3050 50

400 / 50 400 / 50

e and fall tank, filled moveable Rise and fall tank, filled moveable1,520 x 2,520 x 945 2,020 x 3,220 x 1,350

900 1,300

1,500 1,500

200 / 1,200* 450 / 1,450*

1 – 20 1 – 200.001 0.001

50* 50*

25* 25*

0.4* 0.4*

120 120

1,380 x 2,380 1,870 x 3,080

20,000 30,000

1,050 x 2,050 x 1,000 1,550 x 2,750 x 1,000

2,850 3,555

64 bit 64 bitAC-servo-drive AC-servo-drive

max. 8,000 max. 8,0000.001 or 0.0001 0.001 or 0.0001

Cartridge (integrated) Cartridge (integrated)40 40

7,000 13,000

Pick-up linear magazine Pick-up linear magazine15 (50) 20 (50)4/18 4/18

25 25150 150

witching mode, resistorless Switching mode, resistorless100 100

Standard Standard10 10

30 45

4450

6 0 3 0

2750

m a x

. 5 0 0 0

2950

3 9 5 0

20501420

2 2 5 0

GANTRY 400 GANTRY 500

Machine height : 2220 mm Machine height : 2653 mm

GANTRY 1200

Machine height: 3440 mm3690 mm with raised portal

GANTRY 1500

24601625

2 7 0 0

GANTRY 800

Machine height: 2703 mm

5100

6 7 3 0

3440

m a x

. 5 0 0 0

GANTRY 2000

Machine height: 5250 mm5650 mm with raised portal

Machine height: 4760 mm

2450

1 8 7 1


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120%

100%

80%

60%

0%

40%

20% Erosion time Lift-off time

High-Speed-JumpStandard

I n c r e a

s e d p e r f o r

m a n c e

HSJ-Technology

High-Speed-Jump

OPS-INGERSOLL offers with its HSJ-Technology for the GANTRY-machines

400, 500, 800, 1200 an improvement of

the eroding-performance, specially for

difficult applications. HSJ is the high-

performance-servo-system for the Z-axis

with an acceleration of about 1,2 G.

On the base of scientific researches a

new drive- and technology-concept was

created. This results in a reduction of

the working time of about 50% for

e. g. deep-slot applications.

High-Lights

Fundament changes of EDM results:

Increase of the effectiveness due to the considerable

improvement of the ratio erosion versus lifting-time

Secure work for unattended actions,even for deep cavities, without cooling-flush

Guarantee for consistent surfaces

Improvement of Machining-Time up to 50 %

for applications even with deep slot-processing


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Electrode changer

OptionsApplication oriented options for the

equipment of GANTRY-machines:

●

Handling of electrodes and workpieces● RAM-clamping-system

● MultiControl remote-monitoring

and diagnostic

The GANTRY 1200, 1500 und 2000 has a combined electrode-

clamping-system on the slider and the C-axis. For large electrodes

the full eroding demands are utilized through the big clamping-

system on the slider. With this slider clamping system it is

possible to work and handle pallets up to 150 kg and with the

C-axis clamping-system pallets up to 15 kg.

With the additional module MultiControl

you have direct access to all functions

of the 64-bit-PC-NC-control of your

EDM-Machine by ISDN connection.

With the OPS-INGERSOLL Teleservice

our service-technician is able to connect

himself online with your machine for

diagnostics and/or troubleshooting.

MultiControl display

Small electrode changer

Each of our EDM machines is equipped with a standard

electrode changer. For the network with external pre-setup-

and measuring-places, including automatic transfer of the

electrode- as well as the workpiece-offset-data, we offer all

different automation levels as customized solutions.

We have drastically improved the flexibility and operator

convenience for our large machines with a combined

electrode-changer. This guarantees a convenient changeover

from roughing to finishing electrodes.

RAM-clamping-system


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We have built this machine range to meet

your current requirements and future

expectations to achieve shorter develop-

ment times, wide interest for product

variations and the huge pressure for

costs and competition. We developed and

created an universal machining-strategy,

for all process levels.

All our machines are pre-arranged

for automation. The association of an

MC-Handling-System can also be

installed later.

To combine both technologies, HSC and

EDM, we offer you the possibility to join

the two in the MoldCenter. With this fully

automated MoldCenter you will reach an

efficiency, you never could achieve with

two separate systems.

Final Destination!

MoldCenter


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OPS-INGERSOLL Funkenerosion GmbH

Daimlerstrasse 22

57299 Burbach, Germany

Phone: +49 (0)2736 | 446-0

Fax: +49 (0)2736 | 446-510

E-Mail: [email protected]

Internet: www.ops-ingersoll.de

Our brochures:

Spark Erosion High-Speed-Cutting

Automation

Company Profile

Ops-Ingersoll Edm Eng

Documents