WIXLIB

ROBOFIL240 CC440 CC640 CC

ThebenchmarkContentsThe benchmarkApplicationsPerformanceThe mechanical basisCertified accuracyUnique characteristicsThreading functionalitiesCustomized automationA more economical machineThe CC generatorThe spark adapted to materials34-56-1589101112131415Safety and comfortUsage safetyThermoCut SystemThe CNC CT-MillenniumCommunication possibilities16-2118192021EXPERT systems22-23The rangeROBOFIL 240 CCROBOFIL 440 CCROBOFIL 640 CC24-25252525Technical specifications26-27The ROBOFIL 240 CC, 440 CC and 640 CC(ROBOFIL CC) fulfill the wishes of any wire EDMmachine user – to cut faster and obtain excellentaccuracy while maintaining the mechanical andmetallurgical properties of the cut surfaces.The CC spark generator achieves this performance,which ensures a considerable gain in productivity.This increase in productivity is evidently noticeablewhen high cutting speed is the most importantcriterion but also when very precise tools can bemade in less machining passes than before. Thisresults in real benefits that can be seen in the mostdiverse applications.3

ApplicationsGeneral mechanics, molds, cutting tools, extrusiontools, sets tooling, etc.4

Progressive die for element of an electric componentExtruder conformer for a plastic section forComponent of a guidance systemImprint of a mold with pin holdera PVC window frame5

PerformanceThe6 facets of performance7

The mechanicalbasis1zone 1zone 2The mechanical design is that of thefixed bench, combining robustnessand accuracyThe part to be machined restsdirectly on the interdependentfixed table of the polymer concretemain frame. This design, where thepart is static, enables very heavyparts to be loaded without affectingaccuracy. The precision componentsof the machine are used solely tomove the wire guides. Protectedfrom dirt, shocks and stresses,they permanently work in an idealsituation to ensure durable accuracy.Accuracy guaranteed for lifeTo obtain durable accuracy, onlydirect measurement of positions bylinear scales is truly effective. Thissystem enables the actual movementof the slide to be checked directly. Iteliminates all the classic errors thatarise from the ball screw, such asbacklash on reversal, expansion orwear. Accuracy does not vary overtime and no subsequent calibrating isrequired.Greater thermal stabilityThe main frame of the machineis made of polymer concrete. Itsthermal expansion is 25 times lessthan that of cast iron. This materialis also a good electrical insulator,which protects the whole of themachine from potential currentleakages. These are often the causeof corrosion, which is particularlydestructive for the machine tool.The linear glass scales measure theposition with extreme accuracy2stopPosition reached?yes1CNC orderMOV X10no3zone 1zone 2Movement of the axis(encoder motor)Accuracy guaranteedfrom 1 to 6600 lbs.workpiece weightzone 1zone 2Linear glass scalesMachiningGuide waysDirtBall screwRisks of collision84Checking theposition (linearglass scale)

CertifiedaccuracySystematic laser checkTraditional Swiss designand manufacturePerformances of the ROBOFIL CCmachines do not change even afteryears of use. This longevity is due, toa great extent, to the quality of themanufacture. The very high accuracysurface grinding of the guide andassembly surfaces contributes to thisdurable accuracy.Surface grinding of the guidesGuaranteed accuracy of movementsEach machine is subjected to a lasertest, which checks the machineaccuracy to be in accordance withthe VDI 3441 standard. This standardrequires that all axes position withinthe specified tolerances.Checking circularity and pitchto confirm accuracyThe mechanical design of theROBOFIL CC machines ensures veryhigh pitch and circularity accuracy.This is measured and checked inaccordance with the ISO 230-4standard.Circularity measurement of4 in. diameter circles9

Uniquecharacteristics2Cutting tapers up to 45 whatever the height of the part (up to 20 in.)Totally submerged wire cutting ofparts up to 20 in. tallThe powerful CC generator, which isvery effective with tall parts, as wellas rapid filling and emptying of thedielectric tank, make the ROBOFIL CCmachines very productive and welladapted to EDM tall parts, which arereally common in the mold, plasticextrusion or general mechanicsindustries.QUADRAX 45 up to 20 in., a uniquecapacity for tapered machiningThe ROBOFIL CC machines are themost flexible on the market, capableof cutting tapers of 45 whatever theheight of the part (up to 20 in.).The principle of crossed doubleguidance of X, Y and U, V axes, whichare independent and have the samedimensions, enables large tapermachining and therefore enables thepotential range of applications withwire EDM machining to be expanded.Despite the considerable size of thetank, it takes less than 30 secondsto completely submerge an 8 in. tallpart.Ergonomic remote controlMachining in taper mode of –45 to 45 of the whole height of the part (as an option)10

Threadingfunctionalities3Threading performance improved by new functionalitiesThe performance of the machine isclosely linked to the large numberof machining technologies available.In fact, this series has around fiftymachining technologies enablingthe machine always to be usedto optimum effect with variousmaterials and various types ofspecialized or inexpensive wire.Performance can thus be perfectlyadapted to the needs of the user,who will benefit either from thespeed, the quality of machining orthe reduction in operating costs.1. Hole search during threadingFurthermore, it is possible toprogram the hole search. Activationof this function can be programmedby a specific code. The machineattempts, if necessary, up to eightsuccessive threadings over a circulartrajectory around the initially definedpoint.2. Automatic detection of a missingthreading holeIf the start-hole has been forgotten orif it is not located in the programmedposition, the machine movesautomatically towards the nextstart-hole. This ensures unattendedmachining overnight or during theweekend.3. Non-contact search beforemachining launchFor the start-up of machining, thewire cannot touch the part. If thishappens, there will be a short circuitand the spark machining cannotbegin. Now it is possible to move thewire away from the part in a helicaltrajectory until there is no contact.Machining can then begin.1. Example of successful threading after the sixthattempt4. Threading and rethreading underall circumstances with 0.012 in. to0.004 in. diameter wiresSuction in the lower head safeguardsthreading. Furthermore, it is possibleto program the filling height of thetank to the threading, which enablesdifficult threadings to be performedsuccessfully.3. Removal of the wire in a helical trajectoryFirst hole is threadedthanks to the fl ushingabc2. a) The start-hole is offsetb) Automatic detection of the missing threadinghole. Movement towards the next start-holec) Threading and rethreadingSecond hole is threadedthanks to the suction4. Threading with the tank full or partially fi lledsaves time emptying and fi lling the tankbetween several cavities to be threaded11

Customizedautomation4Integrated automation for pallet changesProgressive investmentThe ROBOFIL 240 CC and 440 CCmachines are built to be automated.The ROBOFIL 240 CC and 440 CCmachines leaving the production siteare built to be equipped with severalautomation solutions existing onthe market. They can be adapted atthe production plant or later at thecustomer’s location; the process issimple, fast and economical, enablingthe user progressively to invest intoautomation.Rotary axesCharmilles offers various types ofrotary axes totally integrated into thenumerical control. Their installationis very simple. Rotation controlledsimultaneously with the movementof the X, Y, U and V axes duringmachining is also possible. Thisfunction enables complex shapesto be produced, which would beotherwise unfeasible.The tank of the machine is equippedwith a pre-cut opening at the plantIntegrated automationCharmilles has a range of standardworkpiece changers allowingmaximum use of the machine withouthuman intervention. The automationsolution offers maximum flexibility.This intensive use of the machinereduces production timelines, whatleads to higher production output perhour while reducing operating costs.Workshop managerThe SIGMA workshop planning andmanagement software ensures,with great simplicity, optimum useof the various production equipmentinto which, potentially, ROBOFIL,ROBOFORM, molding machinesand three-dimensional measuringmachines can be integrated.Furthermore, SIGMA enablescontinuous checking of the state ofprogress and the accounting aspectof the work.12SIGMACAD-CAM3D MEASUREMENT (CMM)ROBOFILGraphic of a cell assembly:The whole workshop is optimally managedROBOFORM

A moreeconomicalmachine5Falling costsThe ROBOFIL CC machines isdesigned to control operating costs,using inexpensive wires and areduced filtration cost. Along withlow electrical consumption, thismakes the ROBOFIL CC machinesparticularly economical to use.Optimum filtrationThis series offers a filtration systemequipped with four filters. The largerfilter surface increases the capacityof the filter life, what leads intolower hourly cost of filtration. Theminimum flow of dielectric required,provided in the past by two filters, isnow provided by four. Therefore, it ispossible to lower the cost of filtrationby 25%.Controlled electrical consumptionElectrical consumption of theCC series is less than that of theother EDM machines. In fact, theCC generator enables the dischargeof each spark to be managed inorder to get the maximum powerpossible. The machining speed istherefore maximized and electricalconsumption minimized.:aZXig XVa Xdchjbei dc888dckZci dcVaIf CC speed Conventional speedWith 4 filters (standard), it is possible tolower the cost of filtration by 25%13

TheCC generator6The generator for all situationsThe ROBOFIL CC machines areequipped with a latest generationspark generator. Its unique designuses modern and powerfulelectronic components, whichenable new forms of spark to begenerated. Five years on, thisdigital generator is still unique andunequalled.Besides the fact that this generatorhas anti-electrolysis technology,it eliminates thermal effects,such as redeposition (also called“white layer”) as well as surfacemicrocrackings, what helps to increasetool life.Over 47 in2 / hour at top speedThe CC generator, can reach, cuttingspeeds greater than 38 in2 / hourunder industrial cutting conditions.The ROBOFIL CC machines canthread and rethread stratified wiresessential for fast machining speedsand high productivity.Time saved on roughing cutsThe ROBOFIL CC machines areequipped with the most powerfulgenerator ever manufactured byCharmilles. The high intensity sparksof the CC generator allow high speedcutting of tall parts.HeZZY888dckZci dcVa Z \]iTime also saved on finishing cutsWhatever the quality of finishrequired, the CC generator is faster.The high frequency finishing settingsreduce the number of skim cuts toachieve fine finishes.Gdj\] c\GV; c h] c\8dckZci dcVa88I bZ hVk c\14I