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-Achs-Bearbeitungszentren H: Maschinenkonzept

Cross-bed and travelling column in gated design

  • high stability and damping in the flow of forces through topology-optimised structural components from cast iron
  • optimised flow of forces and thermo-symmetrical design
  • broad range of machining units in a robust design
  • tool changer with two NC-axes for fast automatic tool change
  • large range of tool magazines, chain or rack-type
  • integrated pallet changer and high payload for fast automatic pallet change

4-axis kinematics with horizontal spindle

  • machine bed carries the X- and the Z-axis in a cross bed arrangement
  • the machine column traverses in the X-direction and carries the machining unit
  • machining unit traverses in the Y-direction, compactly integrated into the machine column in a stable manner
  • rotary table traverses in the Z-direction and executes the feed movement
  • NC rotary indexing table (B rotary axis) turns the workpiece continuously (360.000 x 0.001°)

Roller bearing-mounted linear guides and stable YRT bearings in the rotary table

  • linear axes driven by roll guides with ball screws for high feed forces
  • direct, absolute measuring systems (glass scales in linear axes) for optimised precision and low position tolerance
  • speed axis dynamics available as an option for certain sizes
  • NC rotary indexing table with large YRT bearings and automatic clamping for maximum stability and high tilting moments
  • NC rotary indexing table with gear drive for high circular milling torque and damping (H 16000 with direct drive)

Spindle 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-Achs-Bearbeitungszentren H: Arbeitseinheiten

Broad range of powerful machining units

  • horizontal spindle for optimal chip fall
  • HSK-A 63 or HSK-A 100 tool shank correspond to the size of the machine
  • lean spindle neck for perfect reach into the workpiece
  • rigid cast iron guide slide with high dynamic stiffness and damping
  • optimised performance in action with compact overall design and robustly dimensioned spindle bearing arrangement
  • thermal stability and precision thanks to permanent cooling: precision cooling unit and thermal growth compensation for the spindle

3 machining units for machines with HSK-A 63

  • directly driven spindles with speeds of up to 24,000 rpm
  • torques of up to 242 Nm (S6 40 %)
  • tool shank SK 40 / BT 40 available as alternative*
     

5 machining units for machines with HSK-A 100

  • 3 units with gearbox and torques of up to 2,292 Nm (S6 40 %)
  • 2 directly driven spindles with speeds of up to 12,500 rpm
  • tool shank SK 50 / BT 50 available as alternative*

HELLER zero-spindle system for quick and easy spindle exchange

  • spindle exchange without complex adjustments
  • reduces the repair time
  • cost-effective service solution
     

HELLER facing slide system*

  • for automatic adjustment of self-controlling tools
  • control by a fully-fledged NC-axis (U) integrated into the machine control
  • drive fully integrated in the machining unit
  • ideally suited for contour or face turning
  • available for machining units with tool shank HSK


HELLER attachment head support (MSK)

  • for use with adapter heads, e.g. angular heads
  • enlarged location base with three-point location
  • integrated torque absorption and media transfer


HELLER attachment head additional clamping*

  • for additional clamping of attachment heads on the attachment head support
  • for use with attachment heads and with high process forces
  • available only for machining units with gear unit

* not available for all machining units

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-Achs-Bearbeitungszentren H: Werkzeugmanagement

Chain-type tool magazine for fast tool provisioning

  • 4 chain-type magazines with up to 240 pockets for machines with HSK-A 63 (SK/BT 40) to choose from
  • 3 chain-type magazines with up to 150 pockets for machines with HSK-A 100 (SK/BT 50) to choose from
  • rigid tool holder mounted on both sides of a double chain for high chain traversing dynamic
  • tool setting station with optimum accessibility for ergonomic and fast tool setting
  • integrated tool provisioning station for provisioning of the follow-on tool during machining and short tool-to-tool times
  • too shank in closed holders: protects against contamination and optimum hold during positioning
  • tool provisioning during machining for short tool-to-tool times


Options

  • convenient operating terminal at the tool setting station
  • setting during machining
  • tool coding with RFID chip
  • tool shank cleaning, incl. cartridge flushing and drying
  • HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists
  • tool break monitoring during machining

Rack-type tool magazine with high storage capacity

  • two rack-type magazines with up to 425 pockets for machines with HSK-A 100 (SK 50) to choose from
  • rack-type magazine with 409 pockets for machines with HSK-A 63
  • tool handling with highly dynamic loader for fast tool provisioning
  • tool setting station with integrated rotary station with multiple tool pockets for setting during machining
  • convenient operating panel at workpiece loading station
     

Options

  • automatic rotary station
  • tool coding with RFID chip
  • tool shank cleaning with brush and flushing option
  • HELLER TRP (Tool Requirement Planning) for automatic creation of loading and unloading lists
  • tool break monitoring during machining

Fast tool change for short chip-to-chip times

  • two NC-axes with lifting/swivelling principle for a high dynamic and continuous precision
  • stable double gripper for secure hold with high tool weights and tool moments of weight

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 total payload of up to 16 t. The HELLER H-series works to a high degree of precision even with this workpiece weight.

4-Achs-Bearbeitungszentren H: Werkstückmanagement

Pallet changer as standard

  • automatic pallet changer with lifting/swivelling principle (H 16000 with sliding/swivel principle)
  • high maximum payload through robust, hydraulic drive
  • optimised force application to machine pallets due to the fork shape of the lifting/swivelling traverse
  • continuously high changeover accuracy through robust aligning elements and extensive blow-out of the function surfaces
  • hydraulic pallet clamping for secure hold, even with high process forces
  • HF machine pallets with DIN hole pattern and standardised aligning elements for fast mounting of clamping fixtures

Setting and loading during machining

  • manual or automated loading by robot or pallet
  • 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

  • integrated media interface for hydraulic workpiece clamping (60 / 200 bar)
  • additional pneumatic functions: location check and unclamping check via media interface
  • active operator support through automatic functions: automatic setting station door, automatically rotating NC setting station, automatic setting and de-setting sequence
  • machine pallets in DIN T-slot design

NC rotary indexing table as standard

  • rotary tables with gear drive for high circular milling torques and damping (H 16000 with direct drive)
  • large YRT bearing for maximum stability and high tilting moments
  • automatic hydraulic rotary table clamping for high tangential torques
  • compact design for optimum effect in the flow of forces and absorption of cutting forces


Options

  • integrated media interface for hydraulic workpiece clamping (60 / 200 bar)
  • additional pneumatic functions: location check and unclamping check via media interface
  • automatic setting station door

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-Achs-Bearbeitungszentren H: Automatisierung

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-Achs-Bearbeitungszentren H: Ver- und Entsorgung

Central media supply area at the rear of the machine

  • simple maintenance with optimum accessibility, all supply units at a glance
  • compressed air and flushing gun integrated into the machine enclosure at the workpiece setting station
  • centralised oil/air lubrication for the key components
  • seal air and selective blow-out of interfaces for permanently smooth machine operation
  • media interface for hydraulic workpiece clamping at 60 bar or 200 bar (option)

Effective cooling lubricant supply and filtering

  • coolant units: paper band filter or vacuum rotation filter with high tank volume optionally available
  • internal coolant supply (IKZ) through the tool at high pressure 50 bar (option: 70 bar)
  • internal coolant supply with up to 7 pressure stages freely programmable via the NC program
  • external tool cooling with flushing nozzles integrated into the spindle
  • integrated work area flushing with adjustable nozzles for optimal work area flushing and workpiece cooling


Options

  • coolant cooler for high thermal stability and precision
  • automatic filling of the coolant unit
  • oil skimmer for removing foreign oil from the cooling lubricant tank by oil separation

Fast chip removal from the work area

  • 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
  • chip conveyor as either scraper conveyor or hinged conveyor, depending on the application (option)
  • steep side walls and bellow covers with self-cleaning effect prevent chip deposits
  • work area flushing and work area shower support fast chip disposal for machines with coolant units
  • optional: exhaust unit for exhausting cutting fluid mist from the work area

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-Achs-Bearbeitungszentren H: Bedienung und Wartung

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
  • swivelling main operating unit with clamping function optimally integrated into the machine enclosure
  • 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
  • main operating unit in console design with 24" multi-touch screen and HELLER Operation Interface

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
  • HELLER zero spindle system for fast and simple spindle replacement


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

Control

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-Achs-Bearbeitungszentren H: Steuerung

Siemens SINUMERIK 840D sl

  • high-performance control for machining centres that have to meet the highest requirements when it comes to performance and machining precision
  • digital drive technology and state-of-the-art system architecture
  • SINUMERIK Operate user interface for efficient machine operation
  • HELLER Operation Interface for even more comfortable operation (option)
  • optimally integrated and adapted specifically to the requirements of HELLER machining centres
     

Fanuc 31i-B

  • high-performance control for machining centres that have to meet the highest requirements when it comes to performance and machining precision
  • digital drive controller
  • highest requirements for accuracy and reliability
  • operating elements optimally integrated into the machine's main operating unit

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

  • handheld operating unit
  • convenient operating panel at workpiece loading station
  • HELLER Remote Diagnostic Services (RDS)
  • pallet management system for multiple setups
  • alternative strategy
  • order management
  • automatic setting and de-setting sequence

Technical data

Product selection H 2000H 4000H 4500H 5000H 6000H 8000H 10000H 14000H 16000
Positioning range
X/Y/Z
mm 630/630/630800/800/800800/800/800800/800/8001.000/1.000/1.0001.250/1.200/1.1001.600/1.400/1.3002.400/1.600/1.6002.400/1.600/1.600
Rapid traverse speed
X/Y/Z | Power (Speed)
m/min 65 (90) 65 (90) 65 50 (65) 50 (65) 50 (60) 45 41/45/45 41/45/45
Acceleration
X/Y/Z | Power (Speed)
m/s² 8 (10) 8 (8) 6 5 (7) 5 (7) 4 (5) 4 3 3/3/2
Positioning tolerance Tp
X/Y/Z | VDI/DGQ 3441
mm 0,005 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 100HSK-A 100
Chip-to-chip time
t₂,₃ | VDI 2852 | Power (Speed)
s 2,8 (2,3)3,0 (2,5)4,0 4,0 (3,8)4,2 (4,0)4,5 (4,3)5,5 6,7 6,7
Clamping surface
Nominal size
mm 400 x 500500 x 630500 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 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 (500)1.400 (800)1.400 1.400 (1.000)1.400 (1.000)2.000 (1.250)4.000 4.000 8.000
Machine control
Siemens Sinumerik 840D sl / Fanuc 31i-B
Siemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/FanucSiemens/-

( ) = optional values
- = not available

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heller-4-axis-machining-centres-h_en.pdf
Product brochure
4-axis machining centres H
3.7 MB

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