Under the motto ‘Passion for Production’, Gebr. Heller Maschinenfabrik GmbH will present its latest 360° solutions for tomorrow’s production at AMB 2024. Among the exhibits is the latest generation of the F 5000 5-axis machining centre, equipped with a newly developed rack-type tool magazine with a particularly compact footprint. The machine manufacturer will also be showcasing the HF 3500 5-axis machining centre, automated with a highly flexible HELLER robot cell. A wide range of services and forward-looking technology and digitalisation solutions complement the display in Stuttgart.
Designed for Production – F 5000 5-axis machining centre
At AMB, the F 5000 with its new features and key components will be on display. The high-performance 5-axis machining centre is available with a work envelope of 800 x 850 x 1,100 mm (X/Y/Z), a pallet size of 630 x 630 mm and a maximum clamping load of 2,000 kg. Due to its modular design, the F 5000 can be optimally configured for a wide range of applications, always ensuring maximum precision and performance in the production of small to medium batch sizes.
Highlights include the completely redesigned swivel heads and integrated motor spindles, developed and manufactured by HELLER, with an HSK-A 100 tool interface as standard and an HSK-A 63 interface available as an option. The dynamic swivel head with 5th axis ensures maximum machining performance. Its drive is based on a backlash-free drive concept delivering impressive precision.
Tilt kinematics are now available as an alternative to the swivel kinematics. Compared to swivel heads, tilt heads offer a significant increase in flexibility for 5-axis machining. The tilt kinematics can also be used to machine recesses and undercuts, for example. HELLER Head of Development Dr Manuel Gerst explains: “Especially for the production of integral components, which are often required in the aerospace industry, it is very important that the machines used can also machine at a negative angle. Mechanically, this is not possible with swivel heads. We have designed the new tilt heads specifically with these applications in mind. With an HSK-A 63 tool interface and a high-speed spindle, they are predestined for these applications.”
Compact and slim – the new rack-type tool systems from HELLER
Combined with HELLER’s new rack-type tool systems, the F machines retain their compact footprint while still offering high tool capacity. And despite the ample tool space, they are almost two metres slimmer than the previous models. This is particularly useful when it comes to automating multiple machining centres. Four machines can now be placed in a row where previously only three could be installed. The various expansion stages differ only in length. The rack-type magazines, designed for HSK-A 100 tools with storage capacities of 200, 260 (as exhibited on the F 5000) and 340 tools, are no longer than 7,000 mm. They provide 489 storage positions for HSK-A 63 tools. The space-saving arrangement of the tools is crucial to the compact dimensions, enabling a high packing density. The integrated preferential storage module significantly reduces tool provisioning times in practical use. Easy manual tool loading is achieved with an integrated rotary station. It allows up to seven HSK-A 100 or nine HSK-A 63 tools to be loaded in parallel to machining. The racks have also been designed to allow crane loading at any time.
HELLER launches new high-performance F 8000 machining centre
Just in time for AMB 2024, HELLER has added the F 8000 to its new generation of 5-axis machines. Like its smaller ‘siblings’, the machine is suitable for a wide range of users in many industries, from mechanical engineering and power generation to aerospace – from single-part manufacturing through to flexible 24/7 series production. With a width of 4.20 m, the high-performance machining centre is significantly slimmer, and in its basic version, takes up around 25 per cent less space than its predecessor. In addition, the PRO version offers the highest technical specifications, including high axis acceleration in X/Y/Z of 6 m/s2. Equipped with the PRO package, the F 8000 also steps up in terms of precision. Positioning tolerances in X/Y/Z are 6μm – a 25% improvement over the previous model. Other highlights include short idle times, optimum automation capability and compatibility with the H and FP series for a wide range of workpieces.
HELLER automation solutions at AMB
At AMB, HELLER will present an HF 3500 automated with the RZ 50 robot cell. The configuration on display focuses on fast loading and unloading times through handling that is perfectly adapted to the customer’s workpiece and process. The RZ 50 shown is equipped with a flexible 2-finger universal gripper with a jaw change interface. A rotary station enables fully automatic 6-sided machining while a drawer module provides high storage capacity. The robot automation is particularly suitable for series production of medium and large batch sizes.
The HELLER booth will also feature a digital model of a modular robot system that allows combined handling of workpieces and workpiece carriers with an integrated gripper changing function. Visitors will be able to explore the model on their own in a stunning AR experience on Apple Vision Pro. A graphical 3D configurator can be used to create a ready-to-order solution.
In addition, there is a digital mobile rack for the transport of tool sets (16 HSK-A 100 tools) equipped with a standardised interface in the rack-type magazine.
HELLER digital solutions at AMB
On display at AMB will be the digital twin of the F 5000. It provides customers with a digital model of their machine. The simulation behaves exactly like the real machine. Its use saves considerable time and money during development, commissioning and optimisation. Using tested workpiece programs, for example, can help prevent damage to the machine.
SETUP-Assist – exhibited on the F 5000 – is an assistance system that actively supports the operator when running in processes. It can be used to prevent collisions between machine components and between tools and machine components.
PRODUCTION-Assist – displayed on the HF 3500 – actively supports the operator, with features such as forward planning of tooling requirements with load and unload lists, or quick unloading of worn tools at the touch of a button.
At the show, HELLER will present ‘ask-me.GPT’, an AI pilot application that has been trained with real machine condition data from the HELLER Services Interface and machine documentation to provide specific answers to a range of questions.
Lifetime Partnership – HELLER Services at AMB
The HELLER Services Interface provides an intuitive operating concept to ensure transparency in manufacturing, maintenance and service processes throughout the entire life cycle of the machine. This option can also help reduce machine downtime by providing evaluations and statistics. Visualisation of specific machine status information, including status indicators for axes, spindles or other assemblies, enables users to determine the wear status and take preventive action to reduce unscheduled downtime.
HELLER Lens is a web-based AI parts identification system for mobile devices, designed to provide customers with faster and more reliable spare parts identification.
The myHELLER customer portal helps customers to keep track of their entire machine fleet. Spare and wear parts can be ordered quickly and easily – from anywhere, at any time.
HELLER know-how – where experience meets the spirit of innovation
Complete machining on a single machine is the key to increased productivity. That is why HELLER specialists have been integrating various technologies into the current range of machining centres. At AMB, the company will be presenting complex 5-axis machining operations and typical aerospace processes, as well as grinding, turning and high-performance cutting.
