Machine concept

The rigid design and topology-optimised structural components are the basis from which our H-series 4-axis machining centres achieve their high cutting performance and accuracy. You can also rely on top quality – with high productivity.

4-axis machining centres H: Machine concept

Crossbed and travelling column in gate design

  • high stability and damping in the force flow through topology-optimised structural components in cast iron 
  • thermo-symmetrical design and optimised flow of forces
  • a broad selection of robustly designed machining units
  • a broad selection of tool magazine types: chain or rack
  • tool changer with two NC axes for rapid, automatic tool change

4-axis kinematics with horizontally arranged spindle

  • machine bed supports the X- and Z-axes in crossbed arrangement
  • machine column moves in X direction and supports the machining unit
  • machining unit moves in Y direction, compact and stably integrated in machine column 
  • rotary table moves in Z direction and performs feed motion
  • NC rotary feed table (rotary axis B) turns the workpiece with continuous adjustment (360,000 x 0.001°)

Anti-friction linear guideways and stable YRT bearing in rotary table

  • linear axes with roller guideways powered by ball screw drives for high feed forces
  • direct absolute measuring systems (glass scales in linear axes) for maximum precision and low positioning tolerance
  • equipment package Speed available as an option
  • NC rotary feed table with large YRT bearing and automatic clamping for maximum stability and high tilting moments
  • NC rotary feed table with gear unit for high circular milling torque and damping

Machining units

Spindles "Made by HELLER" are among the highlights of our H-series 4-axis machining centres. Thanks to in-house production expertise, they guarantee you the highest possible machining quality and, above all, process stability and optimised performance in operation. A special benefit: The HELLER zero-spindle system. If the worst comes to the worst, the machining spindle can be replaced quickly and simply.

4-axis machining centres H: Spindle units

Robust spindle units "Made by HELLER"

  • maximum performance in operation with compact overall dimensions and robustly dimensioned spindle bearing
  • thermal stability and precision thanks to continuous cooling: Precision cooling unit and spindle thermal growth compensation
  • rigid cast iron guide slides with high dynamic rigidity and damping
  • slim spindle neck for perfect reach into the workpiece
  • horizontal spindle for optimum chip fall

Quick and easy zero spindle exchange with cost advantages

  • easy replacement without time-consuming tuning work due to spindle tuned to zero dimension
  • maximum machine availability due to short repair times
  • cost-effective solution for low TCO (Total Cost of Ownership)
  • reduced spare parts costs due to the integrated zero spindle technology

H 2000 – H 4000

3 spindle units with HSK-A 63 tool shank

  • high-speed motorized INLINE spindles up to 16,000rpm
  • torques up to 228 Nm (S6 40%)
  • with the new Dynamic Cutting spindle perfect for universal use
  • HELLER zero spindle system
  • tool shank SK 40 / BT 40 for selected machining units available as alternative
     

H 5000 – H 6000

3 spindle units with INLINE spindles and HSK-A 100 tool shank

  • speeds up to 13,000 rpm
  • high-torque motorized INLINE spindles up to 400 Nm (S6 40% (5 min))
  • with the new Dynamic Cutting spindle perfect for universal use
  • HELLER zero spindle system
  • tool shank SK 50 / BT 50 for selected machining units available as alternative

3 gear units with HSK-A 100 tool shank

  • three gear units with torques up to 2.292 Nm (S6 40%)
  • speeds up to 8,000 rpm
  • HELLER zero spindle system
  • tool shank SK 50 / BT 50 optionally available
     

H 8000 – H 16000

5 spindle units with HSK-A 100 tool shank

  • two directly powered spindles with speeds of up to 12,500 rpm
  • three units with gear unit and torques of up to 2,292 Nm (S6 40%)
  • tool shank SK 50 / BT 50 for selected machining units available as alternative

Top equipment and features

HELLER facing slide system

  • for automatic adjustment of actuating tools
  • actuation with a full-fledged NC axis (U) integrated in the machine controller
  • ideal for boring contours or facing work
  • available for machining units with tool shank HSK
     

HELLER attachment head support (MSK)

  • for the use of attachment heads, e.g. angular heads
  • enlarged support basis with three-point rest
  • integrated torque input and media transfer
     

HELLER attachment head additional clamping

  • for additional clamping of attachment heads on the attachment head support
  • optimum stability when using attachment heads and under high process forces
  • only available for machining units with gear unit

Tool management

Short tooling times and short idle times – what you can rightly expect from our H-series 4-axis machining centres. The tool changer with two NC-axes achieves maximum precision and optimum movement sequence for short tool change times. The result, in combination with a high axis dynamic, is short chip-to-chip times. 

4-axis machining centres H: Tool management

Rapid tool provisioning

  • 4 chain-type magazines with up to 240 positions for machines with HSK-A 63 (SK/BT) available
  • 3 chain-type magazines with up to 150 positions for machines with HSK-A 100 (SK/BT) available
  • rigid tool holder mounted on both sides of a double chain for optimised traversing dynamics
  • tool provisioning during machining for short tool-to-tool times
  • rapid tool change for short chip-to-chip times
  • two NC axes with lifting/swivelling principle for high dynamics and constant precision
  • stable double gripper for a secure hold with high tool weights and moments of weight
  • tool shank in enclosed holders: protection against clogging and ideal holding during positioning
  • workpiece loading station with optimum accessibility for ergonomic and rapid loading of tools
  • integrated tool provisioning place for provision of next tool during machining and short tool-to-tool times

High storage capacity

  • 1 rack-type magazine with 375 positions for machines with HSK-A 63
  • 2 rack-type magazines with up to 425 positions for machines with HSK-A 100 (SK/BT) available
  • tool handling with highly dynamic loader for rapid tool provisioning
  • rapid tool change for short chip-to-chip times
  • two NC axes with lifting/swivelling principle for high dynamics and constant precision
  • stable double gripper for a secure hold with high tool weights and moments of weight
  • convenient operating panel at workpiece loading station
  • workpiece loading station with integrated rotary station with several positions for tool loading during machining

Fast tool change for short chip-to-chip times

  • two NC axes with lifting/swivelling principle for high dynamic and constant precision
  • rigid double gripper for a secure hold with high weights and moments of weights
  • tool shank in enclosed holders: protection against clogging and ideal holding during positioning
  • tool setting station with optimum accessibility for ergonomic and fast tool setting
  • integrated tool provisioning place for provision of next tool during machining and short tool-to-tool times

Workpiece management

Our H-series 4-axis machining centres knows no bounds when it comes to workpiece size and weight. The machine's pallet changer concept permits a payload of up to 8 t. The HELLER H-series works to a high degree of precision even with this workpiece weight.

4-axis machining centres H: Workpiece management

Pallet changer as standard – ideal solution for the series production

  • automatic pallet changer with lifting/swivelling principle
  • high maximum load with robust, hydraulic drive
  • optimised power grip at machine pallets due to fork shape of the lifting/swivelling traverse
  • consistently high tool change accuracy with robust alignment elements and full blowing-off of functional surfaces
  • machine pallets with DIN hole pattern and standardised alignment elements for rapid mounting of clamping fixtures
  • hydraulic pallet clamping for a secure hold, even under high process forces

Automation

Automation solutions from HELLER are individual concepts that we develop specifically for your production facility. We analyse your requirement and devise a solution that allows you to work to your maximum capacity. We use standardised solutions wherever possible. The H-series 4-axis machining centres are prepared for pallet and workpiece automation.

4-axis machining centres H: Automation

Storage of machine pallets and automated setting of one or multiple machines

  • standardised linear storage systems with up to 15 storage locations depending on type and size (optional)
  • standardised machine interface available for numerous machine sizes (option)
  • everything from a single source: Complete solution for short installation time and commissioning
  • optimal capacity utilisation with continuous pallet feed to one or multiple machines 
  • consequently, increased cost efficiency and more flexibility in the production facility 
  • specific advantages for production tasks with a large part mix and series production with small batch sizes


Options

  • standardised host computer interface for optimal connection to the host computer
  • high number of functions and options for automated production control
  • media interface for hydraulic workpiece clamping

Automatic loading and unloading of workpieces

  • workpiece handling by robot relieves the operator
  • ideal solution for series production
  • machining centre works to capacity thanks to continuous material feed
  • standardised machine interface for robot loading onto the setting station (option)


Options

  • media interface for hydraulic workpiece clamping
  • location check and unclamp check

Supply and disposal

Any machine that mills will cause chip fall. And this is particularly the case with H-series 4-axis machining centres: Extremely resilient and reliable machining centres, these machines are made for production. To keep your results precise at all times, we have an efficient solution for disposal wherever chips accumulate. 

4-axis machining centres H: Supply and disposal

Central media supply area on the rear of the machine

  • easy maintenance with optimum accessibility, all supply units at a glance
  • central oil-air lubrication for key components
  • seal air and selective blow-off of interfaces for consistently smooth machine operation
  • media interface for hydraulic workpiece clamping with 60 bar (H 8000 – H 16000), 80 bar (H 2000 – H 6000) or 200 bar (Option)
  • compressed air and water gun integrated in the machine housing at workpiece loading station

Cooling lubricant supply and filtration

  • coolant units: paper band filter or reversible flow filter with high tank volumes optionally available
  • internal coolant supply (IKZ) through the tool with high-pressure 50 bar (option: 70 bar with frequency converter (FU))
  • internal coolant supply with up to 7 pressure steps freely programmable via NC program
  • external tool cooling with integrated spindle rinsing nozzles
  • integrated work area shower with adjustable nozzles for optimum flushing of work area and cooling of workpiece


Options

  • coolant cooler for high thermal stability and precision
  • coolant tempering unit /on request
  • automatic filling of the coolant unit
  • oil skimmer for removing foreign oil from the cooling lubricant tank
  • IKZ 70 bar with frequency converter (FU)

Rapid chip disposal

  • H 2000 – H 6000: free chip fall below the spindle and fast disposal from the work area with central chip conveyor
  • H 8000 – H 16000: chip disposal using spiral conveyors and a cross-conveyor
  • model: scraper or hinged belt conveyor (option), selectable depending on application 
  • work area flushing and shower support rapid chip removal in machines with coolant units
  • extraction unit (option), supports rapid chip removal in machines with coolant units
  • steep side panels and concertina covers with self-cleaning effect prevent chip deposits

Control technology

Intuitive, easy to program with practical features that make light work of the daily routine. Our H-series 4-axis machining centres offer a choice of two state-of-the-art CNC controls from Siemens and Fanuc.

4-axis machining centres H: Control

Siemens SINUMERIK 840D sl

  • main operating unit designed as console, as standard for the machine models H 2000 – H 6000*
  • high-performance control for machining centres that have to meet the highest performance and machining precision requirements
  • optimally integrated and selectively matched to the requirements of HELLER machining centres
  • digital drive technology and modern system architecture
  • user interface SINUMERIK Operate for efficient machine operation
  • HELLER Operation Interface for even more operating comfort, as standard for the machine models H 2000 – H 6000*
     

Fanuc 31i-B

  • high-performance controller for machining centres, meeting the highest performance and machining precision requirements
  • operating elements optimally integrated in the machine’s main operating unit
  • digital drive controller and modern system architecture
  • Screen Display Function user interface for efficient machine operation
  • iHMI operating software for the machine models H 2000 – H 6000 
  • top precision and reliability requirements

HELLER user interface with extended range of functions

  • main operating unit designed as console for optimum operating comfort on machines with Siemens control systems
  • 24" screen and multi-touch function ideal for displaying documents and drawings
  • HELLER Operation Interface with 4 function areas for extra information at a glance
  • practical Xtends: HELLER extensions with additional functions
  • machine control panel with pushbuttons and 3 overrides for optimum control in all operating situations

  • H 8000 – H 16000: main operating unit designed as console with 24" screen, multi-touch function and HELLER Operation Interface
  • convenient operating panel at tool loading station
  • HT2 hand-held operating unit
  • HELLER4Industry Connect and other products
  • pallet management system for multiple setups
  • alternative strategy
  • job management
  • automatic setting/de-setting sequence

* As standard for the machine models H 2000 – H 6000. For H 8000 – H 16000 optionally available.

Operation and maintenance

When you work with HELLER H-series machines, just how much machine construction has gone into these 4-axis machining centres will be tangible. No matter whether on the workpiece setting station, during tool setting, programming or maintenance – your comfort and safety and, above all, the productivity of your manufacturing facility is paramount at all times.

4-axis machining centres H: Operation and maintenance

Optimal accessibility to all work areas for simple operation and maintenance

  • operating comfort and ergonomic design increase productivity
  • spatial separation between operating and maintenance areas
  • robust operating elements for tough everyday production conditions
  • smooth-running doors and easily removal metal enclosure elements

Maximum operating comfort during setting and production

  • ergonomically arranged operating elements and control screens
  • good view into the work area thanks to large safety screen
  • smooth-running work area door with linear guide opens the work area roof in the operating area
  • operating modes 2 and 3 included in standard scope of supply


Options

  • handheld operating unit
  • screen blow-off device for a clear view when machining with cutting fluid

Setting and loading during machining thanks to the pallet changer

  • large smooth-running door to optimise access for loading and setting by crane or handling systems
  • workpiece setting station, lockable at 90° indexing with foot unlocking mechanism, unrestricted manual rotation
  • operating elements, as well as media guns within reach, integrated into the machine enclosure 


Options

  • automatically actuated setting station door
  • automatically rotating NC setting station
  • software options: automatic setting and de-setting sequence

Optimal accessibility for fast tool setting

  • ergonomically arranged operating elements
  • insertion location at optimum height and with integrated unclamping function for simple handling
  • tool setting at the magazine when spindle is running


Options

  • convenient operating panel at workpiece loading station
  • setting during machining
  • tool coding with RFID chip
  • HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists

Central supply area at the rear of the machine

  • simple maintenance: all supply units at a glance with good accessibility
  • smooth-running doors and easily removal metal enclosure elements
  • simple and direct access to the control cabinet
  • quick-response HELLER spare part service


Options

  • maintenance manager for maintenance planning and operator support on the machine itself
  • HELLER TPS (Total Productive Services): Service Agreements for inspection, service and maintenance measures

Technical data

Product selection H 2000H 4000H 5000H 6000H 8000H 10000H 14000H 16000
Positioning range
X/Y/Z
mm 630/630/630800/800/800800/800/8001,000/1,000/1,0001,250/1,200/1,1001,600/1,400/1,3002,400/1,600/1,6002,400/1,600/1,600
Rapid traverse speed
X/Y/Z | Power (Speed)
m/min 65 (80/80/90) 65 (80/80/90) 50 (65/65/72) 50 (65/65/72) 50 (60) 45 41/45/45 41/45/45
Acceleration
X/Y/Z | Power (Speed)
m/s² 8 (10/10/12) 8 (8/8/12) 5 (7/7/10) 5 (7/7/10) 4 (5) 4 3 3/3/2
Positioning tolerance Tp / At1)
X/Y/Z | VDI/DGQ 3441 / ISO 230
mm 0.005 0.005 0.005 0.008 0.008 0.008 0.008 0.008
Tool shank
SK/BT for selected units available as alternative
Size HSK-A 63HSK-A 63HSK-A 100HSK-A 100HSK-A 100HSK-A 100HSK-A 100HSK-A 100
Chip-to-chip time2)
t₂,₃ | VDI 2852 | Power (Speed)
s 2.5 (2.2)2.8 (2.3)3.4 (3.0)3.6 (3.2)4.5 (4.3)5.5 6.7 6.7
Clamping surface
Nominal size
mm 400 x 500500 x 630630 x 630630 x 630800 x 8001,000 x 1,0001,000 x 1,0001,250 x 1,600
Workpiece dimension
Diameter x height
mm Ø 720 x 850Ø 900 x 1,000Ø 900 x 1,000Ø 1,000 x 1,200Ø 1,250 x 1,400Ø 1,400 x 1,600Ø 1,400 x 1,800Ø 2,000 x 1,725
Clamping load
Power (Speed)
kg 800 1,400 1,400 1,400 2,000 (1,250)4,000 4,000 8,000
Machine control
Siemens SINUMERIK 840D sl / Fanuc 31 i-B
Siemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/-

( ) = optional values
- = not available
1) position uncertainty
2) applies to Siemens SINUMERIK 840D sl

Downloads

HELLER_4-axis-machining-centres-H_EN.pdf
Product brochure
4-axis machining centres H
3.5 MB

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