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Direct drive for real high-speed applications

Direct drive for real high-speed applications

Product catalog summary

Overview: The document is a technical catalog for the DD Series Direct Drive systems by PETER LEHMANN AG, focusing on high-speed applications such as millturn, power skiving, high-performance grinding, and 5-axis simultaneous machining. It highlights the company's Swiss precision technology and its global presence.

Specifications: The DD Series offers high-speed, backlash-free CNC rotary tables equipped with sensors, suitable for Industry 4.0. The catalog details various series like the PGD Series and AM Series, emphasizing their precision and adaptability. Rotary tables are equipped with components such as a microprocessor and a 3D accelerometer for shock sensing, featuring overload protection and compatibility with WLAN and Ethernet interfaces.

Applications: The rotary tables are designed for diverse sectors including automotive, aerospace, medical, dental, and micromechanical parts. They are compatible with CNC controllers from major brands like Fanuc, Siemens, Heidenhain, and Mitsubishi.

Innovative Technology: The catalog introduces the CUBE-design, which is fully sealed and service-friendly, featuring an innovative sealing system, integrated angular position measuring system, and temperature monitoring. It supports high speeds and long duty cycles with optional water cooling.

SmartBox Technology: The smartBox system enhances productivity and availability while reducing downtime and maintenance costs. It supports real Industry 4.0 applications with integrated sensors for speed and other parameters.

Global Network: PETER LEHMANN AG has a wide global network with direct sales and value-added resellers across Europe, America, and Asia, ensuring comprehensive service and support.

Additional Products: The catalog also mentions other products like the EA-P0x P Line Production Solutions and the AM-LOCK zero point clamping system for metal 3-D printing, highlighting their ease of use and integration capabilities.

Company Background: Founded in 1960, PETER LEHMANN AG has evolved into a leader in rotary table technology, maintaining Swiss values of quality, innovation, and long-term business policies.

Commissioning and Documentation: Proper commissioning is crucial, as 70% of optimization issues stem from poor commissioning. A USB stick containing essential setup data, parameter lists, and manuals is provided to facilitate this process. These documents are also available online, ensuring that technicians have immediate access to the latest information without needing an internet connection.

Testing and Measurement: The document includes detailed instructions for testing and measuring the rotary tables, emphasizing the importance of clamping and alignment during measurements. It provides guidelines for using precision dial gauges and height measuring instruments to ensure accuracy.

Service and Support: The document outlines the comprehensive services offered, including pre-sales consultation, commissioning support, application optimization, and aftersales services. It emphasizes the availability of spare parts and support in over 30 countries, ensuring maximum product availability and productivity.

Product Variants and Features: The document details various models of rotary tables, highlighting their features such as high-speed capabilities, fail-safe clamping, and IP67 leaktightness. It also discusses the adaptability of these tables for different machining applications.

Procedures: The document outlines the commissioning process for new machines, including mechanical assembly, alignment, and electrical connections. It emphasizes the importance of professional commissioning to prevent issues and enhance productivity. The commissioning of servopacks and application support for optimizing rotary table settings are also detailed.

Standards and Norms: High geometric accuracies are standard for all rotary tables, with options for increased accuracy. The document specifies tolerances and conditions for measurements, ensuring precision in operations.

Recommendations: The document recommends preventive maintenance to minimize downtime and extend equipment life. It offers lifecycle services and active service options, including visual inspections and status reports with recommendations.

Optimization and Support: Application support is available to improve efficiency and accuracy. The document provides guidelines for optimizing machining processes, clamping control, and CNC parameterization. A helpline service offers technical assistance and diagnostic support.

Key Data and Calculations: The document includes calculations for loads, forces, and moments of inertia to avoid risks and damage. It provides density values for different materials and formulas for calculating torque and other forces acting on the rotary tables.

Specifications and Calculations: The document provides detailed specifications for calculating loads on dividing/indexing and swivelling/tilting axes using Steiner's theorem. It includes parameters such as outside diameter, length, density, mass, and moment of inertia for various shapes like round bars and cylinders. The document also lists limited torques for different rotary tables.

Machining Forces and Tooling: It outlines machining forces, including feed force and resulting torque, emphasizing that these should not exceed the maximum clamping or feed torque of the rotary table. The document provides reference values for drilling, end milling, slot milling, hobbing, and turning, with specific parameters like tool type, cutting speed, feed, depth of cut, and feed force for different materials.

Rotary Table Configuration: Guidelines for configuring and selecting the correct rotary table are provided, including spindle speed limits in relation to weight and diameter. The permissible spindle load to speed ratio is discussed, with specific values for different CNC controllers.

Static Mechanical Compliance: The document discusses the static mechanical compliance of rotary tables, highlighting the impact of material elasticity on workpiece accuracy. It provides compliance values in the Z-direction for different rotary table types and suggests optimization options if static stiffness is insufficient.

Dynamic Behavior and Eigenfrequency: Dynamic analysis using FEM modal analyses is presented, showing eigenfrequencies and vibration modes for rotary tables. The document emphasizes the importance of avoiding machining frequencies that match eigenfrequencies to prevent issues like chattering.

Recommendations: Recommendations include balancing workpieces at higher speeds, adjusting tool speed, number of teeth, machining strategy, and workpiece orientation to optimize performance and avoid resonance issues.

Specifications: The document provides eigenfrequency data for TAP9 and TAP5 rotary tables, both with and without standard loads. The frequencies are given for two modes at 0° and 90° positions. For TAP9, Mode 1 frequencies range from 159 Hz to 237 Hz, and Mode 2 from 196 Hz to 347 Hz. TAP5 frequencies range from 127 Hz to 179 Hz for Mode 1, and 189 Hz to 239 Hz for Mode 2.

Thermal Response and Deformation: Thermal deformations are influenced by external and internal factors such as coolant, ambient air, gear unit, bearings, and motor. The document emphasizes the importance of operating mode, idle time, and optional cooling plates. It provides examples of thermal displacement over time and stresses the need for constant coolant use to maintain precision.

Cooling Types and Thermal Behavior: Different cooling methods (splash water, active cooling) affect motor temperatures and spindle diameter changes. Graphs illustrate the impact of cooling on temperature profiles and position deviations in the X, Y, and Z axes.

Cycle Time and Stiffness: The document discusses cycle time calculations and provides reference values for clamping cycles. It also details stiffness parameters for torsion, axial, and deflection loads, with specific values for different models.

Safety and Operating Parameters: Maximum speeds are limited by standard moments of inertia, and balancing is crucial to avoid excessive vibration. The document outlines safety measures, including temperature monitoring and ensuring safe operation during energy failures. It specifies requirements for safety cabs according to ISO standards.

Technical Explanations: Drive data includes rotational speed, acceleration, and jerk limitation. Gear unit loading and eccentric spindle load parameters are defined, with reference to standard and maximum loads. The document also explains the standard moment of inertia and permissible limits for safe operation.

Catalog excerpts

Direct drive for real high-speed applications-1

Direct drive for real high-speed applications Series Direct Drive Applications for millturn, power skiving, high-performance grinding, 5-axis simultaneous machining

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Direct drive for real high-speed applications-2

Swiss precision technology pL LEHMANN s a medium-sized business that has specialized in rotary tables for over 40 years: Today, pL LEHMANN is still an owner-managed family-owned company present in over 20 countries (see back page of this catalog or visit www.lehmann-rotary-tables.com). 1960 Founding – Contract manufacturing The company is committed to typical Swiss values ● Product quality ● Superior technology ● Innovation and flexibility ● Long-term, sound business policies 1973 Conversion into a stock corporation 1974 Introduction of numerically controlled rotary tables (HUST) 1980 Construction...

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New design – Innovative technology smart doc pL service Center height increase and end cap Cables and connectors Angular-position measuring system, accuracy OLAER cooling unit Rotary union Tailstocks Small parts Commissioning, training Geometry accuracies, spindle loads Machining forces Behavior of the rotary table, tech. explanations Content of workpiece clamping systems 71 ROTOMATION transferBox 112 Rotary tables System & smartBox Overview & Facts Applications Overview and facts Spindle system and accessories Spindle connection dimensions The entire catalog is subject to technical changes without...

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Overview & Facts CNC rotary tables for economic production: pL LEHMANN offers tailor-made and efficient and solutions for practically every sector – plus 10 years of experience in direct drives Medical & dental Micromechanical parts & watches Aircraft & turbines Machinery & tools Components & systems System & smartBox Automobile & Mobility Rotary tables hes/M Watc Service & Technology pL rotary tables in use: on over 200 different machine brands and over 1,000 different machine models. pL expertise for DD: integrations realized for the most commonly used CNC controllers from Fanuc, Siemens, Heidenhain...

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Integrated electronics Monitoring for for plug & play operation & service Quick installed Overview & Facts System & smartBox Not yet available; inquire at the factory Rotary tables Multifunctional spindle system High duty time Service & Technology

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Modular system combiFlex® High value retention: adjustable at any time, benefits of geared and direct drive can be combined Rotary tables System & smartBox Overview & Facts Service & Technology Highest level of flexibility ● Rotary table is available quickly and can be converted at any time ● If needs change, the investment is not lost ay in installments: First the machine, later the P rotary table – can be retrofitted at any time (suitable CNC controller req

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Modular system combiFlex® Standard machine in stock, available at short notice, equipped with matching rotary table Increased sales and service productivity Overview & Facts System & smartBox Lower storage costs, also in service (spare parts) Rotary tables With gear unit rotary table as swiveling / tilting axis With gear unit rotary table as swiveling / tilting axis Wide range of applications for each size Service & Technology

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Flexible spindle accessories From manual clamping tools for single item production through to fully automated systems Overview & Facts Plates, force clamp and jaw chucks, collet chucks Possible systems ● pL LEHMANN (plates) ● FN Niederhauser ● SMW AUTOBLOK ● SwissChuck ● Hainbuch ● Erowa ● TG Colin ● YERLY ● ... Automatable: with rotary unions and collet chuck / release cylinder Rotary tables System & smartBox Zero point clamping systems Centric clamping unit Service & Technology Possible systems ● SCHUNK ● LANG ● Gressel ● Piranha Clamp EVARD TRIAG ... Possible systems ● pL LEHMANN (ripas &...

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Flexible spindle accessories Centric clamping unit for workpiece handling, mounted zero point clamping system for quick vise replacement Overview & Facts Combination possibilities pneumat ic collet actuatio n System & smartBox manual collet change Rotary tables automat ic & manua l possible Service & Technology

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Spindle system and accessories Extremely wide assortment for workpiece clamping. Standardized interface in front and rear: Maximum universality Collet chuck or spindle adapter may be required 1 Overview & Facts Release cylinder for collet chuck System & smartBox Rotary tables Service & Technology Depending on the clamping means, only reduced speeds are allowed for safety reasons. Please check with manufacturer. ollet chuck d80, C pulling Collet chuck d80, pushing ollet chuck KK5, C pushing Spindle adapter KK5 Spindle adapter d80

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Connection dimensions for spindles All spindle connection dimensions front and back for building your fixture. Applies to all variants, EA or T-type rotary table alike Overview & Facts Service & Technology System & smartBox Rotary tables

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New design – Innovative technology Innovative CUBE-design based on 10 years of experience with DD technology: fully sealed, super-fast, safe, versatile and service-friendly – for Industry 4.0 available with FANUC angular position measuring system – 100% FANUC DDR-compatible! Overview & Facts Prepared for water cooling ● For high speeds and/or long duty cycles (for more information see p. 34) Transport and attachment holes System & smartBox Bolt holes for transport ay be used for fixtures, tool monitoring, m measuring probes Rotary tables Angular position measuring system & temperature monitoring...

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smartBox proven in practice over 1000 times Productivity and availability increase, downtime and maintenance costs decrease Rugged cast housing Helps to increase productivity and availability, lower downtime and maintenance costs and permits quick troubleshooting and preventive maintenance. Overview & Facts -smartBox – for real Industry 4.0 Internal pressure System & smartBox Shock / impact Limit value exceeded with real-time stamp Rotary tables 3D accelerometer – shock sensor uty cycle limit – overload protection, D prevents motor damage KAB, WDF, CNC, WMS ● 100% backwards-compatible with blackBOX...

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