sauter PI 49 User Manual

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Product Information PI 49

Disk-type tool turret

Without tool drive

Serie

0.5.480.5xx

With tool drive (axial) Series

0.5.473.5xx

07/2005

PI 49 d

Table of Contents

Disk-type tool turret without tool drive Series 0.5.480.5xx

Table of Contents

Description

Technical Data

Admissible Loads

Selection of the Tool Turret Size

Dimensions

Precision

Fluid Rotary Feed-Through

EK 501 Contol Unit 12

Disk-type tool turret without tool drive (axial) Series 0.5.473.5xx

Description

Performance Data on the Tool Coupling

Performance Diagram

4

6

8

10

11

12

13

14

16

Admissible ON Time of the Tool Drive

Cutting Performance 17

Alternate Configurations

Tool Arrangement 18

Type Key 20 Ordering Details

Please request the following document if required: PI 18 configuration instructions

NOTE The information contained in this Product Information is based on the knowledge available at the time of printing. We reserve the right to perform modifications within the framework of continuous further development.

16

18

21

3

Description 0.5.480.5xx

Disk-type tool turret

Without tool drive 0.5.480.5xx series

Description

Tool turret series

 Without tool drive 0.50.480.5xx

The approved tool turret is suitable for

 Use on turning machines for forward and reverse machining.

 Medium-sized series production

▪ With axial or radial tool holder

Features

 Robust structure

 Simply control

 Short switching times

 Electromechanical drive for swivelling and locking,

thus no additional medium required

 Use of absolute encoders – no reference point travel required

 High degree of stability due to high locking forces

 Locking with special three-part Hirth serration

 Not affected by collisions due to

▪ Low kinetic energy of the drive ▪ Fastening snap ring groove for the tool disk

 Direct control with machine control or EK 501 SAUTER control unit

 Can be installed in any position

 Mechanically largely connection-compatible with series 0.5.440.xxx and 0.5.680.xxx

 Options

▪ Block-shaped housing or with flange fitting for especially high degree of rigidity ▪ Installation of cooling plates for water cooling under the highest standards of

thermal stability.

▪ Central rotary feed-through for fluid-actuated tools and for a high-pressure

cooling lubricant supply

▪ Attachment of sensors for cutting force monitoring

4

3

4

15

14

Turning position

1 Drive motor

Description 0.5.480.5xx

5

2 Planetary gear box

3 Turning drive

4 Curve rollers

5 Locking curve

6 3-part Hirth serration

7 Pre-indexing bolt

8 DC stroke magnet

9 Pre-indexing control switch

10 Attenuation system

11 Cooling lubricant ring

12 Tool disk accommodation

13 Absolute encoder switch absolute

14 Coolant valve

15 T ring groove

Locking position

6

5

Technical Data

Series

Disk-type tool turret 0.5.480.5xx 10

Number of switching positions

8 or 12

Admissible tangential load (turret locked) kNm 0.3

2

Adm. moment of inertia (tool disk and tool holder1)) Kgm

0.15 0.20 0.28

Admissible out of balance (load moment) due to tooling Nm 6

Switching times

Rotating 2) tool disk (incl. unlocking, rotating tool disk, locking)

30° per step (12-fold) s

45° per step (8-fold) s

Only turning

2)

30° per step (12-fold) s

45° per step (8-fold) s

Adm. switching frequency (average switch angle ϕm = 90°)

2)

30° per step (12-fold)

rpm

0.38 0.45 0.52

0.45 0.53 0.62

0.14 0.16 0.20

0.20 0.25 0.30

18 16 14

45° per step (8-fold)

Mass

Mass (without tool disk) kg

Cooling lubricant

▪ Standard bar

▪ Medium pressure valve bar

▪ High-pressure cooling lubricant supply bar

Admissible ambient temperature

°C

6

14

Size

12 16 20 25 32 40

8 or 12

Technical Data

0.6 1.3 3.0 6.0

12

24

0.30 0.60 1.4 0.8 1.4 3.2 1.8 3.2 7.5 4.0 7.0 18.0 9.0 28.0 40.0 20.0 50.0 100.0

15 32 63 125 200 320

0.38 0.48 0.73 0.46 0.59 0.84 0.56 0.72 1.02 0.69 0.89 1.32 0.86 1.35 1.64 1.04 1.60 2.22

0.43 0.55 0.86 0.55 0.71 1.01 0.66 0.86 1.22 0.81 1.05 1.58 1.02 1.62 1.97 1.25 1.92 2.67

0.14 0.18 0.29 0.17 0.23 0.34 0.21 0.27 0.40 0.26 0.34 0.52 0.33 0.54 0.66 0.41 0.64 0.90

0.20 0.27 0.44 0.26 0.34 0.51 0.31 0.41 0.60 0.38 0.51 0.78 0.49 0.80 0.99 0.61 0.96 1.35

16 12 9 11 9.5 7 10 8 5.5 7.5 6.3 4.5 5 3.3 2.8 5 4.5

4

23 46 70 135 250 480

7 – 14 (without filtering)

5 .. 25 (filtering < 100 µm)

100 (filtering < 25 µm)

10 ... 40

1) Further values for moment of innertia and switching times on request

2) The values are valid for 50 Hz operation; deviations of ± 5 % are possible for 60 Hz operation.

7

Admissible Loads

Admissible loads (reference values)

Note: The diagrams refer to static load.

In the case of impact loads (interrupted cutting) much lower values must be expected.

Size 40

Size 32

Size 25

Size 20

Size 16

Size 12

Size 10

Size 16

Size 12

Size 20

Size 25

Size 32

Size 40

8

Size 16

Size 20

Admissible Loads

Size 40

Size 32

Size 25

Size 12

Size 10

Size 40

Size 32

Size 25

Size 20

Size 16

Size 12

Size 10

9

Selection of the Tool Turret Size

Selection of the tool turret size (reference values)

Example

Given machine rating P kW 35 Desired cutting cross-section A mm Tool overhang r mm e.g. 240 Result: Size 0.5.480.520

according to machine power

at v = 200 m/min

2

5

Machine power

Tool overhang

Size 40

Size 32

Size 25

Size 20

Size 16

Size 12

Size 10

according to cutting cross-section

at St 60 (ks = 2200 N/mm

10

Size 40

Size 32

2

)

Size 16

Size 12

Cutting cross-section

Tool overhang

Size 10

Size 20

Size 25

Dimensions

Series Size

Disk-type tool turret

0.5.480.xxx

A1 Standard 50 63 80 100 125 160 200

- - 105 125 160 200 -

A

3

B 90 102 122 112 138 176 220

C 120 150 190 226 280 352 432

D 70 90 120 145 182 220 300

E 6 x M 6 8 x M 8 8 x M 8 11 x M 10 11 x M 12 15 x M 12 22 x M 12

F 140 175 215 255 318 396 470

G 97 120 154 190 240 296 370

H 25 30 40 50 63 80 100

I 6 8 8 9 10 10 12

K 30 32 40 41 52 62 70

L 100 128 138 155 190 220 340

M 153 185 212 250 315 396 490

N 63 90 85 105 106 125 158 198 245

O 135 165 190 220 280 325 440

P 55 80 75 90 95 110 140 176 220

Q 15 18 18 25 30 34 40

R 60 30 32 40 44 48 60

S - 60 32 30 43 56 80

T - - 32 30 43 48 2 x 60

U for M 8 M 8 M 10 M12 M 16 M 20 M 24

V 278 310 352 390 445 516 657

10 12

right left right left

- - 125 150 195 240 -

16 20 25 32 40

11

Precision Fluid Rotary Feed-Though Control Unit EK 501

Precision

Repeating accuracy

(Multiple approach of a switching position from the same direction)

e.g. ± 0.8 µm based on a 100 mm radius

Indexing position

(Multiple approach of a switching position from different directions)

e.g. ± 2 µm based on a 100 mm radius

Fluid Rotary Feed-Through

Die Revolver sind lieferbar mit einer zentralen Fluid-Drehdurchführung:

“Uncontrolled” variation - Fluid supply in all switching positions

e.g. for sealing air, for gripper actuation

“Controlled“ variation - Fluid supply in one switching position

e.g. for KSS, automatic tool change

A maximum of three supply lines are routed through the centre of the turret.

Operating pressure P

EK 501 Control Unit

We offer an EK 501 SAUTER control unit in order to control the tool turret. It includes a complete control logic including malfunction monitoring.

Detailed information: PI 42

12

= 100 bar (standard)

adm

Description 0.5.473.5xx

Disk-Type Tool Turret 0.5.473.5xx series with Axial Tool Drive

Description

These turrets have a modular design. They consist of a basic turret from the 0.5.480.5xx series and a decentralized tool drive mounted in place of the cooling lubricant ring. The tool drive has been designed for

individually switchable, axially placed tools for forwards machining.

The tool drive motor drives the coupling wheel via the spur gear incorporated in the gearbox casing. The relevant tool is switched into the working position by means of the coupling. The drive motor can be located to the side opposite the working position or above the turret casing, depending on the application.

1

2

1 Spur gear

2 Tool drive motor

3 Basic turret

5 6

4

3

4 Tool coupling

5 Tool disk

6 Tool

The tool coupling is designed for spindle heads without the patented spindle locking system. This means that the tools are coupled after searching with the tool drive motor. The performance data and dimensions of the swivel drive and the turret locking are identical with that of the basic turret series 0.5.480.5xx.

13

Perforamance Data

Performance Data on the Tool Coupling

The gearbox is designed for the performance data indicated below for the tool coupling. The actually available performance data depends on:

 the drive motor used

 the speed on the tool coupling

 the duration of activation

 the cutting performance

The values given in the following examples of cutting efficiency can be taken as reliable estimates

Series

Disk-type tool turret 0.5.473.5xx

Gearbox performance data

Recommended drive motors

Siemens servomotor

▪ Adm. drive rating ▪ Adm. torque ▪ Adm. speed

5)

1)

2)

3)

P

adm

M

adm

n

adm

Type 1 FT 6..

Gear ratio

Fanuc spindle motor

6)

motor speed / tool coupling i = n

Type Alpha..

Gear ratio 6) motor speed / tool coupling i = n

1) The values apply for short-time operation.

2) Torque limitation on the motor converter required. The torque values are indicated for shock-free load (e.g. drilling, thread drilling). In case of machining processes subject to shock (e.g. milling), the P 50 % or more without reducing the required speed n

3) Higher values on request

4) Spindle motor

5) Further motors on request

6) Further gear ratios on request

.

c

cutting performance must be reduced by

c

kW Nm

min

-1

mot/n2

14

Performance Data

Size

10 12 16 20 25 32 40

4 8

6000

..044..AK.. ..062..

1.0 1.5 1.0 1.5 1.0 1.32 1.0 1.63 1.0 1.24 1.0 1.3 1.0

α 0.5 α 1 α 1.5 α 2 α 3 α 8 α 8

1.0 1.0 1.0 1.0 2.0 1.53 1.53

5

12.5

6000

AK..

6

20

5000

..064..

AK..

8

32

4000

..082..AK.. ..086..AK.. ..108..AK.. ..108..AK..

10 63

4000

12.5 130

3200

15

160

2500

15

1

Power Diagramm Admissible ON Time

Tool Drive Performance Diagram

Permissible ON time of the tool drive during short-time operation (reference values)

adm

M

0

adm

p

n

adm

0

n

adm

Admissible ON time [OT] (5 min)

Admissible drive power

and

admissible speed

P

c

P

[ ]

adm

n

c

n

[ ]

adm

100 % 80 % 60 % 40 % 25 %

25 % 40 % 50 % 75 % 100 %

P

= Required cutting performance [kW]

c

nc = Required cutting speed [min-1]

= Permissible drive power [kW]

P

adm

n

= Permissible speed [min-1]

adm

(refer to table on pages 14/15)

Example calculation:

Which speed n

and which power Pc with 40 % OT (5 min) are supported on a tool drive, size 20?

c

According to the table on p. 14/15, the following values are valid for disk-type tool turrets, size 20:

Padm = 8 kW, nadm = 4.000 min-1

n

For 40 % ED (5 min) according to table p. 16: and

n

c

adm

= 75 %

P P

c

adm

= 75 %

Pc = P

adm

P

c

·

P

[ ]

adm

= 8 kW · 75 % = 6 kW

and

= n

n

c

adm

n

4.000 min =

c

·

n

[ ]

adm

In this example the tool drive can be operated with Pc = 6 kW and nc = 3000 min

-1

· 75 % = 3.000 min

-

-1

for 2 minutes and then it

must rest for 3 minutes

16

Cutting performance in steel St 60

Blunting factor -1.6 on the tool

Examples (non-binding reference values)

Series Size

Cutting Efficiency

Disk-type tool turret 0.5.473.5.xxx

Drilling HSS spiral drill

Drilling HM short hole drill

Threaddrilling

Keyway cutting Finger milling

Keyway cutting Disc cutting

d x s

mm x mm

/U

d x s

mm x mm

/U

d x P

mm x mm

a x e x s

mm x mm

x mm/min

a x e x s

mm x mm

x mm/min

10 12 16 20 25 32 40

8 x 0.12 12 x 0.14 14 x 0.16 16 x 0.20 20 x 0.25 32 x 0.20 40 x 0.22

12 x 0.05 15 x 0.08 16 x 0.10 20 x 0.12 24 x 0.16 32 x 0.16 50 x 0.12

M 8 x 1

1 x 5 x 45 12 x 8 x 45 16 x 12 x 40

M 8 x 1.25

M 16 x 1

M10 x 1.5

M 24 x 1

D = 50

8 x 8 x 45

M 14 x 2

M 20 x 1.5

20 x 12 x 40 22 x 25 x 40 30 x 20 x 40 40 x 25 x 50

D = 63

10 x 10 x 40

M 18 x 2.5 M 36 x 1.5

D = 80

18 x 18 x 40

M 20 x 2.5

M 42 x 2

D = 100

20 x 20 x 40

M 30 x 3.5

M 48 x 3

D = 125

25 x 20 x 40

17

p

Design Varianten Tool Arrangement

Alternate Configurations

Possible motor arrangement:

osition 9°° or 12°°

9°°

(the cw turret type is shown)

12°°

X

Y

3°°

Working position

d

1

Tool Arrangement

8 pos. – 1 graduated circle

12 pos. – 1 graduated circle

16 pos. – 1 graduated circle

Position with tool drive Position without tool drive

12 pos. – 2 graduated circles

16 pos. – 2 graduated circles

18

Alternate Configurations

Turret

Size

10

12

16

20

Working position

x y

+ 78 0 9°° 16

- 78 0 3°°

+ 98.54 - 17 9°° 20

+ 100 0 9°° 20

- 100 0 3°°

+ 98.54 - 17 9°° 30 + 117.4 - 25 12°° 30

+ 120 0 12°° 30

+ 120 0 9°° 30

- 120 0 12°° 30

+ 150 0 9°° 30

+ 150 0 12°° + 155 0 9°° 40

+ 155 0 12°° 40

- 155 0 12°° 40

+ 170 0 9°° 40

Motor-

position

Coupling profile

DIN 5480 -

W8 x 0.8

DIN 5480 -

W10 x 0.8

DIN 5482 -

B15 x 12

DIN 5482 -

B17 x 14

Tool holder seat

Ø DIN 69880

16

20

30

+ 185 0 9°°

- 180 0 12°° 50

+ 235 - 70 9°° 50

25

32

40

Variants on grey background are preferred

Further variants on request

+ 200 0 9°° 50 + 200 - 20 12°° 50 + 210 0 12°°

- 223.6 0 12°° 60 + 265 - 80 12°°

+ 387.8 - 125 9°° 60

- 265 - 50 12°°

DIN 5482 -

B20 x 17

DIN 5482 -

B25 x 22

DIN 5482 -

B25 x 22

40

50

60

19

ype Key T

Type Key

Series

0.5.480 Disk-type tool turret with electro-mechanical activation

0.5.473 Disk-type tool turret with axial tool drive Coupling process with search run

5

10 12 16

25 32 40

Design series

Size

20

0.5 . 4 8 0 . 5 20

20

Ordering Details

SAUTER disk-type tool turret 0.5.480.5xx / 0.5.473.5xx

Ordering details Possible variations Your selection

Basic turret

Size Number of switching positions Moment of mass inertia (tool disk and tool holder) Cooling lubricant pressure Installation position (Position in turning machine) Cw/ccw type

Tool drive

Working position X / Y Motor position Motor used Gear ratio Coupling profile

Special requirements:

10 / 16 / 20 / 25 / 32 / 40 8 / 12 / 16

0-14 / 5-25 / more

See page 17 3°° / 9°° / 12°° See page 12 / 13

1.0-1.5, 1.5-2.5 See page 17

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