ROBOFORM
350 S550 S
2
Speed Edition
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Contents
Speed Edition
High Speed EDM
Speed Finishing
EXPERT Systems
DPControl
Automation
Mechanics
Options
Technical specifi cations
Hold
pole position
With the new “Speed Edition” range, Charmilles puts all
its know-how into helping you perform well on the most
competitive capital goods markets.
The ROBOFORM 350 S and ROBOFORM 550 S innovations
enable you to gain precious time in “blade” type
applications and pre-roughed 3D cavities.
Objective: to increase productivity while
guaranteeing homogeneous and even shiny
surface fi nishes.
Charmilles accelerates
and you take pole position
3
A true concentration of innovation and technology,
the “Speed Edition” range really lives up to its name.
> Movement speed of the Z axis multiplied by two (295 in/min)*
> Five times greater acceleration (197 in/s2)*
> Faster and more economical fi nishing settings
> New algorithm for management of translation orbits (TRANS-EXPERT)
> Self-cell management combining reliability and productivity (SCM: Self-Cell Management)
> New on-board documentation for accelerated training of the operator
By enabling you to considerably increase your useful machining hours,
the new ROBOFORM 350 S/550 S enable you to approach your markets in pole position.
*ROBOFORM 350 S
4
High Speed EDM
Fast pulsation speed for better
evacuation of particles
Deep rib machining
requires high pulsation
speeds
Previously unseen performances
The increase in the movement speed
of the Z axis and its spectacular
acceleration enable a 30% increase
in performance in the machining of
medium to deep blades.
A profi table choice
This technological choice of Charmilles
facilitates the evacuation of particles
in the cavities due to the pulsation
speed, without fl ushing or distortion.
This is an advantage for applications
such as connector technology, ribbing
or micro-machining.
Technical specifi cations
Z axis speed: 295 in/min
Acceleration: 197 in/s2
With the “Speed Edition” range
from Charmilles, EDM unveils new
standards of competitiveness.
Comparison with/without High Speed EDM 2
5
Speed Finishing
Unmatched surface homogeneity
With regard to the fi nishing setting,
the ROBOFORM 350 S/550 S
machines defi nitely score some
points. The precision of details is
respected due to reduced wear
rates, maintaining the geometry of
the electrodes. “Speed Finishing”
enables fi ne and even shiny surface
fi nishes (Ra ≤ 0.4 μm) of unmatched
homogeneity on small to large
surfaces to be obtained. In most
cases, the expensive and delicate
operations of manual polishing are
reduced or even eliminated.
Win at the fi nish. Obtaining
considerably homogeneous surface
fi nishes during machining gains
precious time.
Speed Finishing box Cavity (cable clamp)
Mold for 16 cavities
(cable clamps)
Comparison with/without Speed Finishing
6
PILOT-EXPERT 4 Guarantees
top performance while taking into
account machining conditions at all
times. It provides for unattended
machining and delivers perfect job
reproducibility.
POWER CONTROL EXPERT Checks
each spark to ensure a perfect quality
of surface fi nish. It also allows to
determine in real time the intensity of
machining discharge as the electrode
surface increases.
TRANS-EXPERT The new algorithm
for calculating planetary translations
enables substantial increases in
machining speed to be made, from
roughing to fi nishing.
SPAC® A Charmilles exclusive.
Allows to eliminate any short circuit
(SC) by applying a specifi c discharge
during a fraction of a second. No
longer slowed down due to short
circuits, machining continues at full
speed and without interruption, thus
improving productivity.
1. Drop in
machining voltage
due to a SC
2. Elimination of
the SC by applying
a specifi c current
discharge
EXPERT
Systems
Optimizing all the parameters.
The Charmilles “EXPERT Systems”
enable you to control performance
right to the end.
Pulse time (μs)
SPAC
V
A
0
1
2
7
The new DPControl (Dynamic
Process Control) interface has
been developed, based on the
fi ndings of a survey conducted
among mold-making professionals.
The study was instrumental in
designing interface functions and
optimizing screen ergonomics. The
user-friendliness of Charmilles
interfaces – already a recognized
standard in the industry – has
been further enhanced to satisfy
the stringent requirements of
die-sinking professionals.
Interactive graphics
All operations such as measuring
and machining cycles as well as
cavity positioning are illustrated
by graphics/icons designed to
facilitate instant recognition and
comprehension by the operator.
Standard Windows XP platform
• Integrated PC
• Touch screen
• CD-ROM
• Network
DPControl
Maximize productive time
DPControl delivers unique solutions:
• Part Express: allows the operator
to interrupt and “remember” the
current machining operation in
progress in order to insert a more
urgent job.
• Job List: organizes job sequence
according to manufacturing
priorities.
Part ExpressThroughput
Steering faster, in total security.
DPControl, the interface that develops
your job, uses all the know-how of
Charmilles to accelerate and secure
each path.
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DOWN ORB ANGUL EXPAN VECT CYLINDRE
DIAG SPHERE ISOGAP CONE CONE HELIC
1. Electrode design
DPControl suggests ideal electrode
undersize and rationalizes the number
of electrodes necessary for effective
machining.
2. Measuring offset and positions
Absolutely imperative for preparing the
job, measurements performed on a preset
station are directly accessible via DPControl.
Dynamic manufacturing process
e-Doc
The “Speed Edition” range unveils
a new Online documentation.
Enables the operator to fi nd relevant
information as quickly as possible.
This is achieved through simplifi ed
access of the help menu, a clearly
organized navigation interface, which
is more user-friendly and simpler to
understand, as well as a search by
keywords or with the user index.
Machining examples are produced
in paper format and presented in a
succinct manner. These examples
can be found in the online help to
make it easier to follow a machining
operation step by step.
With additional descriptive
documentation, e-Doc enables
knowledge to be transferred to the
operator, enabling improvement of
skill while reducing the number of
days for training.
1
2
3
45 6
2D/3D machining cycles Measurement cycles
2D only
5. Notifi cation via SMS
All information related to machining status
may be transmitted directly to the operator
via SMS.
6. Evaluation of completed job
DPControl automatically creates a full
report on job execution readily accessible to
the operator via the network or directly on
the machine.
3. Flexible job organization
Whether you work on a PC or on the
ROBOFORM 350 S/550 S, DPControl allows
you to organize the jobs according to your
own priorities.
4. Close monitoring
Due to the automated protection features
of “EXPERT Systems”, DPControl delivers the
results you demand.
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Automation
Integrated by DPControl, the
complete automation solution of
the ROBOFORM 350 S/550 S cells
enables productivity records to be
beaten. This means that you gain
time to dedicate to the essential
– surpassing the competition.
Objective: 7000 hours of EDM/year
The self-cell management system
maximizes machine time, increasing
it from an average of 2500 hours
to almost 7000 hours per year.
Importing CAD/CAM data into the
DPControl interface and reference
taking, optimization of the space for
loading the changer and programmed
but fl exible machining guarantee
results whilst enabling continuous
production.
Record productivity
This new cell management system
enhances the functionalities of
DPControl. Almost total autonomy of
each cell radically optimizes machine
time, which eliminates the risk of
error and reduces stress for the
operator.
Automating champion refl exes.
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Automatic CAD/CAM link
The different EDM machining
sequences are automatically
integrated into DPControl at the
design stage.
Preparation in concurrent
operation time
Preparation (mounting blanks in
the electrode holder, palletization
of the workpieces, identifi cation of
the chips) and reference measuring
are carried out in a clean area in
concurrent operation time. The data
collected are automatically integrated
into DPControl.
Optimization of
the tool changer space
Identifi cation of the electrodes by
electronic chip enables them to be
loaded in the changer magazine
without having to worry about the
machining phases. Only optimization
of the space available and correct
direction of the tool is important.
Autoscan automatically identifi es and
selects the tool corresponding to the
job programmed.
Machining fl exibility
and reliable results
Due to the automation of the
machining sequences integrated into
DPControl with the Part Express
design and functionality, productive
hours are maximized, while urgent
jobs can be fi tted in easily. Reliability
of the process is ensured from start
to fi nish.
CMM• Tools offset
• Parts reference
PC• CMM software
• DPControl 2.1
Machine• DPControl 2.1
• Autoscan
Identifi cation• Pallets
• Electrodes
Data transfer
Self-Cell Management (SCM)
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3
4
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Linear glass scales
for lifetime precision
To obtain lasting precision, only
linear glass scales are truly effective.
They eliminate all common errors
caused by backlash, expansion
and ballscrew wear. The Dual Loop
Positioning System (DLPS) developed
by Charmilles is a true closed-loop
feedback solution designed to deliver
high precision regardless of travel.
It does away with the need for regular
maintenance and calibration.
Rugged mechanical design
A short oversized cast-iron “C” frame
delivers mechanical stability and
precision for the life of the machine
– regardless of workpiece weight
or dielectric volume. In addition, a
rugged design absorbs all machining
forces, in order to maintain a precise
gap between workpiece and
electrode.
Resolution
of scales: 0.000002 in
CNC order
G0X10
yes
no
STOP
Movement of the axis
(encoder motor)
Checking the
position (linear
glass scale)
Short “C” frame
Position reached?
Mechanics
Building unfailing endurance. Without
reliability, performance is not enough.
Mechanical stability and the precision of
the ROBOFORM 350 S/550 S machines are
guaranteed over time by tried and tested
mechanical sturdiness.
12
<60s
ICP
Increased autonomy
without manual intervention
Production of a mold often requires
a large number of electrodes, for
which machining time can vary
considerably from one cavity to
another. The new rotary changer of
the ROBOFORM 350 S/550 S offers
a large storage capacity for up to
160 electrodes. A double gripper,
which reduces unnecessary
movements, considerably speeds up
the loading and unloading process.
Increased security
with the Autoscan function
The Autoscan function automatically
identifi es the electrodes required
for each machining phase even if the
electrodes are arranged randomly.
The electronic ID chips, with which
they are equipped, enable them to be
localized wherever they are and to be
selected in the allocated order. The
risk of error is eliminated and the
preparation time noticeably reduced.
Tool changer:
160 electrodes
max.
Double gripperAutoscan
ICP (Integrated Collision Protection)
on the changer’s arm
Change from electrode to
electrode in less than 60s
Options
Choosing the right options is a matter
of strategy. To race ahead, several
options enable you to personalize
your solution in accordance with your
productivity requirements.
180°
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High precision measurements (option)
To ensure positioning precision
to within a micron, an optical
transmission probe can be managed
by the ROBOFORM 350 S/550 S.
Being both more accurate and more
reliable than an electrical touch
system, optical transmission of
measurements allows dimensional
inspection of machined cavities as
well as the taking of references of the
part, without having to extract it, thus
saving a considerable amount of time.
Furthermore, a measurement report
is automatically generated by
DPControl, enabling rigorous
checking and monitoring.
The measurement is transmitted
by light beam
Measurement cycle and
measurement report
Dynamic characteristics
without equal
It is not uncommon to be confronted
with machining where the electrodes
must be mounted away from the
spindle chuck center line, evenshifted
so far out that maintaining their
position or stability during machining
becomes problematic. Pulsation
movements in a liquid medium (the
dielectric) generate lateral forces
(in a vacuum or in rotation) on the
electrode, to which the C axis can be
subjected. Thanks to its very robust
design, the Accura-C allows very high
moments of inertia, up to 1708 lbsin2,
to be absorbed.
Automatic generation of the measurement
report in DPControl
Automatic indexation of the C axis for
greater measurement accuracy
Accura-C
Technical specifi cations
C axis travel 360°
Speed of rotation 100 rpm
Max. electrode weight 110 lbs
Admissible machining current 128 A
Measurement resolution 0.0001°
Max. inertia 1708 lbsin2
Motor torque 21 lbf
The most outstanding axis on the market
Renishaw
probe
Dielectric
1 Thermostat enables the
temperature of the dielectric to
be controlled
2 Water/dielectric heat exchanger
3 Circulation of the dielectric
integrated into the table
Air
4 Thermostat with two
temperature probes enabling
the air temperature to be
adjusted to that of the dielectric
5 Water/air heat exchanger
6 Coolant solenoid valve
Diagram showing the principle
of double thermostabilization
Thermo-
stabilization
Mechanical stability:
a unique solution
The double thermostabilization
system of the ROBOFORM 350 S is a
world fi rst in preventing the impact
of temperature variations, which are
inevitable in the workshop, on the
precision of part machining. This is
a major innovation when working on
a scale of microns.
This solution avoids the waiting time
for thermostabilizing the environment
the machine is in and guarantees
precision, both in positioning and
geometry. The quality of the fi nished
product is therefore impeccable.
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ROBOFORM 350 S (Speed Edition) ROBOFORM 550 S (Speed Edition)
Machine
Architecture Compact machine with fi xed table Compact machine with fi xed table
Dimensions (*) in 74.80 x 66.54 x 99.29 119.68 x 111.41 x 116.53
Total weight (without dielectric) lbs 6200 9920
Complies with “Machines, Safety and Health” directive 89/392/CEE 89/392/CEE
Complies with “Electromagnetic Compatibility” directive 89/336/CEE 89/336/CEE
X, Y, Z axes
X, Y, Z travel in 13.78 x 9.84 x 11.81 23.62 x 15.74 x 17.72
Movement measurement system Linear glass scales Linear glass scales
X, Y, Z measurement resolution in 0.000002 0.000002
Work area
Tank type Drop tank Drop tank
Tank dimensions (*) in 31.50 x 21.65 x 14.57 48.03 x 34.25 x 18.50
Min./max. dielectric level in 3.94/12.80 programmable 5.7/17.32 programmable
Table dimensions (**) in 19.69 x 15.75 29.53 x 23.62
T-slot dimensions (number) in 0.47 (3) 0.47 (5)
Electrode and workpiece
Max. electrode weight lbs 110 220
Max. workpiece weight lbs 1100 3530
Max. workpiece dimensions (*) in 30.71 x 20.87 x 11.81 47.24 x 33.46 x 15.75
Min./max. distance between table and chuck in 5.91/17.72 5.91/23.62
Dielectric system
Filter type 4 built-in paper cartridges 8 built-in paper cartridges
Reservoir volume gal 108 216
Generator
Type ISOPULSE ISOPULSE
Standard machining current A 64 (128 ***) 64 (128 ***)
Power supply
Three-phase input voltage V 400 400
Main network frequency Hz 50 or 60 50 or 60
EXPERT Systems (ROBOFORM 350 S/550 S)
PILOT-EXPERT 4: optimization and automatic monitoring of machining parameters Standard
POWER CONTROL EXPERT: machining current, self-adapting according to electrode geometry Standard
SPAC®: protection against short circuits (CT patent) Standard
TRANS-EXPERT: automatic optimization of planetary translations depending on the geometry of the electrode Standard
Technical
specifi cations
* Width x depth x height ** Width x depth *** Option
ROBOFORM 350 S ROBOFORM 550 S
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ROBOFORM 350 S/550 S
Modules
C axis (***) Standard Accura-C
Max. electrode inertia 683 lbsin2 1708 lbsin2
Measurement resolution 0.001° 0.0001°
Electrode weight 55 lbs 110 lbs
Spindle chuck (***) System 3R Macro/Combi
Erowa ITS/ITS-Compact
Hirschmann H8.11.7
Tool changer (***) Linear (standard tooling) 4 (350 S)/6 (550 S) positions
Linear (Combi tooling) 5 (350 S)/6 (550 S) positions
Rotary (standard tooling) 16-80 positions
Rotary (Combi tooling) 30-160 positions
Thermostabilization table + cabin Option (ROBOFORM 350 S), not available (ROBOFORM 550 S)
Autoscan (only with 3R chip) Option
Multicavity fl ushing (***) 6 outputs
Additional power module (***) 64 A
Adapter kit for external robot Option
e-ConnecT Option
e-Control, e-Supervision Option
Programming system on PC Standard
Autorestart Standard
High Speed EDM (ROBOFORM 550 S) Standard (142 in/min – 40 in/s2)
High Speed EDM 2 (ROBOFORM 350 S) Standard (295 in/min – 197 in/s2)
Renishaw probe Option
Speed Finishing Standard
DPControl functions
Automatic measurement cycles for workpieces and electrodes
Importation of measurement results from preset station
3D machining cycles with geometrical pattern
Multicycle
Machining strategy for all combinations of materials
Dedicated technologies for each type of application
Aid to defi ne undersize and number of electrodes
Machining sequencing assistant according to manufacturing priorities
Graphic machining simulation and graphic follow-up
Machining report for each job execution
Job List – Management of pending jobs by order of priority
Part Express – Instant insertion of urgent jobs
Contextual aid with graphics explanations
Online documentation (e-Doc) on the use of the machine
Self-Cell Management (SCM): automated cell management
Numerical control
Architecture PC multiprocessors
Operating system Windows XP
Processor Pentium® 1.6 GHz
RAM memory 512 MB
Screen LCD 12” TFT
Data input Touch screen – keyboard
Keyboard PC-style alphanumeric standard
Remote control Standard
Hard drive 40 GB
CD-ROM drive Standard
PCMCIA Port, Ethernet RJ45, USB (x2) Standard
ROBOFORM 350 S ROBOFORM 550 S ROBOFORM 350 S ROBOFORM 550 S
Charmilles Technologies SA
rue du Pré-de-la-Fontaine 8-10
1217 Meyrin 1, Geneva/Switzerland
Tel. +41 (0)22 783 31 11
Fax +41 (0)22 783 35 29
www.charmilles.com
Agie Charmilles Group
25
98
04
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6/0
5.0
7/U
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Contact
© The technical data and illustrations are not binding. They are not warranted characteristics and
are subject to change. Please consult the General Sales Conditions of Charmilles Technologies SA.