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Machines

The new F seriesSetting standards in 5 axis

HELLER Machines. Made to work.www.heller-machinetools.com

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HELLER Machining Centres

4693_HE_Br_F-Baureihe_RZ-Nachdruck.indd 1 10.11.2009 18:13:57 Uhr

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Contents

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FP 2000/4000 Efficient, universal, highly-productive 14

Control The choice is yours 16

CAD/CAM integrationFrom idea to finished product 17

Tool management Fast, precise, flexible 18

HELLER ServicesThere for you throughout every phase 20

HELLER locationsWe are here for you. Worldwide. 22

FP 2000/4000The production machine 12

FT 2000/4000 Enhanced space and precision 10

5-axis competence in HELLER quality 3

Innovative spindle technology Process stability times three 6

FT 2000/4000The workshop machine 8

The new F series Machine concept 4


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HELLER – for good reasons

Your investment in a new machining centre has to pay off. To

make your production future-proof, you need reliability, precision

and high productivity. We are here to help you.

Our answer: the new F series.

5-axis machining centres designed to offer more than their

competitors.

A plus in sturdy engineering:

HELLER is synonymous with milling and with high-quality

machining since 1894. The F series embodies our complete

know-how gained from the development of the 5-axis MCH-C

series and its predecessors. The F series is a safe investment:

it offers productivity and precision from the very first minute.

A plus in process experience:

Our extensive process experience forms the basis for this 5-axis

machine series allowing you to respond swiftly and flexibly to

changing machining tasks, whilst ensuring maximum output and

optimum quality.

A plus in productivity:

Highest productivity in continuous operation – that is what the F

series has been designed for: the FT type for ergonomic table

loading, the FP type with pallet changer for compatibility with all

HELLER automation systems, 5-sided and simultaneous 5-axis

machining, robust machine design, powerful spindles.

A plus in flexibility:

Cutting costs through complete machining – the F series provides

the response to this trend in the machine tool industry. Being able

to perform as many tasks as possible with the same machine

provides flexibility now and in the future.

A plus in availability:

The F series was specifically designed for robust processes. This

means: not chasing after peak values but providing adequate

speeds, proven components, truthful characteristics. What are the

benefits to you? A machining centre with staying power offering

unparalleled opportunities.

A plus in service:

The HELLER service concept is designed to accompany you from

process design, machine installation through to the purchase of

new equipment and to ensure constant productivity. What is so

special about it? We are wherever you are. All it takes is a phone

call.

Optimised life cycle costs:

The running costs of a machine over its complete lifecycle are easy

to calculate from the cost of investment and the cost of operation.

Keeping these costs at a minimum, without compromising on the

quality and reliability of the machine, is the quintessence of what

we do. This is exactly what we have achieved with the innovative

manufacturing concept offered by the F series. The savings are

directly passed on to you.

5-axis machining: milling from solid material. Aluminium housing component (machine industry).

5-axis competence


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Die neue Baureihe FThe new F series

The new F series: machine concept

Strong basis for high cutting capacity Bed manufactured from epoxy resin concrete: efficient damping

of machine movements, reduced emissions, optimised overall

weight

Steel column with optimised topology in Y axis with minimal

deflection

Statically and dynamically optimised by means of structural

mechanics simulation

Optimised feedback control

Optimised resilience and thermo-symmetry

Quick chip evacuation for higher precision Z axis with concertina cover below the spindle prevents

contaminants from leaving the work area

Steep and extremely smooth chip chutes

Free chip fall from rotary table

Clean work area due to integrated flushing nozzles

Easy to clean due to good accessibility to work area

Customised coolant treatment Mesh-type filter system

Paperband filter system

Vacuum rotation filter system

Flexible installation Installation without anchoring

Quick installation, easy relocation

No separate foundation required

Low operating costs

Production precision down to the micron Absolute encoded, direct measuring systems

High-resolution rotary encoder

YRT bearing with integrated measuring system

Precise dynamics Proven axis kinematics of the tool: X, Y, C and A

Workpiece provides 2 axis: Z, B

Linear axes covered with tried and tested concertina covers

FT type: the workshop machine

FP type: the production machine


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Das MaschinenkonzeptMachine concept

Ease of operation you can feel Effective safety guarding

Optimum access to the work area for workpiece loading

Linear guided, smooth opening doors provide optimum access

for loading operations

Single-handed philosophy: short-stroke doors can be opened

with one hand

Lowered loading sill at knee height

Operating panel at the setting station with integrated flush/air

guns

Easy to connect to all common HELLER automation systems (FP)

Control Programming in the familiar system environment

SIEMENS Sinumerik 840D sl or HEIDENHAIN iTNC 530

Flexibility of choice according to individual requirements: with

automation for high-volume output or for manual loading in the

workshop

High processing power and easy operation

Complete integration into the CAD/CAM process chain


The new F series

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Spindle technology

Innovative spindle technology:process stability times three

High performance cutting with Power

Cutting Universal PCU 63

C swivel range from +15° to –195°

High torque due to powerful 1PH8 motor

Robust housing in cast iron

HELLER zero-spindle system

Media supply directly through the spindle

Suitable for dry machining

State-of-the-art RMP wireless measuring

probe

Benefits:

Transmission provides extreme rigidity

and damping

1 : 1 gear train

HSK, SK and BT spindle taper

High cutting capacity

Perfectly suited for cast iron, steel and

titanium

Speed cutting with Speed Cutting

Universal SCU 63

Benefits:

Swivel motor spindle with energy and

media supply through the centre of the

swivel head

HSK, SK and BT spindle taper

High speed: 16,000 1/min

High chip removal rate

Swivel head geometry designed for opti-

mum stability

Speed cutting with Speed Cutting

Tilt SCT 63

A axis swivel range +30°, up to –120°

below centre axis

Robust housing in cast iron

Motor spindle mounted in fork head with

bearings

Energy and media supplied through the

outside of the fork head

New cooling system provides reduced

thermal growth in the machine and highest

workpiece precision

Media supply directly through the spindle

Suitable for dry machining

Benefits:

For machining up to a +30° angle below

centre axis

Clearly arranged cutting geometry

High speed: 16,000 1/min

High chip removal rate

The F series with swivel head The F series with fork head


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The workshop machine: FT 2000/4000 for table loading

Sample workpiece Formula One racing car (aluminium) Integral component (aluminium)

Entry into HELLER 5-axis machining

Classic workshop machine for manual loading

Flexible, powerful, highly precise

Outstanding accessibility: F series for table loading (FT)

For a wide range of parts and materials produced in low

volumes

For frequently changing tasks and prototype construction

Combination of highest cutting capacity and optimum surface

finish on the market

Tool provides 5th axis via HELLER swivel or fork head

Storage capacity for up to 240 tools in chain-type magazine or

409 tools in rack-type magazine

Unparalleled ease of access to work area through three-part

work area door

Table with large clamping surface, optionally with hardened

surface

Glass mould with cooling holes (cast iron)

FT 2000/4000


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Technical data FT 2000 FT 4000

Work area X = 630 mm X = 800 mm

Y = 630 mm Y = 800 mm

Z = 830 mm Z = 1,000 mm

Table size Ø 720 mm

Workpiece Ø x height max. 1,000 mm x 1,300 mm 1,200 mm x 1,500 mm

Max. workpiece weight 800 kg 1,400 kg

Chip-to-chip time* 3.5 s 3.7 s

Rapid traverse 60 m/min

Acceleration 6 m/s2

Tool Ø x length (chain) 160 mm x 350 mm 160 mm x 450 mm

Tool Ø x length (rack) 188 mm x 350 mm 188 mm x 450 mm

Spindle tapers SK 40 / HSK 63 / BT 40

Spindles** PCU 63: 10,000 1/min, 44 kW, 242 Nm

SCU/SCT 63: 16,000 1/min, 40 kW, 80 Nm

* Limitations see technical data** S6 – 40% duty cycle

The workshop machine


FT 2000/4000


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Workpiece management

Safety and ease of operation have a crucial impact on

the availability of a machine. Faster and more efficient

operation minimises operating errors and risk of failure.

With the F series you can profit from our application

experience day in and day out.

Well-designed workpiece management allows you to machine

workpieces with a wide range of geometries and weights whilst

ensuring high process stability and perfect machining precision.

The loading concept of the F series is based on the experience

gained from the H series. The result is impressive: more space, less

chip accumulating surfaces, higher precision able to take

work piece weights up to 1,400 kg.

FT for manual table loading

Optimum access to the work area

Quick and easy handling of workpieces

Exceptionally well suited for workshop operation

Ideally suited, e.g. for tool and die manufacturers with

frequently changing tasks and small batch sizes

Robust rotary table for high workpiece weights

Maximum speed: 30 min-1 (F 2000/4000)

Workpiece support plate in optional design (slots, threads)

Hydraulic workpiece clamping (optional: 5-point services

interface with 60 or 200 bars oil pressure or 200 bars with

proportional technology)

Ball screw drive arranged in the centre

Hydraulic supply via bored holes in support plates

Component maintenance can be performed from outside the

work area

FT: enhanced space, user-friendly ergonomics and precision


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FP 2000/4000

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The production machine:FP 2000/4000 with pallet changer

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Highest productivity: F series with pallet changer (FP)

For machining of large workloads

Prepared for unmanned operation using pallet and

workpiece automation

Flexible for short-term job changes

Perfect for production-oriented users with high output

High cutting capacity for a wide range of tasks from

5-sided machining through to machining of complex

free-form geometries

Simple and cost-effective pallet automation solutions

Fully compatible with HELLER H series

State-of-the-art 5-axis production machine

with pallet changer

Designed for highest availability and productivity

Hydraulic housing (cast iron, plastic) Aerospace valve housing (titanium) Housing component from mould and die making (aluminium)


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The production machine

Technical data FP 2000 FP 4000

Work area X = 630 mm X = 800 mm

Y = 630 mm Y = 800 mm

Z = 830 mm Z = 1,000 mm

Pallet size 400 mm x 500 mm 500 mm x 630 mm

Workpiece Ø x height max. 720 mm x 850 mm 900 mm x 1,000 mm

Max. workpiece weight 800 (600)* kg 1,400 (1,000)* kg

Chip-to-chip time* 3.5 s 3.7 s

Rapid traverse 60 m/min

Acceleration 6 m/s2

Tool Ø x length (chain) 160 mm x 350 mm 160 mm x 450 mm

Tool Ø x length (rack) 188 mm x 350 mm 188 mm x 450 mm

Spindle tapers SK 40 / HSK 63 / BT 40

Spindles** PCU 63: 10,000 1/min, 44 kW, 242 Nm

SCU/SCT 63: 16,000 1/min, 40 kW, 80 Nm

* Limitations see technical data** S6 – 40% duty cycle

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1414

FP 2000/4000

PP Pallet pool PMB Basic pallet magazine


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FP with pallet changer

Compatible with horizontal machining centres from HELLER H

series and combines with pallet pools with 6 pallets per

machine, pallet handling via turntable

Integration into various pallet magazine systems:

PMB: basic design with 10 to 24 pallets per machine, handling

via stacker crane

PME: extended version with 8 to 42 pallets per machine,

handling via rotary fork

PMF: flexible design from 16 pallets per machine, handling

via telescopic fork

Robot automation with standard robot cell or individual

solutions

HELLER machining centres are synonymous with productivity.

They provide precise and reliable operation over many

years even under constant load. We expect the same from

our automation solutions: maximisation of productive time

and throughput, increase of production and flexibility in

terms of modifications. From swift and easy manual loading

to the setting station through to a fully integrated flexible

manufacturing system – the F series is ready for any solution.

FP: efficient, universal, highly-productive

Automation

WRS Robot with trolley system


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The new F series

Control:the choice is yours

The new F series is equally suited for machining of individual

parts in tool and die manufacturing and the requirements

of high-volume production using 5-axis machining.

SIEMENS Sinumerik 840D slfor high output with automation

Highly precise control of speed and acceleration

Highly adaptable for precision and surface finishes

Exceptionally well suited for machining of sculptured surfaces

Graphical cycle support

Remote diagnostics via ePS

HEIDENHAIN iTNC530for manual operation in the workshop

Highly precise control of speed and acceleration

Highly adaptable for precision and surface finishes

Short block processing time of 0.5 ms

Free contour programming

DCM – dynamic collision monitoring

User-friendly setup functions

Simply choose the type of control that suits your

requirements best: SIEMENS or HEIDENHAIN.

Workpiece and pallet management

Clearly arranged graphical and tabular visualisation of pallets

and programs

Easy allocation of NC programs

Preparation of pallet data for pending jobs

Clearly arranged display of machining status

Tool management

Extensive tool tables

Cutting data tables for automatic calculation of spindle speed

and feed from workpiece-specific data

Replacement tool strategy

Monitoring of tool life and usage

Tool loading during spindle operation and in automatic mode


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Control

CAD/CAM integration:from idea to finished product

Fast, highly precise machining without unnecessary correction

loops – that is what is required of a 5-axis machining centre.

Benefit from maximum flexibility by programming at the machine

combined with innovative technology and machining cycles or use

the existing CAD/CAM chain at your facilities. Be a master of your

processes at any time with the F series. If you are dealing with

frequently changing tasks or complex shapes, the machines provide

the precision and efficiency you need.


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The new F series


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Tool management

What do you require in terms of tool management from a

5-axis machining centre made by HELLER? You might wish

to utilise your existing stock of tools, use a wide range of

tools and large tool geometries; you require a flexible

solution that will meet your production requirements in

the most efficient way. At the same time, tool loading times

and downtimes as well as idle times should be minimised.

No problem: the new F series can provide all of this.

Tool changer

Motor arranged outside of coolant and chip area

Optimised accessibility for belt tensioning.

Torsionally stiff housing due to enclosed design

(only assembly openings)

Easy exchange of motors on the ZT1 axis due to use

of elastomer coupling

Chain-type tool magazine

Chain-type tool magazine with 54, 80, 160 or 240

storage places

Max. tool diameter: 160 mm

Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000

Max. chain speed: 32 m/min

Tool axis moves along the chain path

Optimised tool provisioning time

Magazine only fixed to console

Tool loading parallel to machining

Rack-type tool magazine

409 magazine places

Max. tool diameter: 188 mm

Max. tool lengths: 350 mm on F 2000, 450 mm on F 4000

Reduced space requirements due to double-sided arrangement

Magazine access

Loader axes with NC technology

Leakproof floor pan, no leakage of coolant or lubricant

Manually operated rotary station, optional: automatic rotary

station

HSK, SK and BT spindle tapers

Proven basic structure: tools aligned in Z direction, storage and

r etrieval unit moves in X, Y and Z direction

Short tool selection path

Compact, space-saving layout

Tool management:fast, precise, flexible


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HELLER Services: there for you throughout every phase

The new F series

The purchase of a machining centre is much more than an investment into a new generation of machines: it starts with

project planning and goes beyond efficient spare parts service. The HELLER service concept accompanies and supports

you throughout the complete lifecycle of your machine. Our focus is clear: constant availability of your machines. We are

committed to achieve this.

Practical training for practical application

Training for operators, programmers and maintenance staff

On-site training

Troubleshooting workshops

Training

Customer and project-specific training courses

Comprehensive training for turnkey projects

E-mail support for programmers

Higher performance for your machine

Conversions

Retrofits

Modernisations

Engineering

Machine and system-specific diagnostics modules

Machine upgrades and additional peripheral equipment

Optimum machining and processes

Technology and process consulting

Production support and training

Equipment selection and specification

Part changeover

Tool optimisation

Process optimisation

NC program development and optimisation

Customer-specific detailed developments

Close to you wherever you are

Commissioning

Fault rectification

On-site repairs

HELLER ServiceLine

Preventative teleservice

Maintenance

Full service

Decommissioning and re-installations

Here for you around the clock

HELLER original spare parts

HELLER original wear parts

HELLER original parts packages

HELLER service kits

Availability of HELLER original parts for your machines

Attractive financing

for new and used machines

Attractive financing for new and used machines

New machinery financing

Used machinery financing

Project financing

Machinery insurance

Proven services at cost-effective prices

Repairs

Sub-assembly overhauls

Factory overhauls and retrofits

Buy-back of your used HELLER machine

Sale of used HELLER machines, fully or partially

factory-overhauled


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Service concept


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HELLER worldwide

HELLER locations:We are here for you. Worldwide.

GERMANY

Gebr. Heller Maschinenfabrik GmbH

Gebrüder-Heller-Straße 15

72622 Nürtingen

Telephone +49 7022 77-0

Telefax +49 7022 77-5000

[email protected]

HELLER Services GmbH

Nürtingen

Gebrüder-Heller-Straße 15

72622 Nürtingen

Telephone +49 7022 77-0

Telefax +49 7022 77-1200

[email protected]


Chemnitz

Sandstraße 116

09114 Chemnitz

Telephone +49 371 844949-0

Telefax +49 371 8449-2720

[email protected]


Goslar

Vor dem Nordhees 12

38644 Goslar-Jerstedt

Telephone +49 5321 6834-0

Telefax +49 5321 6834-2199

[email protected]


Hattingen

Hüttenstraße 45

45527 Hattingen

Telephone +49 2324 9245-0

Telefax +49 2324 9245-2399

[email protected]


Saarbrücken

Neumühlerweg 75

66130 Saarbrücken-Güdingen

Telephone +49 681 88372-0

Telefax +49 681 88372-2044

[email protected]


Kirchheim

Paracelsusstraße 3

73230 Kirchheim

Telephone +49 7021 80758-0

Telefax +49 7021 80758-2699

[email protected]


Salem

In Oberwiesen 10

88682 Salem-Neufrach

Telephone +49 7553 91677-0

Telefax +49 7553 91677-2266

[email protected]


Nürnberg

Vogelweiherstraße 33

Gebäude M4 – 2. Obergeschoss

90441 Nürnberg

Telephone +49 911 400896-0

Telefax +49 911 400896-2819

[email protected]

BRAZIL

HELLER Máquinas Operatrizes

Indústria e Comércio Ltda.

Rua Joaquim Machado, 250

Bairro Aparecidinha

Caixa Postal 126

18087-280 Sorocaba - São Paulo

Telephone +55 15 2103-3000

Telefax +55 15 2103-3032

[email protected]

CHINA

HELLER Machinery & Trading (Shanghai) Co., Ltd.

Section A1, Floor 3rd, No. 475, Fute (W.1) Road,

Shanghai Wai Gao Qiao Free-Trade Zone

200131 Shanghai

Telephone +86 21 58666188

Telefax +86 21 58682815

[email protected]


2323

HELLER worldwide

HELLER Machinery & Trading

(Shanghai) Co., Ltd.

Beijing Branch

Chaowai SOHO, Building D, Room 1203

6B Chaowai Street

Chaoyang District

100020 Beijing

Telephone +86 10 59003652

Telefax +86 10 59003752

[email protected]

FRANCE

HELLER Machines Outils SAS

Parc d‘Activités des trois Noyers

15, Avenue James de Rothschild

Ferrières-en-Brie

77614 Marne-La-Vallée Cedex 3

Telephone +33 1 60 94 20 70

Telefax +33 1 60 94 20 72

[email protected]

GREAT BRITAIN

HELLER Machine Tools Ltd.

Acanthus Road

Ravensbank Business Park

Redditch, Worcs. B98 9EX

Telephone +44 121 275-3300

Telefax +44 121 275-3380

[email protected]

ITALY

HELLER Italia Macchine Utensili S.r.l.

Via Galileo Galilei 6

37029 San Pietro in Cariano

Verona

Telephone +39 045 6838510

Telefax +39 045 6838530

[email protected]

MEXICO

HELLER Machine Tools de Mexico

S. de R.L. de C.V.

Cortazar No. 102 – Col. Hidalgo

C.P. 37329 Leon, Gto.

Telephone +1 248 288-5000

Telefax +1 248 288-9560

[email protected]

SLOVAKIA

HELLER Services s.r.o.

Hlavná 1409 / 48

95201 Vráble

Telephone +421 37776-8300

Telefax +421 37776-8309

[email protected]

SPAIN

HELLER Iberica Machine Tools, S.L.

Antic Cami de Caldes, 1 b

08480 L’Ametlla del Vallès

Barcelona

Telephone +34 93 8430209

Telefax +34 93 8430333

[email protected]

USA

HELLER Machine Tools L.P.

1225 Equity Drive

Troy, Michigan 48084

Telephone +1 248 288-5000

Telefax +1 248 288-9560

[email protected]


Machines

Machines Services

Inside Competence.Our extensive know-how allows us to offer innovative and comprehensive

production solutions for powertrain, drivetrain and chassis components. Highly productive. For minimal piece-part costs.

Made to work.Application know-how and technological competence to cater for all production

requirements. With a new generation of machining centres offering a wide range of options in our proven quality.

Just closer to you.Individual services and custom-made service packages ensure optimum

productivity and highest availability of your machines. Anywhere in the world, on site and around the clock.

HELLER Machines. Made to work.www.heller-machinetools.com

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. © 1

0.20

09 G

ebr.

Helle

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enfa

brik

Gm

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heller machines. made to work. - iniram precision machineryiniram.com/media/heller_f...

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