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CARLTON
Salesman Training Meeting
NOTES
M
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r
HORIZONTAL FLOOR TYPE BORING MILLS
Now let’s discuss the Carlton Horizontal Boring Mills. Due to their rugged
construction, speed and productivity, they are in a class all by themselves.
The Carlton head is perfectly balanced between the bifurcated column and the
ways of the column have a span of 54-3/4”. The head is guided on a hardened and
ground steel replacement way and is guided vertically on precision preloaded
“
tychoway” bearings. The precision, roller type recirculating preloaded bearings are
used to give the head the precision tracking and smooth movement. The head ways
are of a non-metallic fiber material with oil grooves to carry pressurized lubrication
the full length of the head ways during any vertical movement of the head. The head
is clamped to the column by wedge type double acting hydraulic clamp cylinders
front and rear of the column. The double acting cylinder gives positive opening of
the clamp for positioning the head vertically and positive closing of the clamp for
stiffness during machining operations.
The head design minimizes the distance between spindle and vertical ways. This
eliminates deflection and provides for maximum metal removal and stability while
milling. On a Carlton 5H bar this distance is less than 6”. The milling stability of
competitors
’ machines is decreased as the spindle is moved away from the column to
make room for transmission gearing, etc., giving a longer moment arm, from spindle
to gibs. Also “X” positioning is affected due to heat expansion during high speed
operations. The column positions accurately but the “X” position moves by the
amount of heat growth between the spindle and column.
The spindle in the Carlton head is carburized and hardened to the full 1/8
depth of case, with a minimum hardness of 60 Rockwell “C”
. This spindle is housed
in a spindle sleeve that supports the spindle on its hardened bearing steel liners.
■
These liners are ground to give a minimum slip clearance between the spindle and
liners. The sleeve, for machine with normal spindle speeds, is supported by opposing
taper bearings which are preloaded for more rigidity and resistance to machining
!
forces. For machines with higher speeds than normal, these bearings are replaced by
preloaded ball bearings. The spindle is supported inside this driving sleeve for the full
length of travel. The sleeve is then supported in the rear by another ball bearing for
more
stability in the drive area.
”
The spindle extension, or feed drive member, is attached to the end of the
spindle and is always completely contained within the confines of the head. To feed
the spindle we use a rack and pinion type motion rather than ball screw. This gives
us a much more rapid advance and sensitivity of the spindle when surface sensing
and
rapiding to an “R” plane for milling and boring. The backlash in the feed gear
train is taken up by a hydraulic boring assist to hold preload pressure on the feed
gears on all boring operations, thus holding operational accuracy. The hydraulic
power tool lock is an instantaneous operating lock allowing rapid and positive
pushbutton tool change anywhere regardless of spindle position. Instead of a draw-in
1
bolt used by competitors, this design is a positive, wedge locked device, quick acting,
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incorporating positive tool ejection. The draw bar on this tool lock is hollow to
allow the passage of coolant. This allows the use of oil hole drills for maximum
penetration rates without adapter on torque bars. Either flood or spray mist coolant
can be used.
Driving this spindle is the transmission extending back between the twin
column, containing drop forged and ground gears and shafts. The main spindle drive
gear is a spiral bevel gear for more driving contact between transmission and spindle.
36 speeds and 18 feeds can be selected either by manual preselect or on tape, the
feeds ranging from .001 to .125 inches per revolution, and spindle speed ranges of
10 to 1 000 RPM., 12 to 1 200 RPM., and 1 5 to 1 500 RPM. The main drive clutch is
a heavy duty disc type forward-reverse clutch for maximum reversals up to 600 RPM
for unlimited tapping duty. Competitive machines that reverse the motor for tapping
are severely limited as to frequency of tapping cycles and this limitation increases as
the motor horsepower increases. This is an important and unique advantage. The
main motor is used just for driving the spindle so no power is diverted to run
auxiliary functions. The main drive clutch is readily accessible from the rear of the
machine for simple adjustment.
The spindle feeds and speeds can be preselected either by manually dialing them
in and depressing the shift button, this activates the hydraulic shifters; or they can
be automatically selected by tape. The spindle can be manually fed into the work by
disengaging the power feed and using the hand wheel located at the top of the top
left-hand side of the head. The HB has a feed depth dial on the front of the head
calibrated in .002
” increments for use when manually feeding the spindle; this is not
needed on the HC because of switchable position readout in the control. For
manually traversing the spindle to the work (there is a hand wheel on the front face
of the head) or a fine feed hand wheel on the top of the head.
The high speed spindle to sleeve milling clamp is right up front near the face of
the head where it should be for more rigidity under milling operations and can either
be operated manually or tape selected. On competitors machines the spindle clamp
actually clamps the feed screw that feeds the spindle out. When this is done, there
are tolerances to be taken up all through the spindle train from the screw up to the
tool so the end result is axial movement of
the
spindle and chatter in the work piece.
This being a wedge type pressure clamp eliminates the need to position the spindle,
then stop and manually clamp it, then start the milling operation. When spindle
reaches the “Z” point asked for on tape, it is automatically clamped and held
throughout the milling operation.
All Carlton horizontal machines are equipped with our exclusive patented
surface sensing feature. This eliminates the need for tool offset or pre-set tooling
when drilling, and tapping. It also simplifies programming by use of canned cycles. A
canned cycle is one that, when programmed, performs a series of machine moves
and/or operations, by programming one code. This relieves the programmer from
calling out on tape each individual move, thus making our tapes shorter and using
less programming time. When actuated for drilling, the spindle starts to turn and
rapidly advances to the work. When the tool hits the work, the spindle automatically
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changes from rapid traverse to feed. And the control starts to measure from this
point. After it feeds to the “Z” programmed depth, it changes back into rapid and
traverses back to the home position. For tapping, the spindle rapid traverses to the
work piece with the spindle not rotating. When the tap hits the work, the tap is held
against the workpiece by the rapid traverse pressure while spindle rotation starts.
This is a timed cycle to allow the tap to start the first thread. Then the pressure is
reduced to a tap assist value. When the tap has penetrated to its programmed depth,
the spindle then reverses and backs out of
the
threads. When the tap has cleared the
last thread, the spindle then rapids back to the home position.
For multiple holes, we also have a short stroke operation that is used along with
the surface sense. When programmed, this allows the spindle to stop the back
traverse motion when the tool has cleared the work by about one inch. The machine
is then allowed to move to the next hole position, thus drastically reducing the hole
to hole time in any of the surface-sense operations. The combination of
surface-sense and short stroke with our rapid spindle advance, gives us the fastest
metal to metal time or piece floor to floor time in the business.
The elevating nut in the head is a precision, preloaded ball nut to give a
minimum of wear on the screw and a maximum of accuracy while positioning. It is
constantly lubricated under pressure during all of its movements.
On the IIB machine, the elevating screw, while traversing, is driven by a
two-speed drive unit, the higher speed used for fast movement to the work and the
slower, or creep, used for more accuracy while Final positioning on the work piece.
There is also a separate variable speed milling drive that will move the head on the
column at a rate of from 1 to 20 inches per minute and is infinitely variable between
these speeds so the operator can select the proper milling feed for optimum chip
removal.
The HC machine has a S.C.R. servo drive that completely drives the “
Y” axis
for feed and traverse. This machine has a rapid traverse of 125 I.P.M. It has milling
feeds from .01 I.P.M. to 125 I.P.M. in increments of .010 inches per minute.
The twin column is cast in one piece and has a common crown and base, which
gives extreme rigidity. It also allows the transmission and motor to be carried
through the column to the back, balancing the whole assembly on the elevating
screw and counterbalance for longer machine life and better machining
characteristics. When the column is perfectly aligned with the bed by two opposing
jack screws at the rear of its base, it is then pinned in place on the saddle.
The
saddle is the carrying member that transports the column along the bed
ways. It has non-metallic way strips that are oil grooved from end to end for
constant pressurized lubrication during all horizontal movements. The HB saddle is
equipped with super precision “
tychoway
” bearings riding on hardened and ground
replaceable steel ways. When the saddle is moved, there are hydraulic cylinders
mounted directly over each set of “
“
tychoways
” against the steel wear strips, thus relieving the slip-stick action between
the saddle wear strips and the bed ways. The lack of
tychoways
” that are pressurized forcing the
total constant surface to surface
contact allows a maximum accuracy of positioning and repeatability during any
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series of moves. When the saddle has reached the end of a move, the hydraulic
cylinders over the “
tychoway
” bearings are depressurized, then the hydraulic clamp
is applied holding the saddle in perfect position for machining. The saddle is always
positioned in one direction to take up any backlash in the rack and pinion drive. The
saddle is guided along any given move by the hardened and ground ways on the bed.
The guiding “
tychoways” are preloaded to guide the saddle into position and hold
alignment accurately. The saddle is traverses on the bed by a drive unit much like
the traverse unit used for elevating the head. It has that fast traverse for moving into
position at a rate of 150
” per minute and the much slower, or creep for accurately
positioning on the workpiece. The variable speed milling drive unit is capable of
driving the saddle under milling speeds of from 1 to 20 inches per minutes and
infinitely variable between these speeds to allow the operator to get the best feed for
the tool and spindle speeds. On standard machines the length of saddle bearing on
the bed is 90 inches and the span of the runway is 53-3/4 inches.
The H.C. saddle is guided on a center hardened and ground way by preloaded
recirculating roller bearings. The saddle itself rides and positions on recirculating
roller bearings. The saddle is retained on the bed ways by pressure lubricated taper
gibs faced with teflon bronze. Some competitive machines are offering hydrostatic
bearings on the saddle but we can get the same accuracy and speed of movement
without any of the problems of hydrostatic bearings. These problems include larger
hydraulic power units with their sound and space difficulties, chance of
contamination of the bearing oil, with coolant, C.I. dust, etc., chance of pressure
loss while machining, causing the bearing surfaces to be marred or nicked and
causing the bearing to become inoperable. We feel there is much more reliability and
stability in the recirculating roller bearings.
The drive for the H.C. saddle is an S.C.R. servo drive with two motors and two
separate gear trains. The two pinions mesh with a hardened and ground rack. This
drive is such that the two motors have a net torque difference that eliminates
backlash under all conditions. This produces a very stiff drive which greatly
improves positioning accuracy and repeatability. With this type of bearing and drive
we can accomplish any 1
” X or Y movement in less than 2 seconds. The bed, or
runway, is a rugged, box framed, semi-steel casting. It is machined to a close
tolerance to receive the hardened and ground ways. It can also be machined at both
ends to receive additional bed sections for more longitudinal travel.
The machine actuating elements, such as motors, solenoids, hydraulic valves,
etc., are directed and sequenced, either from manual pushbuttons or from the
numerical control, by means of an easily maintained solid state control, using
integrated plug-in circuitry and modular construction.
The control for the Carlton HB machines is available with 2 or 3 axis
positioning. The X and Y axes are programmable to 999.9999 inches. Z axis is
programmable to 99.9999 inches and can be programmed either in inches or metric,
but this must be specified prior to the time of order.
The head mounted control panel includes Manual Data Input Keyboard of all
addresses, and 3 digit operation sequence number readout. Pushbuttons to control
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tape reader for Forward, Rewind, Stop and Continuous, Block by Block, Selective
Stop, Normal-Reverse switches, for Plus or Minus programming. Z axis control to
spindle including drilling, tapping, co-boring and spot facing. R plane for operation,
such as boring and reaming, and includes Surface-Sensing for drilling and tapping.
The Control Cabinet is machine mounted and contains the motorized photo
electric tape reader that reads at a rate of 300 characters per second, and 7-1/2” tape
reels, miscellaneous functions MO thru M99, plus or minus programming, and mirror
image, 6 tool offsets that are 5 digits each up to 9.9999. The offsets are retained in
the event of power loss to the controls. (The connecting cables between controlling
units are carried horizontally by a crawler type service carrier.) The precision
positioning is accomplished through the precision rack mounted on the column rear
of the bed and on the spindle extension and pick up through resolvers mounted on
the head and saddle to convey the position to the controls. The resolver has a
built-in torque motor to take up any backlash in the rack and keep the rack and
resolver pinion in constant contact.
The control for the H.C. machines is a floor mounted General Electric 7500 I.C.
Numerical Control system. It has as standard 3 axis positioning and (optional) 2-axis
(X-Y) contouring features.
The control also includes manual data input keyboard with readout of all
addresses (switchable to command/position of XYZ, or to 3 digit operation
sequence number) with “
H” letter block search, optional four digit tool number
address, and reference set and grid zeroing selection. The connecting cables are
supplied with plug-in connection.
Mounted on the front of the column is a telescoping operator’s platform. This
can have an optional auxiliary landing that is extended hydraulically toward the
front of the spindle. When extended, none of the machine’s functions will operate,
and will not operate until the landing is fully retracted. This, along with the safety
spindle tool lock, suspends all operations until the tool is locked into position.
Another Carlton standard feature is a refrigerated oil cooler that maintains a
constant temperature for the head lubricating oil to prevent spindle growth and
bearing failure at high speeds during long machining cycles.
As an optional item, we offer a rotary table on a cross positioning slide. The
tables are equipped with a pointer and scale graduated to read in degrees, an
automatic lubrication system, a power operated clamping system for table top to
table base, machined A.S.A. Standard tee slots, and either manual or power rotation,
and index pin, and bracket, with at least 4 positive index stops at each 90°.
The revolving table units can be mounted on a 36”, 45
” or 54
” wide runways
with optional runway travel from 3’. The tables slide are equipped with a two-speed
rapid traverse unit that has a high speed of 75 inches per minute and a slow down
rate of 4 inches per minute to creep into final position, and have a ball screw feed
and pushbutton control, hardened and ground replaceable ways, power operated
clamping system of table base to runway, and non-metallic ways between table base
and runway. The tables and slides are controlled by a forward and reverse
pushbutton pendant station which is attached to the unit with flexible cable. All
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operations are either operated by manual control or on an optional tape 4th axis.
Also optional are stainless steel “
Steel-Flex
” roll-up way covers, for mounting at
both ends of the bed.
All the Carlton H type machines can be supplied with an optional cross slide
movement that moves the column perpendicular to the bed on an auxiliary saddle.
This normally has a 30 inch travel and can be supplied either with manual controls
or a 4th axis tape control. This cross slide has 100% anti-friction guiding and the
drive is an anti-friction ball screw.
Any of these Carlton Horizontal machines can be ordered with a 4, 5. or 6 inch
spindle.
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ULTRA CENTER
The Carlton Ultra-Center is the fastest, most versatile, precision Machining
Center in the industry today.
The head is mounted on a head saddle that rides the “Y” axis or vertically on
the column from the base. The head rides in the “Z” motion on the head saddle or
perpendicular to the column. The outer ways of this saddle are hardened and ground
replaceable steel ways. The head has pressurized lubrication to the “
tychoways
” on
any of the head movements. The head is supported and guided on super precision
“
tychoway
” bearings that are preloaded to give the head the structural stiffness
needed under machining loads.
The spindle is made of a hammered forging and carburized to the full 1/8 depth
of case, then ground to a precision size giving us a very close T.I.R. The spindle is
supported by a sleeve that has a liner made of hardened bearing steel. These liners
are precision ground to give a minimum of axial motion to the spindle while still
allowing it to slip through freely. This sleeve is supported by bearings that are a
matched set of thrust ball bearings that are preloaded and set right out in the head
extension for extra support. Where the head extension is mounted to the head there
is another set of precision ball bearings for further support. The spindle is driven by
drop forged hardened and ground stub shafts. There are three different feed ranges,
high, medium and low, each having its own electrically operated hydraulic clutch
and having the total of 205 spindle speeds, ranging from 19 to 1500 RPM.
The spindle drive is a 20 H.P. DC motor with an SCR power supply.
The spindle nose will receive a #50 taper tool holder and carry a maximum tool
weight of 35 lbs. The maximum tool length to be used will be 10-1/2” from the
gauge line.
On the Ultra-Center when surface-sense drilling, the head rapids out to a preset
“R” plane, then the spindle starts to rotate and rapids out to contact the work.
When the work is contacted, the spindle is locked in position and the head feeds out
on the column saddle until the pre-selected “Z” depth is reached. Then the head
retracts and the spindle retracts to home position unless short stroke is programmed.
If short stroke is programmed, the head will traverse back to the “
R” plane and the
spindle will traverse back so the tool clears the work by 1”, then the back traverse
motion is stopped and the machine moves to the next hold position. When tapping
with the surface-sense, the head rapids out to the present “R” position, then the
spindle rapids out with the spindle not rotating and when the tool contacts the
work, the tap assist pressure helps the tap into the work as the spindle starts to turn.
After the tap has made a thread or so, the tap assist pressure is released and the
spindle is allowed to “
float”, allowing the tap to do the feeding. At the time the tap
contacts the work, a resolver is clutched in which will generate an error signal any
time the spindle begins to pull out of the head. This error signal is used to cause the
carriage to follow closely behind the spindle. When the tapping depth has been
reached, the spindle reverses and backs the tap and the head out of the hole (the tap
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and head again staying in close relative position to one another). Then as the tap
leaves the point of contact, it rapids back, if
short stroke is programmed, to 1
” from
the work piece and then the spindle stops rotating and moves to the next hole. When
the last hole in the sequence is reached, the spindle, upon leaving the work, rapid
traverses back into the head; then the head traverses back to the home position.
The Tool Changer on the Ultra-Center has 24 tools, each of which are stored
radially around the spindle in its own hydraulically operated programmable arms
with the tool holder completely covered to eliminate the possibility of chips and
foreign matter contaminating the spindle nose when the tool is loaded. When a tool
is selected, either on tape of by M.D.I., the hydraulic cylinder on the tool arm is
activated and the arm comes out approaching the centerline of the spindle while the
protective doors around the tool holder open. When the arm reaches a parallel
position to the spindle, the arm stops, but the hydraulic cylinder continues on
driving the hardened fingers that actually carry the tool holder directly to the
centerline of the spindle. The spindle is automatically oriented, and advances and
receives the tool holder. The tool holder is automatically locked into the spindle and
the hydraulic cylinder pressure is reversed, releasing the fingers from the tool holder
and pulling the tool arm back into its nest. After the arm reaches this point, the
spindle retracts to its original position and is ready for the next machining
operation. When the tool is ready to be stored in the tool changer again, the
operation is just reversed. This whole tool change cycle takes only 6 seconds. When
the tool is locked in the spindle, there is an electrical, tool present signal, going to
the control, allowing the machine to function normally. If for some reason the tool
is not locked into position, the machine will remain inoperable. Also, there is an
electrical interlock that says when the tool is present in the spindle that no other
tool can be loaded into the spindle, thus disallowing the tool changer to make any
tool load operations causing costly wrecks. When the tool changer is operable, there
is a red light on the side of the tool changer carrier, warning the operator to stay
away from the front of the machine, that the arm may come out any time a
different tool is selected in the program. When the tool changer is locked, by
pushing the tool lock selector button, there is a locking ring behind the arms that
lock the tool changer arms into position so they cannot be extended. Then the red
light goes out telling the operator it is safe to walk in front of the machine for piece
part inspection or replacement of worn tools.
The head lubrication and hydraulic oil are kept at a constant temperature by a
refrigerated heat exchanging unit for a minimum of spindle growth at high working
speeds for extended periods of time.
On the Ultra-Center when “Z” axis is operated, the head advances rapidly to a
preset “
precise lengths, depending on the proximity of
R” depth. Then the spindle rapidly approaches the work to 6 different
work
to
the spindle. These are called
“W” positions and are 0”, 6-3/4”, 9-1/2”, 13”, 16-1/2”, 20”. When the spindle
reaches the selected length, either by manual data input or on tape, the spindle is
clamped in position and the head feeds at a programmed or pre-selected speed, to
the “Z” depth required, and then the operation is reversed.
il
1
V.
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When boring, the same procedure is followed as described before.
When milling, the head rapids out to a preselected position, or “R” position;
then the spindle rapids out to a preselected “W” stop; then the spindle is clamped
into position and the head feeds on out to the preset milling depth and stops and the
“X” or “
Y” feed, whichever is to be used, starts. Upon reaching the end of the
milling cut, if another or deeper cut is required, the head feeds out to the next cut
depth and stops and so on until the milling cycle is finished, whereupon the spindle
and the head retracts to home position.
The tool lock is the same type positive, fast-acting, that is used in the HB type
machines. The tool lock has the hole through it to allow coolant through the
spindle, either spray mist or flood type.
The
head saddle under ways, or the ways facing the column, have oil grooves to
carry pressurized lubrication to the ways. It rides on hardened and ground steel ways
mounted on the column, and is supported by and guided by super precision
preloaded “
tychoway
” bearings.
The Ultra-Center has a vertical rapid traverse rate of 215 I.P.M. Milling feed
rates are programmable in increments of .01 I.P.M. from .01 I.P.M. to maximum tra
verse rate. The “Y” and “Z” motion feed screws drive through preloaded ball nuts
for precision incremental moves. The S.C.R. feed drives in these motions are directly
programmable either by manual data input or on tape in increments of .01 I.P.M.
The counter balance is a hydraulic accumulator type that balances the full weight of
the head, head saddle, and tool changer for an even, non-binding vertical move.
The column is designed with a combination heavy box section and diagonal
ribbing to be extremely resistant to bending and torsional loads. It is mounted on
the column saddle.
The column saddle has pressurized lubrication to the “
tychoway
” bearing on
the runway. The column saddle is totally supported and guided by, preloaded, super
precision “
has the same feed rates as does “
tychoway
” bearings. The saddle is traversed at a rate of 215 I.P.M. and
Y” and “Z”
. It is powered by two S.C.R. drives and
is moved by a rack and double pinion. The double pinion is used to eliminate any
backlash in either pinion; when the main feed drive motor is driving the other lags
behind it, thus acting as a torque motor. Tliis gives us the effect of a power drive
torque motor backlash take-up unit, allowing constant contact of the pinion and
rack during all horizontal movements.
The bed is a heavy box frame member that can allow any extension in
increments of 12
” after the 48
” standard. The ways are hardened and ground steel,
and are replaceable.
Telescoping
or
roll up way covers, to prevent damage from foreign material or
accidents are offered as an optional feature.
All ways and screws are lubricated from a central, time controlled, positive
displacement lubricating center. A warning system is provided, should any failure
occur.
The machine actuating elements, such as motors, solenoids, hydraulic valves,
etc., are directed and sequenced, either from the manual pushbuttons or from the
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numerical control, by means of an easily maintained solid state control, using
integrated circuitry and modular construction.
The control system used on the Ultra-Center is the General Electric 7500 I.C.
Numerical Control system. It has as standard 3-axis positioning or an optional 2-axis
(X-Y) contouring feature. The “X” and “Y” axes are programmable to 400.0000
inches. “Z” axis is programmable to 99.9999 inches and can be programmed either
in inches or metric, but this must be specified prior to the time of the order. During
any tape operation where feeds are used, this control has 100% feed override in 10%
increments. This means 100% of the maximum feed that has been programmed. It
has the “H” letter block search, 4 digit tool number address where the tool changer
is used, and reference set and zeroing selection.
The control mounted operator station includes manual data input keyboard,
with readout of all addresses, switchable to command/position of X-Y-Z, or to 3
digit operation sequence number, pushbuttons to control tape reader for forward,
rewind, stop, continuous, block by block, selective stop, normal-reverse switches for
plus or minus programming. Z axis control to spindle includes drilling, tapping,
co-boring, and spot facing. R plane for operations such as boring and reaming, and
includes Surface-Sense for drilling and tapping.
The control cabinet is floor mounted and contains the motorized photo-electric
tape reader that reads at the rate of 125 characters per second, miscellaneous
functions M0 thru M99, plus or minus programming, mirror image, 8 tool offsets
that are 6 digits each up to 99.9999. The offsets are retained in the event of power
loss to the controls.
The precision positioning is measured through the precision rack mounted on
the column, head saddle and the rear of the bed and picked up through resolvers
mounted on the head, head saddle, and column saddle. The resolver has a built-in
torque motor to take up any backlash between the rack and pinion, thus keeping the
resolver pinion in constant contact with the rack.
As optional features we offer various sizes of
rotary
tables that can be manually
or tape indexed to 4 or more positions or tape control rotation to 360,000 parts of a
circle.
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4 B.A.
On the Carlton 4 B.A. type machines, the bed and saddle are built to the same
specifications as on the HDB machine, except that the welded steel saddle is drilled
and machined for the one piece, non-rotating column, either 19
” or 26
” in diameter.
This column is especially built for this numerically controlled, open sided drilling
and tapping machine. It is heavily ribbed, thick walled and cast in one piece for a
more rigid machine member. The bed and saddle for a 19
” diameter column
machine are the same as the MB specifications.
The column has a fixed key for positioning the arm. The patented key clamp
holds the arm at right angle to the runway holding a close accuracy throughout the
full vertical travel of the arm. The key clamp is actuated prior to the arm clamp
function and is disengaged after the arm is unclamped, thus the clamping forces the
keyway in the arm to the same side of the column’s fixed key every time it’s
actuated. When the manual elevating switch is returned to the stop position, a
directional switch is activated and makes the arm pulse in the up direction for
clamping.
The arm casting is the same type as is used on the radial drills, with the triple
box frame and the dovetails on the front, hardened and ground steel ways at the
front and rear for supporting the balanced head.
The head and gearing are of the same configuration as on our radial drills. The
same clamping device is utilized on the head to arm clamp.
The spindle has the surface sense feature and is operated either semi-automatic
or by N/C. The spindle also has 36 speeds and 18 feeds that are preselected manually
or by tape. Numerical controls enable these machines to take full advantage of their
speed. These machines can be supplied with G.E. Mark Century or Bendix Controls.
Any of these have as standard, “X” and “Y” positioning, “X” being the standard
longitudinal travel, “Y” being the head feeding perpendicular to the bed on the arm.
sequence numbers, plus and minus programming and M functions. Optional features
available, speeds and feeds by tape control, automatic spindle depth control using G
address for canned cycles, including surface sense drilling and tapping.
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4 ARS
The 4 ARS is a versatile, planer type, vertical drilling and tapping machine.
The Carlton radial type head is suspended under a rail that is rigidly supported
by two box columns that are joined to the top brace and bed. The twin elevating
screws keep the rail parallel to the table at all times, each screw adjustable vertically
for maintaining parallelism. The head rolls on 4 adjustable double row ball bearings
which roll on two hardened and ground ways, one way on each side of the rail.
Standard machine work areas range from 48
from 36
” to 120
” long in 12” increments. This machine can also be used with two
tables for more ease of setup and less part to part time on production machining.
The ARS, vertical spindle, numerically controlled drilling and tapping machine
is ideally suited for relatively flat work pieces, where precision drilling is required on
one side or opposite sides.
The General Electric, Mark Century control, usually supplied is a 2 axis
numerical control, “X” axis is programmable to 999.9999 inches, “
the head traveling across the bed, is also programmable to 999.9999 inches. The
control cabinet is floor mounted and contains the motorized photo-electric tape
reader; M functions, plus or minus programming, and mirror image. The operator’s
control panel is mounted in the control cabinet also and has, sequence number
readout, 3 digits; full zero shift, for floating zero; manual data input for “X”
and all miscellaneous functions. Also the pushbutton control for the tape reader for
forward, rewind, stop and continuous block by block selective stop switch
reverse switches for plus or minus programming.
” to 66
” wide in 6
” increments and
Y” axis, again
, “Y”
; normal
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Page 14
RADIALS
Carlton was the pioneer of the underarm head design. This underarm head is
designed to balance on the arm for longer life, for better positioning, and clamping
of the head to the arm. The head travels on two sets of adjustable double row, sealed
ball
bearings rolling on parallel hardened and ground steel ways on the front and the
rear of the arm, allowing a minimum of wear in traversing. This lack of wear
eliminates the periodic scraping and realignment of the head. The head is guided by
dovetails. This, plus these adjustable ball bearings, eliminate the tapered gibs needed
for an over-balanced head on competitive machines.
The dovetail is also used when clamping the head in position. The head is
clamped by hydraulic power applied to the upper dovetail, thus relieving the ball
bearings when clamping the head against both top and bottom surface of the
dovetails; also back against the face of the arm for 3 plane alignment of the spindle
and the arm.
Power is transmitted under the arm to the spindle driving gear. These gears are
wide faced and transmit maximum torque with minimum twist to the spindle. The
spindle is supported by precision taper roller bearings which maintain spindle
alignment, runout and stiffness for the heaviest work loads. This is especially
beneficial to the customer when making heavy intermittent cuts.
The spindle on all Carlton machines is driven on the largest diameter of the
spindle for the full length of travel. Our Carlton spindle is supported on selected
precision taper Timken roller bearings that can carry enormous loads and has force
feed lubrication. These bearings on a 4A. for example, can support up to 87,000 lbs.
demonstrating the extra reserve on a Carlton, provided to meet every conceivable
requirement by any customer. The spindle bearings are completely housed inside the
head and never leave the head. On some competitive machines, as the spindle feeds
out, the spindle bearings feed out also, thus losing the support of the head and only
maintaining the support of a running fit guide.
The spindle itself is made from a hammered forging and is carburized the full
depth of case, 60-63 R.C. scale. The spindle is counter-balanced by a counter-weight
that is geared to the spindle through a solid pinion and counter balances for the full
length of travel. This hardened and ground pinion is our feed pinion also. We have
provided for normal tool weights in this counter-balance but in the event that
heavier than normal tools are to be used, we have also provided an auxiliary
counter-balancing spring which is adjustable to compensate for this. When used, the
counter-balance spring is adjusted to the proper tension necessary to balance the
heavier tool. This adjusting is made manually with a lever extending from the upper
right side of the head.
On some competitive machines, the spindles are driven by a much smaller
splined shaft on top of the spindle and cannot stand the torque load needed for
heavy work. The spindle feed rack of the Carlton spindle is completely contained
inside the head at all times, preventing any contamination of the feed mechanism.
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Page 15
On other machines driven from the top the feed rack must necessarily be on the
lower end of the spindle and when the spindle is fed out of a head, the rack feeds
out also, exposing it to chips and dirt and other foreign matter allowing for jamming
of the feed mechanism.
The powerful transmission driving this Carlton spindle consists of all spur gears
made of drop forgings with hardened and ground teeth for unlimited tapping
reversals. The gear shafts are short and stubby. Multiple splined, hardened and
ground, none of which are over 8
” long, and they all run in a continuous bath of
filtered oil. Through the transmission and feed gearing we can select 36 different
spindle speeds and 18 different feeds, including 4 selected tap leads, either manually
or by power preselect. The drive clutch, for this transmission, completely designed
and built by Carlton, is ruggedly built and operates at a constant speed at all times
transmitting constant H.P. throughout the full speed range, and as this is the only
clutch driven by the main drive motor, it makes it possible for Carlton to deliver
more of the horsepower of the main drive motor to a spindle than any other radial
drill. This, in fact, is the only friction clutch to be found on the entire Carlton radial
drill. By eliminating more clutches and more points of adjustment, Carlton thereby
reduces maintenance and costly downtime.
The positive feed clutch on the Carlton radial drill has serrated teeth and is
designed to provide a positive feeding of drill into the work. The simplicity of design
is for trouble-free operation. It is built with 18 feed and tap leads including .004 of
an inch per revolution to .125 of an inch per revolution. Other feeds and tap leads
are available to meet most requirements. When the clutch is engaged, it transmits
constant penetration to the spindle. The clutch is easy to engage. A touch of the
finger on the feed lever is all that is required. Adjustment to the clutch is made from
the front of the head and it isn’t necessary to remove any large components. The
safety feed clutch is placed on the output side of the feed mechanism where it
transmits constant torque regardless of the speed/feed combination selected. It will
transmit 50% more thrust than the rated load of the machine. When overloaded, it
will release with a clicking sound. This tells us that the springs in the clutch will no
longer transmit torque and override the teeth. This, or course, prevents breaking of
parts and destruction of valuable tools. For full protection for the life of the
machine, this clutch is tested at the factory and never needs adjustment.
Located on the front lower center of the head is a power, hand feed selector.
This disengages the feed from power for positive hand feed of the spindle by using
the small hand wheel at the lower right side of the head.
The tapping interlock is standard equipment on the Carlton radials. It eliminates
any possibility of engaging the power feed. Turning the interlock a few degrees
restricts the movement of the levers so that the operator can advance or retract the
spindle without engaging the feed when tapping or reaming.
When the head is rapid traversed into position on the arm, it has its own traverse
motor, used solely for this purpose. After reaching the approximate work position,
the head is then exactly positioned by using the hand wheel located on the right side
of the head. This motor, along with other auxiliary motors, operate all auxiliary
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Page 16
functions, such as arm clamp and unclamp, column clamp and unciamp, raising and
lowering the arm, plus an optional coolant motor where coolant is needed, and
operate intermittently only as required.
The
main drive motor is the only motor that runs continuously and uses all of
its valuable metal cutting energy to drive the spindle. On competitive radial drills,
the main drive motor must through clutches and gearing drive most of the auxiliary
functions, thus diverting precious cutting horsepower from the spindle.
The
arm supporting this head is a fine-grained semi-steel casting. It has a large
triple box section heavily ribbed design to afford rigid support to overcome
vibration and resist the bending movements and torsion transmitted under heavy
drilling and boring loads. Automatic internal lubrication and dual shear steel wipers
are an important Carlton designed feature contributing to smooth trouble-free
operation of arm and column.
When the arm is raised or lowered on the column, by depressing one
pushbutton, it is automatically unclamped and lubricated, then moved. When the
stop button is depressed, the arm stops instantly, and the elevating nut is reversed to
the “Up” direction, removing backlash. The arm is now clamped to the column
automatically.
The arm elevating unit consists of its own motor, gear drive unit, the elevating
screw and the safety elevating nut, that is really two nuts. The main nut carries the
weight of the arm. The auxiliary or safety nut carries no load. Should the threads of
the main nut ever wear out and strip the threads, the safety nut will hold the arm
securely so that it will not move up or down. The elevating nut and screw are
lubricated automatically to insure long thread life. Again, there are no clutches to
adjust nor clutch parts to replace. The arm rate of travel on the column is 50
” per
minute. Here again the elevating motor is just used for this once function. It
operates only when raising and lowering the arm and has the exact electrical
specifications to do the job.
The arm and column are automatically lubricated at the time the arm is elevated
or lowered. Wipers installed on the top and bottom of the arm shear the column
clean of all foreign material and prevents scoring of the arm and column.
Both the inner and outer columns, like the arm, are made of close grained
semi-steel castings. The inner column is of
tubular design and is heavily ribbed all the
way down to the bottom. The ribs extend directly to the bolt holes in the flange of
the inner column which is bolted to the base. The outer column revolves on
anti-friction bearings around the hardened ground steel ring, shrink fitted to the
column.
Clamping the outer column on to the inner column requires a minimum of
energy. The lower part of the apron on the column is split vertically from the
bottom up in four places. Then a clamping band is wrapped around this section to
give a complete 360 degree clamping. In this manner the greater amount of clamping
force is used to clamp the two together rather than dissipating most of it to contact
the old-fashioned tee split column that are still used by our competitors. This type
of clamping reduces spindle-displacement or movement to a maximum of .001 of an
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Page 17
■ h and gives 20% more rigidity and better finishes because of
column
stability.
mC Tt the top of the column is an electrical rotary unit carrying power to the head
and arm an
more v
The base
d this unit allows the column and arm to swing up a full 360 degrees for
ersatility in the machine.
of the Carlton radial drill is a heavily constructed box frame semi-steel
casting with a rib supporting each of its tee slots. There are several different optional
base configurations. The standard base with extension, a profitable place to mount a
plain or tilt table. A double end base is generally used when floor space is inadequate
for right angle base. A standard base with right angle base provides two productive
work stations. A triple end base provides three work stations and is for accelerated
time-saving production. And, of course, the 4-way base has four work stations. A
half round" base provides working area for sequence operation on production work.
Full round bases provide ample area in which to accommodate large work pieces.
These two are
tables that have accurately planed top and sides with parallel tee slots, the
box
normally used in large die shops. For smaller work, we have the plain
profitable production piece that facilitates full production. The tilt table tilts a full
90 degrees. A calibrated indicator shows the degrees of tilt; has accurately planed
top and sides with parallel tee slots. These are recommended for tool room work.
!
i
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