Tradition and Innovation

Building portal milling machines has a long tradition at WaldrichSiegen, with its roots dating back to 1951. In 1961, WaldrichSiegen entered into a joint venture with Ingersoll USA, thus making a quantum leap towards the manufac-ture of high-performance portal milling machines so far not known in Europe.The milling tools available on the market at that time did not meet the high requirements of these new generation milling machines. Therefore, a new and modern company for the production of suitable high-performance milling tools was built as a Greenfield project in Burbach,Germany, WaldrichSiegen’s present location.Soon thereafter, WaldrichSiegen introduced the use of fully hydrostatic guideways on milling machines, which led to a further pioneering development in the manufacture of heavy-duty, high-performance machine tools.With this new technology it became possible to perform even heavy-duty cutting operations on WaldrichSiegen por-tal milling machines on almost friction-free guideways with unlimited lifetime. We supplied more than 400 machines of this type to customers around the world.

Milling machine, 1953

02 | Tradition03 | Concept04 | Technology

Based on WaldrichSiegen’s wealth of experience, we have considerably enhanced our proven milling machine con-cept, attaching special importance to:§significant increase of performance and torque as compared to all other concepts currently available on the global market§reduction of complexities with the aim to provide efficient and economic solutions§increase of availability while reducing maintenance and repair cost§development of a modern machine enclosure of functional, minimalist design, reflecting our Corporate Design

Standards & Modules

WaldrichSiegen offers a clear-cut, modular machine pro-gram with three machine sizes, covering a complete spec-trum of configurations§torque up to 10.000 Nm§table length up to 12.000 mm, larger tables in double-table design§ram travel between 1.500 and 4.000 mm§integrated rotary tables §tool changer (chain) with 40/60/80 pockets§tool changer (rack) with 80 to 480 pockets

Machine Structure

All major machine components are made of high-quality cast iron and are machined in-house at WaldrichSiegen to maintain the highest precision and quality. The fully hydro-static design in all machine axes guarantees nearly unli-mited lifetime, zero backlash, highest static and dynamic stiffness as well as maximum table load.

WaldrichSiegen hydrostatic worm drives or master-/slave/rack drives ensures high dynamic stiffness of the table drives and for the column drives (for gantry-type machines).Preloaded ball screws guarantee for highly precise posi-tioning of the adjustable cross rail. Electrically preloaded master-/slave drives for Y-movement of the milling unit provide for high dynamics as well as for excellent positio-ning accuracy. Physically induced minimal deflections of the system are compensated by applying compensation curves to the portal and cross rail guideways.Controlled vertical and horizontal heal clearance provides for optimum cutting performance and excellent surface qualities.

ProfiMill | Concept 03

Size 1 Size 2 Size 3

Clearance width

2 - 4 m 2,5 - 5 m 4 - > 10 m

Clearance height

1,5 - 3 m 1,5 - 5 m 2 - > 10 m

Milling power 50/65 kW 70/80 kW 80/100/120 kW

Design table table & gantry table & gantry

ProfiMill series

Masterhead Concept – up to 120 kW at the Tool

Masterhead concepts for milling attachments have been in use for quite some time. Traditionally, large heavy-duty machines had rams with integrated main spindle and tool taper interface, allowing the tool to be mounted directly into the ram. WaldrichSiegen is the first manufacturer, who consequently further developed the Masterhead concept for machines with highest power and torque: the “spindle” is reduced to a simple drive shaft, with substan-tial advantages:§limitation of speed to an technologically reasonable extent allows for large bearing diameters as well as grease lubrication at drives shafts and numerous milling attachments§no temperature increase and thus no geometrical distortion within the ram§long service life of bearings supporting the drive shaft§slip rings or rotary transmissions for liquid media are not required§low noise level due to low speeds in the power train§exchangeable milling attachments for highest performance

§improved overall efficiency§increased availability§decreased maintenance cost

All milling attachments are adapted through the Master-head interface. For high speeds, a universal milling head with exchangeable motor spindle can be adapted. Thus, all required spindle speeds are available. All milling attach-ments can be equipped with life-time grease lubrication. Additional cooling and lubrication circuits are not required. Also, the number of media transfers at the Masterhead interface can be reduced. The result is a reduction of downtime and an improvement of overall machine availa-bility and maintenance cost. The Masterhead interface is provided with four self-locking clamping elements with a high clamping power of 120 kN at relatively low hydraulic pressure of 80 bar.

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Drive Concepts

The machines of the Profi Mill series are equipped with a motor gear box with an ideal speed-torque characteristic. The 2-step planetary gear unit is integrated into the ram. Water and oil cooling provides for best possible thermal behaviour of the unit.

Located in the upper part of the ram, the motor gear box is accommodated in a so-called media transfer plate. Due to its special design, the media transfer plate prevents any potential heat transmission into the ram.

The media transfer plate serves as distribution block for all media, which are forwarded through hoses to the ram’s Masterhead interface, thus providing for:§ minimum installation efforts and cost§no leakages§minimum maintenance efforts

Speed-torque diagram for ram – 600 x 600 mm

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Hydrostatic Guideways and Drives

WaldrichSiegen has continuously further developed hydrostatic worm drives and guideways for heavy-duty cutting processes. We have gained excellent ex-pertise in both the engineering and the production of hydrostatic worms and racks. The dynamic stiff-ness of all elements has been extremely enhanced.

The hydrostatic guideway principle was also applied to the guideways of the ram. The square-shaped ram is completely hydrostatically guided and thus achieves highest stiffness combined with unsurpassed damping characteristics.

Up to 4 individual hydrostatic guideways with pump per pocket systems on WaldrichSiegen tables allow for loads of up to 40 tons per meter of table length, cor-responding to workpiece weights of up to 500 tons.

The portals of the gantry machines are also equipped with hy-drostatic guideways and worms. The Y-axis (saddle on cross rail) is driven by an electrically pre-loaded master-/slave drive.

Hydrostatic worm

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Customized Solutions

Especially with regard to larger machines, the gantry de-sign offers advantages due to considerably reduced space requirements. State-of-the-art control concepts with ma-ster-/slave drives assure smooth and accurate movement of all axes. The WaldrichSiegen hydrostatic worm drive for portals or tables assures highest static and dynamic stiffness.

The high level of modularity of the ProfiMill concept allows for optimized adaption of the machine to individual requi-rements of customers’ workpieces and installation sites.

Modular design of the individual modules:§clearance width: in steps of 500 mm §rotary tables: in steps of 500 mm§clearance heights: in steps of 500 mm§ram travel: in steps of 500 mm§table length: in steps of 1,000 mm§milling power: 50 to 120 kW§tool changer: 40 to 480 pockets

The long-term experience with milling machines, those in-stalled at our customers’ sites and those we use for our own Turbine housing

production purposes, are the basis for WaldrichSiegen’s competence in specifying and designing these machines to be tailor-made for our customers’ applications. In this context, the later economically efficient use of the equip-ment is an important criterion.

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Attachment Changer

The diversified range of different workpieces requires a large number of optional attachments. Depending on the application, the required attachments are automatically exchanged via an attachment changer.

The changing carriage moves on a guideway system. The exact positioning of the changing carriage relative to the ram is carried out via a servo drive. The transparent cover of the changing unit does not only protect the Master-head interfaces from contamination, but at the same time emphasizes the consistency of this machine concept’s design elements. The attachments are accessible for in-spection and maintenance during machine operation.

Universal fork head with electro spindle

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Tool Changers

In case only a small number of tools is required, a chain type tool changer is used (40 to 120 pockets). The chain type changer is installed at the side of a portal column. A gripper system is handling the tool changing process. If a larger number of tools is required, a rack type tool changer is available (80 to 480 pockets), which provides for optimized utilization of storage space. Tools with a ma-ximum weight of 75 kg, a maximum length of 500 mm and a diameter of 360 mm can be stored. Individual pockets for special tools can be provided for. Other tool changing systems are available upon request.

A separate tool loading station allows to prepare the maga-zine with new tools for the next workpiece to be machined parallel to the production process. The Waldrich- Siegen tool management system operates indepen-dently from the machine control and is characterized by§optimized utilization of storage space including collision check §monitoring of storage capacity§tool life time control§additional data interfaces to external devices (e.g. CAM system, tool presetting, machine control via Ethernet)§optional data input devices: barcode scanner or identification chip, serial interface

Tool changer with manipulator, spindle positions infinitely variable between 0 to 90°

Tool magazine and manipulator

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High Availability

Centralized transfer blocks for different required media reduce the maintenance-intensive hose connections to a minimum. Easily accessible valves, pumps, pressure and temperature switches as well as terminal boxes facilitate fast and easy access to all necessary maintenance units. A centralized locking system ensures easy opening of the cover of the milling unit in a minimum of time, thus redu-cing maintenance times.

With the Masterhead concept main spindle, tool taper and pre-loaded bearings within the ram are no longer required and potential failure sources are thus eliminated.

These are only a few examples reflecting the importance we attached to user-friendliness and easy maintenance when designing the ProfiMill series.

Controls

The ProfiMill machines are available with Siemens 840D sl control or, as an option, with Fanuc 30i control especially for the Japanese and the US market.

As for machines equipped with Siemens 840D sl, these are also provided with the Siemens-Sinamics drive con-cept. Digital interfaces with “drive-cliq” function allow for simple configuration and diagnostics.

Operator panels and operator platforms are designed precisely to our customers’ requests.

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Machine Design & Enclosures

State-of-the-art machine concepts must comply with the applicable safety regulations, must operate at low noise levels and must be ergonomically designed. Last but not least, these machines should also address the operator on an emotional level. The machines of the ProfiMill se-ries fulfil these requirements in each and every respect. To achieve this, WaldrichSiegen had to do quite some pioneer work.

The machines’ color concept reflects the rules of our cor-porate design, its new shapes and contours provide the machine with a functional elegance and the transparent enclosure allows for optimum view into all working areas.If applicable, safety standards require a full enclosure of the machine, this is realized with a glass enclosure concept.

Frameless sandwich glass elements were required to pass extensive safety testing procedures before they were ad-mitted for use with our ProfiMill machines. Standardized elements in different configurations and shapes allow the machines to be adapted to local conditions in an econo-mical way.

Standard glass element as sliding door with position-controlled drive

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WaldrichSiegen Werkzeugmaschinen GmbH · Daimlerstraße 24 · 57299 Burbach · GermanyT: +49 (0) 2736 493-02 · F: +49 (0) 2736 493-559 · waldrich-siegen.de Id

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