GEMINI CNC Gantry Style Plate Fabrication Center for Drilling, Tapping, Milling, Marking and Thermal Cutting

Standard tECHniCal FEaturES•Twinbeamboxconstructionforminimumdeflectionwhenmachining•FanucCNCcontrolsforproductiveoperationalreliabilityandworldwide servicesupport•LowbacklashhardenedandgroundhelicalrackontheX&Y&Uaxes•Simplefloormountedinstallationwithouttheneedforspecialfoundations•Minimalfootprint(upto60%lessthanothersolutions)•Highspeedmillinganddrillingwith6,000RPMspindlespeedsandautomatictoolchanger

•Integratedautomaticplateclampingrequiresnosetupandeliminatesvibrationtoachievehighratesofproductivity

andtoollife•Precisionlaserforplatereferencingeliminatestheneedtosquareplatespriortoprocessing

•SecondaryXaxisincreasesproductivityandpermitsmillingwithouttheneedtopositionthegantry

•Toolchangingoccurswhiletheplateremainsclampedforprecisiontapping,countersinking,boringandmilling

•Helicalmillingforlargerholeswithlowcosttooling

•Facemillingforbearingsurfacesinconstruction/machineapplicationsandcolumnsinstructuralsteelfabrication

•200,260or400ampplasmasystems•Abilitytokeepmultipleremnantsonthetableeliminatesthematerialhandlingandneedtoreturnandretrievethemfromstock

•Cuttinglengthsfrom5-30m/20-100ft.•Air/mistorliquiddrillcoolant

OptiOnal FEaturES•CNCbevelplasmaheadforweldpreparations•Multipleoxy-fueltorches•Optionaltoolmonitoring•Downdraftorwatertables•Platemarkingandlayout“scribing”withpatentpendingtechnology•Pinmarkingforlowstressapplications•Markingwithplasma•Maximumplatewidthsof8’(2,540mm),10’(3,100mm)and11’9”(3,600mm)•Chipvacuumevacuationsystems•Magnetictableforstand-alonemillingoperations

CNC Gantry Style Plate Fabrication Center for Drilling, Tapping, Milling, Marking and Thermal Cutting

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Plasma torch with laser height sensing

Plate clamping and sub X axis with 8 position tool changer

Thecompleteplateworkingsolutionforfabricatorsandmanufacturersofallsizes.TheGeminihandlesfromlighttoheavyplateforthermalcutting,marking,milling,drilling,tapping,bevelingandmoreallononesystemwithunprecedentedaccuracy.Thisachievesthelowestcostduetoitsminimalfloorspace,lowcapitalinvestmentandproductivity.

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CuttinGThe Gemini’s mobile gantry design allows for a greaterrangeofplatesizesandthicknesseswithoutconcernfortheplateweightandmaterialhandlingduetothesimultaneousprocessingandloading/unloading.Supplied with plasma and optional oxy-fuel torches, theGeminicancutplatesfrom3/16”(5mm)to12”(305mm)insteelandfrom3/16”(5mm)to1-1/2”(40mm)instainless,brassandaluminum.Machine positioning accuracy of .004” (.1 mm) ensuresqualitypartsforbetterfitupandlessweldingtime.Forheavyplatework,theGeminicanbesuppliedwithupto threeoxy-fuel torchesforaccuratestrippingormultiplepartcutting

MarKinG and SCriBinGTheGeminicanbefurnishedwithawidevarietyofmarkingdevicesdependingonyourneeds.Fabrication and bending lines can be indicated with ascribingtoolorplasmamarking.Identificationmarksandpartnumbersforfabricationcanbeaddedwiththescribingtool,plasmamarkerorapinmarker.Deeper marking suitable for viewing after painting orgalvanizingcanbeperformedwithscribing.Centerlocationsforthepositioningandweldingofpartswithreference points are produced with our “patent pending”scribingtool.

The Gemini can be equipped with different optionalHypertherm plasma torches and with the WinNESTsoftware package to maximize material utilization withefficientpartnesting.FanucCNChardwareisprovidedwithahumaninterfaceusingFicepPegasosoftware.

Nesting report

Nesting CNC Fanuc control

Hypertherm control panel

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Exhaust system for the plasma and/or oxy-fuel torches

EdGE BEvEllinGThe Gemini can make weld preps either by milling orplasma beveling. For precision bevels, milling is moreaccurateandJgroovebevelscanalsobeachieved.Forvariablebevels,largepartsandKpreps,plasmabevelingisthemosteconomicalprocess.Forenhancedefficiencyin welding, J preps and thickness reduction can beperformedwithmillingtools.

FaCE and SlOt MillinG

Onmachinepartsandmanystructuraldetailitems,slottedholes,milled bearingmating surfaces, etc. are required.Traditionally these operations were performed on largemachining centers or boring machines after fabrication.TheaccuracyoftheGeminiinbothcuttingandmachiningmeans thatmanyof theseoperationscanbeperformedonthestockplate,thuseliminatingtheexpense,handlingcost,floorspaceand lead-timeofsecondaryoperations.For fabrication the milling of weld prep surfaces candrasticallyreduceweldingcosts.

GEMINI XD 36

GEMINI XD 36 - front

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J groove edge beveled for deep penetration and no back welding

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Parts drilled and marked

Thick parts drilled and cut

drillinG and tappinG

About60%ofplatecomponentsorpartscontaindrilledholes.TheGemini’shighspeedmachiningspindleallowsextremelyproductivedrillingofholesfrom1/8”(3mm) to 3.15” (80mm). For larger holesup to 15,7” (400mm), theGemini canmillholeswithexceptionalaccuracy(<0.004” (.1mm) toleranceondiameterandconcentricity).

Thehighspeedspindlepositioning (subXandYaxis)combinedwithwideareaclamping provides very high productivity for themost common hole sizes (18 –15/16”(22mm)diameterholesperminuteon4”(100mm)centers).

TheprecisionoftheGeminiprovidesunprecedentedaccuracyofbothholetoholeandholetoedgelocations.

Formanyapplications,tappedholesinthecomponentscanreducewelding,fittingandassembly time. For tapping, thedigital control systemprovideshighqualitythreadsontappedholesassmallas1/8”(3mm)forcableclips,etc.andupto15/16”(22mm)forstructuralbolts.

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HARDWARE & SOFTWARE

Pegaso is the new generation CNC for Ficepmachines. PC,CNC and PLC are integrated on a single board, to have themaximum reliability.Pegaso isbasedonfieldbus technology:CanBusandEtherCAT,withupto32axescontrolled.

TheCNCispositionedonamobilecontrolpanel,sotheoperatorcanhaveacompleteviewofthemachine.Themostof input/outputinterfacedevicesandbrushlessmotorsdrivesarelocatedonthemachine.

programming• Simplifieddatainputwithgraphicaldirectpreview• 3Dpieceview• Diameterprogrammingwithautomatictoolassignment• Linear,matrixandflangepatterns• Programmingwithmillimetersorinches(alsofractions)• Linearnesting

processing• Automatictoolassignment• Unitoffsetautomaticsumming• Automaticgroupingandorderingofoperations• Setupmodificationlinesgeneration• Rototraslationofexecutingprogramtofollowsheet

orientation

Execution• Automaticcyclestopfortoolsetupmodification• Probingcapabilitytoadjustprogramquotestoactual

materialposition• Automaticsoftwaretopreventmachineunitcollisions• Automaticsoftwaretopreventtoolcollisionsagainst

material• Toolmanagementwithoperatingparametersandtoollife

management• Messagesandalarmnotificationstotheoperatorusing

customerlanguagewithhistorylog• Graphicscreenstodisplaymachinepieceshandlingtables• Productiontimesrecording

pEGaSO SYStEM

pC characteristics• CPUAMDOntario1.6GHzDualCore• Ram2Gb• DiskCompactFlash8Gb• USB6HighSpeed2.0(oneonthefront)• LANEthernet10/100/100Mbit• KeyboardIndustrialPS2• DisplayLCDLedtechnology15“withtouchscreen• Industrialpanelwith42pushbuttons• Op.Sys.Windows7EmbeddedwithEWFfilter• Teleservicesoftwareforremotediagnostics

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The gantry is provided with a travel length of 6 mt (20 ft.) as standard, and longer lengths are available as an option

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CAPACITIES AND SPECIFICATIONSHP25 HP32 HD36 XD36

Material dataPlatethickness(min.) mm/inch 5(3/16") 5(3/16") 5(3/16") 10(3/8")Platethickness(max.) mm/inch 80(3") 80(3") 127(5") 305(12")

Platedimensions(min.) mm/inch 800x1250(32"x48")

800x1250(32"x48")

800x1250(32"x48")

800x1250(32"x48")

Platedimensions(max.) mm/inch 2540x24400(100"x80')

3100x24400(80')

3600x24400(141"x80'),(3200x24400

(126"x80'withbevel)

3600x24400(141"x80'),3200x24400

(126"x80'withbevel)

axesCNCinterpolatedaxes number 4 4 3or5(6or9) 3or5(6or9)CNCtotalaxes number 5 5 10(18) 10(18)Plasmatorches number 1 1 1(2) 1(2)Plasmabevel(option) 1 1 1(2) 1(2)Oxy-fuelcuttingoption(max.) mm/inch 100/4" 100/4" 127/5" 305/12"drilling unit(s)Verticaldrillheads number 1 1 1(2) 1(2)Toolsperdrillhead number 8 8 24 16SpindleRPM rpm 6000(8000) 6000(8000) 6000(7000) 4500(5000)Spindletaper ISO40 ISO40 ISO40 ISO50Spindlelubrication internal/external internal/external internal/external internal/externalSpindleatS3rating kW/hp 11/15 11/15 26/35 58/78Holediameterdrilling(max.) mm 32(1.25") 32(1.25") 40(1.57") 80(3.15")Holediameterinterpolatedmilling(max.) mm 240(9.5") 240(9.5") 400(15.7") 400(15.7")

installationWorkinglevelheight mm/inch 650(25.6") 650(25.6") 700(271/2”) 700(271/2")

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