ROBOFORM

350 S550 S

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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

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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

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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

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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.

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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

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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

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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.