In addition to energy and raw materials, floor space in manufacturing facilities is now incurring high costs. Therefore, the experts at Carl Benzinger GmbH, a manufacturer of high-quality precision turning and milling centers, have developed the particularly compact 5-axis machining centers of the Compact5 series. With a footprint of only 1.4 m², they can flexibly process small, complex components fully automated, from single pieces to medium series. This particularly applies to components for jewelry and watches, as well as for medical technology and precision mechanics. The 5-axis machines can even correctly orient, set, and mount diamonds and gemstones on watch cases and jewelry in the automated manufacturing process.
Marcel Elsäßer, Managing Director at Benzinger in Pforzheim, says: "With the Compact5 machining centers, we have realized stiff and highly accurate machines with high drive power and fully integrated automation for the first time in an extremely compact design in our 110th anniversary year. In their features and performance, they are on par with proven, but significantly larger machines – for example, our 5@Work. However, due to their very compact, highly integrated structure, they require only minimal floor space."
Productive through high performance
To manufacture economically and productively, the Compact5 5-axis machining centers are equipped with industrial, water-cooled main spindles. These have a drive power of 6.2 kW at speeds of up to 50,000 min -1. They accommodate tools in rigid, robust, and industrially proven HSK-E25 tool holders. In these holders, tools can be clamped either mechanically (collets, Weldon) or thermally (shrink fit). This allows for the full drive power to be utilized for efficiently machining even challenging materials, such as titanium, stainless steel, and ceramics.
The guides and drives of the swivel and feed axes are also designed according to industrial criteria. This significantly contributes to the fact that the compact 5-axis machining centers Compact5 can operate reliably and process-safely in a productive manner over very long periods.
Integration minimizes space requirements.
A significant advantage of the Compact5 machines is their high degree of integration. All components required for automated and unattended manufacturing are located within the enclosure. This includes the workpiece storage with a total of 64 positions, designed as a carousel around the Z-axis column. It accommodates workpieces – both raw blanks and finished components – on universal and standardized carrier pallets in a chaotic mix. For raw blanks and workpieces, Benzinger manufactures individually tailored trays using 3D printing technology.
With the option "Mounting of gemstones," the proven gemstone magazines are also integrated into the machine and transported. In addition to these and the workpiece carriers, the magazine also stocks clamping units, such as zero-point clamping systems and various clamping collets, which are also automatically exchanged in and out.
A gripper removes the workpieces and clamping systems from the magazine and feeds them to the machining spindle. In the machining spindle on the rotary swivel table, components to be machined are reliably clamped using a zero-point clamping system in either pull or push collets, jaw chucks, or clamping sleeves. Alternatively, the Compact5 5-axis machining centers can also manufacture from bars (up to 14 mm in diameter and a maximum of 145 mm long). The latter proves particularly advantageous for jewelry, such as pendants for necklaces. Depending on the workpiece geometries, Benzinger's 5-axis machining centers operate unattended over multiple shifts.
The tool change magazine, with a total of 70 positions, also contributes to this. The Compact5 machines automatically change the necessary tools from this magazine. Minimal non-productive times are ensured by positioning the tool magazine to the change position for the tool to be replaced during processing.
To minimize setup and downtime, the experts at Benzinger have additionally implemented a workpiece and tool change that is carried out parallel to the main time. Through a lockable opening in the enclosure, operators can change workpieces and tools in the respective magazines during main time.
Highest precision
Regarding the accuracy and stability of the innovative 5-axis machining centers, Sascha Jentner, Application Technology & Technical Sales of Jewelry Machines at Benzinger, explains: "Our new 5-axis machining centers Compact5 are built with the same solid and industrially proven components as our previous precision machines."
Thus, we can ensure that the compact machines manufacture with the highest precision for many years. This means that they can also process small workpieces with diameters or edge lengths of only a few millimeters to tolerances in the IT 5 range.
For process-safe manufacturing with the highest precision, the Compact5 5-axis machining centers are additionally equipped with a laser measurement system. After tool changes, it measures and verifies the tool geometries and dimensions, and also detects tool breakage. This is particularly essential for tools with the smallest diameters. It prevents the production of scrap due to inaccurate or even damaged tools.
When machining watch components and jewelry made from high-quality, expensive metals, it significantly helps to avoid costs and delays in processing.
Digitally networkable
In order for manufacturing companies to operate not only process-safe and unattended but also according to the Industry 4.0 concept in a smart factory, the Compact5 5-axis machining centers from Benzinger are optimally equipped with the latest control technology. They feature interfaces according to the OPC-UA standard, allowing for seamless networking with higher-level planning and control systems and other machines.
"By investing in our compact 5-axis machining centers Compact5, which are equipped with state-of-the-art drive and control technology as well as mechanics, manufacturing companies are optimally and future-proofly prepared for the economical and efficient production of watch cases and jewelry," summarizes Marcel Elsäßer the advantages of Benzinger's precision machines.
High-quality complete equipment at a glance:
5-axis machining centers Compact5 from Benzinger:
- minimal space requirement of only 1.4 m² due to the highest integration of all automation components within the enclosure
- Working area Automation: up to 45 mm x 55 mm edge length (e.g. watch cases), up to 25 mm high
- Processing optionally of individual pieces on pallets or from the bar.
- 64 positions in the workpiece storage with automatic workpiece change for unattended production.
- 70 automatically interchangeable tools in the tool change magazine
- Laser measurement system for checking and measuring exchanged tools
- Accuracy better than 3µm across the entire working range.
- high-quality, industrially proven mechanics and drive technology
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