Repetition accuracy and long-term stability are fundamental requirements for a tool changer. The milling and eroding machines from OPS-INGERSOLL Funkenerosion GmbH are also based on these. That is why the machine tool specialist from Burbach relies on the HIWIN GmbH axis systems in the milling machines of the HIGH SPEED EAGLE V5 and V9 series.

4-axis machining, 5-axis machining, shaft machining – the OPS-INGERSOLL milling machines enable numerous variants of multi-axis machining. The Multitool tool magazine is used as an option. ‘The main focus in a milling machine is not actually on the tool changer,’ explains Michael Gräfe, Head of Design at OPS-INGERSOLL. ‘Nevertheless, it must function reliably, require as little maintenance as possible and ensure a high level of process reliability. You simply expect a tool changer to last the life of the machine.’
The MultiTool can hold either 100 or 150 tools for machining, which must be ready for use automatically and within the shortest possible changeover times, depending on the machining process. And this is where a HS22 dual-axis system from HIWIN GmbH comes into play: the bendable unit for positioning in the X and Y directions serves as a feeder axis and also takes over the storage and retrieval of tools. Consisting of a HD double axis in the X-direction and an HT linear table in the Y-direction, each driven by a toothed belt, the axis system ensures the necessary repeatability. The tool changer works with a control-supported magazine assignment. The HIWIN two-axis system transports the required tool from a magazine location to the insertion location in a highly dynamic manner. The tool is identified by means of a QR reader. Manual entries on the machine control and the associated potential sources of error are eliminated, which ensures additional process reliability.

Linear axes with high-quality rolling elements were crucial

The original design of the tool changer was based on axes with a sliding guide. However, initial tests showed that the required accurate positioning and long-term stability could not be guaranteed in the long term. ‘It was clear that we had to opt for axes with high-quality rolling elements,’ reports Michael Gräfe. ‘In addition, the installation space was of course also a challenge. Thanks to the high power density of the HIWIN axes, we were able to choose a smaller size and still get the performance we needed.’ Users are bendable in the configuration of HIWIN axis systems: from a stroke that can be freely selected in millimetre steps, a variety of options are also available, for example energy chains, limit switches and a drive adaptation including gearbox, suitable for every motor type. This means that the motion technology specialist offers complete systems from a single source. HIWIN provides sizing tools and product configurators free of charge on its website to help with product selection. ‘The interaction between online tools and personal advisors is excellent,’ says Michael Gräfe. ’We had already worked intensively with the sizing programmes and configurators on the website in advance, and for the final sizing we were then in direct contact with our responsible internal and field service, because we still like to work with people. The additional short delivery times ultimately convinced us completely.’

Conclusion: With the MultiTool 100/150, OPS-INGERSOLL is providing its customers with a high-performance tool changer that takes up little space in its milling machines. The use of the two-axis system from HIWIN guarantees consistent precision over the entire runtime. The two partners are already looking to the future: ‘The high scalability of the axis systems and the good cooperation are convincing. This will certainly lead to further follow-up projects,’ says Michael Gräfe.

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