Transparent Machine Tool: Schaeffler Presents its System Expertise

Date: 2013-09-21

Transparent Machine Tool: Schaeffler Presents its System Expertise

With its “Transparent Machine Tool,” Schaeffler is not only making a visual splash at the EMO 2013. With its numerous innovative solutions for feed spindles, main spindles, rotary and linear axes, as well as for condition monitoring, Schaeffler showcases its broad competence in high-performance and efficient machine tools, creating tools that offer reliability, cost effectiveness, as well as dynamics and precision. Schaeffler’s “Transparent Machine Tool” provides an exciting glimpse into the heart of a machine tool – right where forces are transferred and performance is realized in precision and productivity.

“With the Transparent Machine Tool, Schaeffler is highlighting its strategy of using extreme customer proximity and system understanding to develop products and solutions that enhance our customers’ competitiveness and make them successful, in other words coming up with ideal ways to satisfy their demands both technically as well as economically,” explains Martin Schreiber, the new manager of Schaeffler’s Production Machinery Business Unit since August 1, 2013. “Optimizing the overall system is always front and center in our minds. Our system level expertise is the prerequisite for developing perfectly harmonized individual components and modules,” continues Schreiber. Along with bearing supports and guidance systems, this opens up for Schaeffler not only the entire direct drive technology, but also the integration of additional functions into rotary and linear bearing systems, such as damping and measuring systems.

The new leadership of the business unit signals continuity: Martin Schreiber has more than 20 years of experience under his belt in the area of production machines. Together with his predecessor Helmut Bode, he has been key in helping to shape and globally underpin the strategy of the business unit, most recently in his work as Manager of Market Development & Application Technology. Since April 2012, he has been working as Senior Vice President Sector Management Industrial (OEM & Industrial Aftermarket) in the Asia/Pacific region. Martin Schreiber is filling the place of long-time head Helmut Bode, who is now taking over the responsibility for Schaeffler’s industrial business in China as President Industrial Schaeffler Greater China.

Schaeffler’s Product Highlights at the EMO 2013:

Rotary Axes: Absolute Angular Measuring System Integrated into the Bearing
Schaeffler has developed an angular measuring system integrated into the bearing with an inductive mode of operation that is ideally suited to the demands of direct-driven highly dynamic and precise rotary axes in machine tools. This has resulted in further developments to the principle of integrating the SRM measuring system into a rotary axis bearing that was already implemented successfully in the YRTM series. The SRM measuring system combines high measuring speeds and precision as well as installation space reduction and robustness. It is not sensitive to contamination, features a center opening in the rotary axis, and impresses with how little alignment work it requires. It therefore represents a convincing alternative to optical assembly angular measuring systems. Bearings of the new INA series YRTSMA are available in borehole diameters ranging from 200 mm to 460 mm. This is the mechanical equivalent to the highly rigid YRTS high-speed bearing series.

Direct Drive Technology for Turning and Milling Operations
The rotary high-performance direct drive series RKI of INA Drives & Mechatronics AG & Co. KG (IDAM) offers outstanding performance characteristics that have not been achievable up until now. The drives have 30% more torque compared to conventional torque motors. This gives speed and mechanical performance that is five times greater. At the same time, power loss is reduced by as much as 60%. This means that less heat is produced. Energy efficiency is improved, and the operating costs drop significantly since cooling requirements are lower. For improved performance, it is possible to use smaller motors for the same capacity, thus reducing costs for the converter and motor. In providing a compact bearing support for rotary axes, Schaeffler has optimized the inner design of the double row ZKLDF..B axial angular contact ball bearings so much that the achievable limiting speed has been doubled, while the frictional torque goes down at the same time. The high precision and rigidity of the bearing remain uncompromised. Especially when combined with speed-optimized RKI torque motors from IDAM, this opens up new possibilities in turning and milling operations that have previously not been attainable with standard components.

Main Spindle: High-Speed Axial Bearings for High Performance and Precision
The use of high-speed FAG axial bearings of the BAX series now makes speed parameters possible for combinations of open axial bearings with cylindrical roller bearings on main spindles that were previously only able to be attained with spindle bearings. At the same time, this bearing combination features a separation of the axial and radial load in the bearing support. Since this means that there are no tilting effects that have to be absorbed, the kinematics are not adversely affected when there is a combined load. This makes the bearing support particularly robust. The user profits from a high degree of operating precision as a result of the high rigidity. The load carrying and rotary capacity are both excellent, giving good cutting performance and high productivity.

Main Spindle: Friction Optimization by Means of Modern Bearings
With the FAG RS (“Robust and Speedy”) for spindle bearings and TR (“Thermally Robust”) for cylindrical roller bearings, Schaeffler offers a combination of high load carrying capacity and high performance reserves for increasing speeds. At the same time, the friction-optimized inner design makes it possible to reduce the friction loss of the bearing support. This is primarily noticeable when the spindle runs for a long time at high speeds. The option to lubricate the bearing support with grease even at high speeds increases the operating safety of the spindle and lowers costs by eliminating the need for compressed air to supply the bearings with lubricant.

Linear Technology: Integrated Magnetic LMSA Travel Measurement System
Schaeffler has developed the LMSA (“Length Measuring System – Analog”) series measuring system for integrated travel measuring in main axes. It is based on an inductive analog measuring principle that attains a precision of +/- 3 µm/m. With its high degree of robustness, it is not sensitive to magnetic interference fields and is free of hysteresis in its operation, without any magnetism or residual magnetism. Similar to the integrated LMST and LSMD measuring systems that are already known, the complete linear recirculating ball bearing and guideway assembly of the KUVE..LMSA series consists of a carriage with an adaptable housing for the measuring head and a guideway for locating the dimensional scale. Measuring is carried out according to the inductive principle of a transformer with a moving reluctance core. A sensor head probes the incremental dimensional scale in the guideway head by means of a high-frequency alternating field, producing two sensor signals that are displaced by 90°. A stainless steel band with high-precision photolithographic etched partitioning forms the dimensional scale. The motion between the probe head and the measuring tape produces a compensating mutual inductance of the individual spools, thus generating sine-wave signals. In this way, the LMSA measuring system has a 1Vss analog output with a non-partitioned signal period of up to 10 µm. This allows the measuring system to be easily combined with existing control systems.

Diagnosis Systems for Quality and Process Reliability
Component replacement based on actual conditions during planned downtimes, consistently high processing quality, reducing costs caused by lost production – all are important for today’s operators and manufacturers of modern machine tools. As a manufacturer of components and condition-monitoring systems, Schaeffler Industrial Aftermarket is a reliable sector partner with its proven products and valuable consultation service. There are various bearing diagnosis systems available to suit the demand and monitoring strategy chosen, such as FAG Detector III, FAG DTECT X1 s, and FAG ProCheck. For use in machine tools, Schaeffler is offering an innovative online system in FAG SmartCheck that provides comprehensive information on the condition of the machine components while taking additional parameters into consideration. Machine tools can be monitored in three expansion stages using FAG SmartCheck. In the first stage, individual components are monitored in a decentralized fashion. It is possible to access the device directly in line with the data. Based on the measuring data, FAG SmartCheck generates the proper alarm thresholds. A SmartCheck app enables data to be accessed via a smartphone. If the user selects the second phase, the device is integrated into the machine control system in an intelligent fashion. Process integration can be realized through communication interfaces. The third phase allows for service activities to be expanded. This may involve remote access via an Internet connection or even consultation and other services. Process integration of the FAG SmartCheck into the control system can be carried out using the communication options provided by the available inputs and outputs. This represents a possibility and a basis for communication with the machine using interfaces – which also applies within the context of Industry 4.0 – meaning that machines will be capable of functions such as self-diagnosis in the future. Moreover, there is a series of additional monitoring systems that can be implemented depending on customer demand.

(Schaeffler Group USA Inc.)

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Transparent Machine Tool: Schaeffler Presents its System Expertise

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