www.heller.biz

Machining centres

The H series4-axis machining at its best

HELLER solution competence: Efficiency for your production. Worldwide.

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Goslar, Hattingen, Kirchheim, Nürnberg, Nürtingen, Saarbrücken, Salem

MExico

Queretaro

BRaziL

Belo Horizonte, Gravataí, Joinville, Sorocaba

inDia

Pune

cHina

Beijing, Changchun, Changzhou, Chongqing, Nanning, Shanghai

RUSSia

Yekaterinburg

Spain

Barcelona, Santander

iTaLy

Verona

FRancE

Paris

SLovakia

Vráble

SWiTzERLanD

Niederbüren

SWEDEn

Värnamo

Uk

Redditch

USa

Troy, MI

conTEnTS

Machining of titanium

Machining of stator housing

HELLER solutions: knowing how it’s done.

Machining of nickel base alloy

Machining of transmission cases

High-performance milling

HELLER out-facing head

our quality promise: Made by HELLER 4

H series: for high outputs 6

Machine concept: structure and basic construction 8

Machining units: highest precision 10

Tool management: comprehensive know-how for your tooling 14

Workpiece management: high precision and process stability 16

chip disposal: perfect solutions to suit your requirements 18

operation: proven and perfected 20

control: programming in the familiar system environment 21

Maintenance: optimising overall costs in next to no time 22

Energy efficiency: package offers providing maximum savings 23

options: typical extra quality from HELLER 24

automation: solutions for increased efficiency 26

HELLER Services: ensuring maximum productivity 28

3H series

a simple principle forms the foundation for the quality and precision of

any HELLER solution: HELLER machines are produced on HELLER machines.

Our machining centres are manufactured within a global production network operated to HELLER’s high quality standards. All components determining the reliability, precision and quality of a HELLER machine are developed and produced in-house. Wherever the daily availability of your HELLER machine is concerned, a high degree of vertical integration is paramount to us. That is why the Made by HELLER seal of approval is something you can rely on.

H seriesFlexibly configurable 4-axis machining centres

F series5-axis production machines with or without pallet changer

c series5-axis mill/turning centres for complete machining

our quality promise

MaDE By HELLER

4 5H series H series

H series

FoR HigH oUTpUTS

These compact and powerful machining centres are ideally suited for a wide range of parts and materials. From machining of individual parts through to high-volume production. From light-metal machining to heavy-duty cutting.

Machines designed for stable processes at adequate speeds that can be operated at full load even to the limit

Highly standardised series, but still configurable to individual requirements

Models H 2000 to H 14000 provide pallet sizes of up to 1,000x1,000mm with a maximum loading capacity of 4,000kg per pallet

Chip disposal for highly productive applications is configurable in accordance with customer requirements from a wide range of options

Proven and perfected operation and cost- optimised easy maintenance

Basic scope of supply comprising technical added value

4,000

2,000

1,400800

pallets (mm x mm) 400 x 500 500 x 630 500 x 630 630 x 630 630 x 630 800 x 800 1,000 x 1,000 1,000 x 1,000 1,000 x 1,000

x (mm) 630 800 800 800 1,000 1,250 1,600 2,000 2,400

y (mm) 630 800 800 800 1,000 1,200 1,400 1,400 1,600

z (mm) 830 800 800 800 1,300 1,100 1,300 1,300 1,600

v (m3) 0.33 0.51 0.51 0.51 1.30 1.65 2.91 3.64 6.14

H 14000H 12000H 10000

H 8000

H 6000H 5000H 4000 H 4500H 2000

Max. pallet loading capacity (kg)

6 7H series H series

Every machine from HELLER is constructed from main components developed using FEa techniques, including a machine bed provid-ing optimised rigidity and a column with reduced masses for high dynamics. at the same time, the vibration-optimised machine structure provides an optimal surface finish of the workpiece and extended tool life.

1 H 2000 – 6000: NC rotary feed table moves in Z axis direction, driven by two ball screws H 8000 – 14000: NC rotary feed table moves in Z axis direction, driven by one central ball screw For all sizes: optimal force flow and thermo- symmetrical design

2 H 2000 – 6000: free chip fall below the tool spindle H 8000 – 14000: optimal chip disposal through use of 3 spiral conveyors

3 Highly robust cast-iron machine bed carries X and Z axis

4 X axis designed as cast-iron column

5 Powerful and precise spindle units in the Y axis. Equipped with spindle growth compensation as standard

6 Pallet changer: highly precise even at high load

7 Tool changer: fast and precise also with high tool weights and moments of weight

8 Use of high-precision linear guideways and absolute encoded measuring systems (glass measuring scales, encoders)

9 Pneumatic weight compensation provides high dynamics

H 8000

H 10000

H 12000

H 14000

H 2000

H 4000

H 4500

H 5000

H 6000

22

3 Machine Bed

8 Linear guideways1 nc rotary feed table

6 pallet changer

4 column

7 Tool changer

5 Machining unit

9 Weight compensation

3 Machine Bed

8 Linear guideways

4 column

1 nc rotary feed table

7 Tool changer

5 Machining unit

6 pallet changer

9 Weight compensation

Machine concept

STRUcTURE anD BaSic conSTRUcTion

8 9H series H series

Machining units

HigHEST pREciSion

options Multihead location with and without additional clamping for selected spindle units

HELLER out-facing head as a fully featured axis integrated into the NC control for contouring and face turning operations

Spindle units “Made by HELLER” are key components determining the performance of a machining centre, including its capacity, accuracy, quality and precision.

Guide slides cast from one piece provide high process stability

Robust construction of spindle neck interface to the guide slide

Dynamically stiff, short overall design of the spindle units and sophisticated water cooling of the spindle neck provide high precision

The spindle cooling is always equipped with a precision cooling unit to provide maximum thermal stability.

Additionally, spindle growth compensation is standard

Extraction of internal coolant from the spindle provides fast chip-to-chip times, a clean work area and clean tools

HELLER zero-spindle system provides proven solution for main spindle replacement

Economic cutting 100 High power cutting 50 power Speed cutting 100 Speed cutting 63

10 11H series H series

Machining units Well set up for the most demanding tasks

Machining centreHSc 40/63

(High Speed cutting)

Sc 40/63

(Speed cutting)

pc 40/63

(power cutting)

Sc 50/100

(Speed cutting)

Ec 50/100

(Economic cutting)

pSc 50/100

(power Speed cutting)

pc 50/100

(power cutting)

Epc 50/100

(Enforced power cutting)

Hpc 50/100

(High power cutting)

H 2000 – – – – – –

H 4000 – – – – – –

H 4500 – – – – – – –

H 5000 – – – –

H 6000 – – – –

H 8000 – – – –

H 10000 – – – –

H 12000 – – – –

H 14000 – – – –

Technical data

Speed range rpm 5 – 24,000 5 – 16,000 5 – 10,000 5 – 12,500 5 – 12,000 5 – 12,500 5 – 8,000 5 – 8,000 5 – 6,000

Torque 1) nm 40 95 242 166 242 500 822 1,146 2,292

power 1) kW 25 40 38 52 38 52 43 60 60

Spindle taper Sk/HSk/BT –/63/– 40/63/40 40/63/40 50/100/50 50/100/50 50/100/50 50/100/50 50/100/50 50/100/50

HELLER out-facing head – – –

HELLER multihead location – –

HELLER multihead location with additional clamping – – – – – –

Standard

– not available

Option1) At duty cycle S6 – 40%

12 13H series H series 13

chain-type magazine1 Chain-type magazine with tool holders arranged

on both sides of a double chain for optimal traversing dynamics

Compact build providing high tool packing density

Rack-type magazine2 Rack-type magazine with highly dynamic loader

for tool provisioning

Optimal operating strategy provides short loading times

Tool changer Perfect interplay of tool changer and chain-type

or rack-type magazine. For short chip-to-chip times and provisioning of the follow-on tool parallel to machining

3 Traverse attachment acting as a link between chain-type magazine and tool changer provides precise positioning of tools for tool change at all times. On rack-type magazines this function is provided by the loader

optionsFast tool breakage monitoring for effective process control

Selected magazines for tool loading parallel to machining

Tool shank cleaning

Tool coding

Measuring probe using wireless or infrared technology

1

3

Tool management

comprehensive know-how for your tooling

2

Magazinechain-type magazine Rack-type magazine

c 54 c 80 c 160 c 240 c 50 c 100 c 150 R 409 R 265 R 425

H 2000 – – – – –

H 4000 – – – – –

H 4500 – – – – – – –

H 5000 – – – – –

H 6000 – – – – –

H 8000 – – – – –

H 10000 – – – – –

H 12000 – – – – –

H 14000 – – – – –

Spindle taper (Sk / HSk / BT)

40/63/40 40/63/40 40/63/40 40/63/40 50/100/50 50/100/50 50/100/50 –/63/– 50/100/– 50/100/–

Tool1) (mm) Ø 160/Ø 72 Ø 160/Ø 72 Ø 160/Ø 72 Ø 160/Ø 72 Ø 280/Ø 112 Ø 280/Ø 112 Ø 280/Ø 112 Ø 188/Ø 72 Ø 280/Ø 72 Ø 280/Ø 72

Bridge-mounted tool (mm) Ø 260 x 160 Ø 260 x 160 Ø 260 x 160 Ø 260 x 160 Ø 460 x 280 Ø 460 x 280 Ø 460 x 280 Ø 300 x 188 Ø 485 x 280 Ø 485 x 280

Length (mm) 4504) 4504) 4504) 4504) 600 600/(800)5) 600 4502) 600 600

Weight (kg) 12 12 12 12 25 (35) 25 (35)/35 25 (35) 12 25 (35) 25 (35)

Moment of weight 2) (nm) 10 10 10 10 30 (50) 25 (35)/50 30 (50) 10 30 (50) 30 (50)

Hzp loading 3) – – – /incl. incl. incl. incl. incl.

1) adjacent places free / all places occupied2) referring to tool gripper groove3) HZP= parallel to machining

4) observe limited tool length for H 20005) for model H 8000 and larger

Standard

Option

– not available

( ) optional values

15H series 15

3

4

pallet changer1 Fork shape of the swivel traverse ensures

force application for overall loads of up to 8t

2 Air nozzles at the swivel traverse remove chips

Option for cleaning of functional surfaces of the rotary table and setting station with maintenance function

nc rotary feed table3 Equipped with worm gear to provide opti-

mal damping at high rigidity for demanding 4-axis operations

Compact build allows high permissible tilting moments

Rotary table clamping with oil-hydraulic diaphragm brake

High tangential and circular milling torques

Rotary feed table positioning using direct path measurement with absolute rotary encoders

2 Blow air ensures clean pallet locations, pallet locking and coupling points of media transfer

Pallet alignment by means of diamond-type dowel pin and indexing pin for consistent clamping and alignment

Optionally with services interface option for hydraulic workpiece clamping with 60bars, 200bars or 200bars using proportional valve technology

Workpiece setting station Friction-locked 4 x 90° indexing at the

setting station with foot release

4 Optional automatic rotating setting station with automatic setting station doors

Optional pneumatic location check, unclamp/position check

Services interface option for hydraulic work-piece clamping at the setting station with 60bars or 200bars

2

1

Workpiece management

High precision and process stability

16 H series

chip disposal perfect solutions to suit your requirements

chip conveyor and coolant unitExtendable with scraper belt or hinge band conveyor – depending on the requirements of the machining process

Coolant units with paperband filter or vacuum rotation filter technology

High pressure coolant supply, optionally with 50 or 70bars

Internal coolant supply through the spindle with up to 7 pressure steps, programmable via NC program

Coolant units with large reservoir volumes and high volume flows

Optional additional coolant cooler for an in-creased level of process dependability by providing thermal stability

Work area1 H 2000 – H 6000: free chip fall below the

spindle and central chip conveyor for fast chip disposal and higher production rates

H 8000 – H 14000: use of 3 spiral conveyors provides optimal chip evacuation from the work area

Perpetual self-cleaning effect of moving con-certina covers through stainless steel blades

Numerous flushing nozzles for wet machining included as standard to keep workpiece and work area clean

Additional machine bed flushing

Easy to clean due to good accessibility to work area

Air and wash gun as standard

Optional coolant extraction from the work area

1

18 19H series H series 19

operation1 Safe and comfortable operation ensures

highest availability

Optimal accessibility of operating stations

With optional screen blow-off device at the main operating door

Workpiece setting station2 Short reach to stetting station centre for

comfortable handling

Automatic loading/unloading sequence provides high process dependability and short idle times

Ergonomic integration of the operating panel into the safety guards

Linear guideways provide smooth operation of setting station doors

Tool loading3 Tool loading at the magazine while spindle is

running

Linear guideways provide smooth operation of setting station doors.

Option: comfortable operator panel

Sinumerik 840D solution line and Fanuc 31i-BIncreased operator convenience

Operating modes 2 and 3 included in standard scope of supply

Integrated pallet and program management

User-guided setup functions / automatic return to home position

Trust is good, control is better HELLER IPM (Integrated Process Monitoring) for process, collision and tool breakage monitoring

Tool breakage monitoring parallel to machining

RDS – remote diagnostics of the machine and coolant unit

CDS – Condition Monitoring

practice-oriented functionsComfortable programing with HELLER technology cycles (drilling, milling, measuring)

Job management/management of multiple clamping

Alternative strategy (program continuation e.g. in case of tool breakage)

Tool requirements planning

Technology package milling

Automatic loading/unloading sequence

3

4

2

1

operation

proven and perfected

control

programming in the familiar system environment

20 21H series H series

1 Supply units and maintenance points are limited to a few locations to ensure quick and easy inspection and operation

2 The quick response times of the HELLER spare parts service helps to keep production downtimes in emergencies short

3 All function-relevant systems and components are installed within quick and easy reach

Easily removable guard panels arranged for ease of maintenance provide access at the touch of a hand

4 The proven HELLER zero-spindle system provides quick replace-ment of the milling spindle

4

1

2 3

Maintenance

optimising overall costs in next to no time

Energy efficiency

package offers providing maximum savings

HELLER BLUE Energy efficiency packages for energy savings of up to 30%

At HELLER, the use of regenerative drive systems, servomotors with efficient utilisation of the overall speed range and power-reduced valves has been standard for years just as consistent use of methods for topology optimisation of structural components (e.g. beds and columns).

These methods help to increase stiffness and to optimise masses of moving components. The new HELLER BLUE energy efficiency packages allow to unlock further potential – independent of the manufacturing situation. The more uni-versal and varied the machining task, the more important is adaptive (i.e. requirements-based) current consumption of peripheral equipment and main units in order to be able to optimise various operating points.

HELLER BLUE basicBasic supply for all HELLER machines from the H, F and C series

Use of IE2 motors with up to 5% lower power consumption

Shut-down of individual consumers after a programmable time interval

HELLER BLUE supplyRequirements-based shut-down of consumer air

Constant media and filter monitoring supports the smooth operation of your machine

HELLER BLUE smartsupplyFlexible deactivation/activation of all consumers

In addition to BLUE supply, this option includes shut-off or sleep mode of further functional units, including cooler, pumps, lights, chip conveyor, seal air and other separate options

HELLER BLUE coolantThe use of a frequency converter allows to per-fectly adapt the volume flow of the high-pressure coolant pump, and thus energy consumption, to the requirements of your machining task

HELLER BLUE chillFlexible control instead of ON/OFF control

As with the coolant pump, the central cooler can be controlled by means of a frequency converter in accordance with operating requirements

In combination with a new type of compression technology this results in a significant reduction in power consumption

HELLER BLUE hydraulicsHigh pressure on demand

Booster technology based on the principle of pressure amplification provides low-noise and energy-saving high pressure supply, whilst mini-mising heat input into the hydraulic system

Energy efficiency made by HELLER

23H series

3

4

options

TypicaL ExTRa qUaLiTy FRoM HELLER

1

2

6

5

1 Fast tool breakage monitoring

2 Air nozzles at the swivel traverse, pallet location, pallet locking and coupling points of the media interface ensure highest process dependability

3 Tool cleaning function for chain-type and rack-type magazines – on chain type with tool pocket flushing, on rack type with brush and flushing option

4 Measuring probe for wireless or infrared technology

5 HELLER multihead location, also with additional clamping for critical operations or tools

6 HELLER out-facing head for performing turning operations on a machining centre

HELLER zero-spindle principle for quick replacement of the main spindle

Spindle growth compensation as standard, for optimisation of manufacturing accuracy

25H series 25

The machining centres from the H series epitomise productivity: in addition to their high precision and efficiency they provide maximum reliability, even under constant load, and can be flexibly adapted to new tasks.

The same is true for our automation solutions. They have been designed to optimise your production process and provide maximum added value. The results are maximised effective machining time, optimised throughput and increased production output.

We provide automation solutions ideally geared to your requirements that are continually enhanced and refined. The resulting advantages in terms of cost savings and safety are passed on to you directly.

Solutions range from simple pallet pools to pallet rack systems through to flexible robot cells for complete workpiece handling.

automation

SoLUTionS FoR incREaSED EFFiciEncy

1

4

5 6

2 3

1 Manual supply via roller conveyor

2 Fully automatic loading via travelling robot

3 Pallet rack system

4 Pallet and tool automation system

5 Rotary pallet magazine

6 Semi-automatic loading using balancer

26 H series

HELLER Services

EnSURing MaxiMUM pRoDUcTiviTy

HELLER standard rebuild packages

To increase the efficiency and productivity of your HELLER machines, HELLER is offering a wide range of standardised rebuild packages. With these packages HELLER is providing a fitting solution to your optimisation requirements, e.g. when adapting the machines for a new machining task. They cover the following areas:

Machining unit

Media supply

Measuring probe

Process optimisation

Safety guards/machine frame

Software/control

Workpiece management

Tool management

Increase of energy efficiency

HELLER retrofit – renewed productivity

To get existing equipment ready for new production tasks, we provide all relevant aspects of retrofitting:

Condition check and disassembly

Overhaul of the basic machine

Overhaul of assemblies

Retrofit of control

Retrofit of control cabinet and replacement of cabling

Replacement of covers and safety guards

Acceptance at factory prior to delivery

The result is a machine that is as good as new, providing an increased level of productivity and safety. The benefit to you: a retrofitted machine is backed by the same warranty, warranty regulations and service availability as a new machine.

HELLER training

The HELLER TrainingCenter offers numerous practice-oriented training courses, effectively qualifying your staff for working with a HELLER machine. For this purpose we provide basic and advanced courses in the following fields:

Operation

Programming

Maintenance

If required, HELLER Services can arrange customer-specific training – also at your premises. The contents of these premium training courses are tailored to the specific requirements of your company and cover all specialist fields of HELLER (technology, control engineering and machine technology).

In global competition, maximum productivity is considered the key to success in the metal cutting industry. Several aspects play a role in achieving this: in addition to the optimisation of the manufacturing processes, the most important aspects are the reduction of unscheduled downtimes and increasing machine availability. That is why HELLER machines and the services provided by HELLER Services go hand in hand. With a global presence, quick response times and qualified customer care HELLER Services ensures highest machine availability over many years. For you we are offering a comprehensive range of services:

HELLER TpS – modular service packages

For optimal support in maximising your productivity HELLER has developed the modular TPS (Total Productive Services) range of services. It comprises various service packages which integrate seamlessly into your production system – always with due consideration of your maintenance strategy. You decide which one of the three packages is ideal for you:

TpS performance package:Annual manufacturer inspection

TpS Maintenance package:Annual manufacturer maintenance

TpS Full Service package:All inclusive

28 29H series H series

HELLER solutions: knowing how it’s done.