Friday, 28 February 2014

Matrix 1000 Dynamic - Machining centre with moving bridge

Machining accuracy and speed, these are the strong points of the Matrix 1000 Dynamic, the Breton gantry-type machining centre. The solutions adopted to assure high performance and strength include the use of high power, high torque electrospindles, and a hybrid structure (Metalquartz®) in electro-welded steel and a quartz-polymer matrix composite material.

When machining medium-large size parts it is essential to be able to rely on a machine tool offering excellent structural rigidity. The concept of "broad shoulders" encapsulates the core construction philosophy of the Breton Matrix 1000 Dynamic.
The company, based in Castello di Godego (TV), uses the experience gained in fifty years in the industry to produce gantry-type machines with moving bridge supported on shoulders that are large (for milling of large size parts) and extremely sturdy (to guarantee high chip removal volumes without any negative effects).

For all materials
This 5-axes gantry-type machining centre with moving bridge was designed by Breton to meet new requirements associated with high speed machining of large, complex parts for the aerospace and automotive, die-manufacturing and design industries. The Matrix 1.000 Dynamic has a 2,200 mm X-axis travel, 1,000 mm Z-axis travel, and a Y-axis travel that ranges from 2,500 to 6,000 mm.
In addition to the generous working range, one of the characteristic features of this machine is its ability to mill parts made of various materials, namely steel, aluminium, resin and composites.


This machine in fact can be fitted with a vast range of electrospindles with continuous power outputs of up to 40 kW and torque outputs of up to 137 Nm, which combined with a rotation speed of 28,000 rpm offers a notable milling capacity. The software-controlled compensation of the electrospindle’s natural thermal expansion, and its thermal stabilization guarantee high precision machining.


These spindles are housed in the cast iron dual fork head, which guarantees high structural rigidity and an excellent vibration damping capacity. The direct drive twist head, positionable at any angle of its operating field thanks to powerful hydraulic brakes, makes it possible to use spindles with a continuous power output of up to 40 kW and torque of 51 Nm or 100 Nm and is able to reach speeds of up to 18,000 rpm, to the benefit of the chip removal capacity and surface finish quality, also on complex profiles.

Alternatively, the electrospindle with 20 kW power output and continuous torque of 38 Nm in S1 is the best choice for high speed milling of steel and lightweight alloys, from roughing to precision finishing, thanks to the maximum speed of 28,000 rpm.

Innovative structure
An interesting feature of Breton machines and of the Matrix 1000 Dynamic in particular, is represented by the strong shoulders produced using innovative Metalquartz® technology: a sandwich structure made of stabilized arc welded steel, with ribbing embedded in a quartz polymer matrix composites. This exclusive technology ensures a very high structural rigidity and vibration damping, which guarantees a better surface finish and a longer service life of the cutting tools and parts subject to wear. In addition, this composite material has the same thermal expansion coefficient as the steel parts of the structure, thus preventing dimensional changes in the structure.
The face of the bridge is equipped with a rigid guideways-holder  carriage composed of an electrowelded and normalized steel structure. The carriage travels transversely across the bridge on recirculating ball shoes moved by a system with a ground ball screw with double preloaded ball nut, driven by a brushless motor. To guarantee the highest accuracy, the position of the carriage is read directly by an ultra-high precision, micrometric resolution Heidenhain pressurized linear encoders.
The guideways are balanced by two cylinders permanently charged with inert gas and positioned symmetrically at the side of the structure. A system with emergency load-holding brake mounted on the vertical ways ensures the highest safety in the event of a power loss or loss of the cylinders' gas supply.
The head structure is equipped with a three-axis accelerometer that is invaluable for tool balancing control and essential to monitor possible collisions and reduce potential damage in the event of accidental impact, also during manual operations. The plant is supplied complete with software to establish monitoring and trip thresholds.
The quality and precision of the machining work are achieved also thanks to the thermal symmetry of the structure and to the action of the temperature stabilization system for the Z axis ball nuts and bearings and the axis drives, which keeps the temperature of these parts aligned with that of the machine structures.

The carriage and beam travel on properly dimensioned recirculating roller guideways to ensure machining accuracy and stability. Linear axis speed can reach 60 m/min thanks to the digital drives with brushless servomotors and the ground ball screw and double preloaded ball nut assembly. To guarantee the highest accuracy, the position of the beam and carriage is read by optical scales.
For the maximum safety, the machine is enclosed by steel framed guarding that is openable at the front thanks to the presence of a series of manually operated sliding doors equipped with large inspection windows. During machine operation the doors are secured in the closed position by electric safety locks.

Customization
Performance at a dynamic level, offering high power and precision, are not the only advantages, and the machine can be customized with a series of accessories to meet the customer's specific requirements. In this context Breton offers tool magazines with a rapid tool changer to reduce tool change times. These magazines are installed outside the work area so they can't come into contact with milling dust or residues, and can be fitted with a system for the automatic encoding of tool data and a chip reader for an even higher level of plant automation.























The standard tool magazine has 30 locations designed to accommodate tools with a maximum diameter of 140 mm and length of 300 mm. The total weight that can be handled, including the tool holder, is 10 kg.
Matrix 1000 Dynamic can also be equipped with a laser probe for tool presetting and a radiofrequency touch probe to acquire the workpiece coordinates and dimensions.
On the basis of the milling operations to be performed, the tool cooling system may use compressed air, a spray mist system, or coolant sprayed inside and outside the spindle at an internal pressure of up to 70 bar.
For customers machining composites and resins we can supply dust extraction systems to install on the spindle nose, in addition to top-roof bellows to isolate the work area from the surrounding environment, protecting the operator from any noxious or harmful elements. The fact that all the kinematic mechanisms have been located at the top of the machine is proof of the focus on operator safety. Finally, to meet every possible application requirement, the Breton Matrix 1000 Dynamic can be configured for pendular machining in two work areas.


The numerical control is the Siemens 840D Solution Line unit: this model, which is an evolution of its 840D predecessor, incorporates a series of functions designed to reduce total energy consumption of the machine without limiting power output or performance. The numerical control also incorporates the remote assistance package, software for management of the Blum laser tools presetting system and the workpiece touch probe management software.

The machine is equipped with a control console at the front, with function pushbuttons, LCD display and the numerical control keypad. In addition to the main control panel, the machine is supplied with a remote handheld control unit incorporating control buttons to select axis movements, spindle stop/start buttons and a handwheel to move the axes. The handheld control unit, which is cable-connected to the CNC unit, can be brought to any position in the working area by the operator, thus simplifying procedures for positioning and zero setting of the workpiece.


Demanding applications
Matrix 1000 Dynamic is a gantry-type machining centre with travelling bridge, designed and built in particular to meet demands for high speed milling for the production of die tools and design parts, and hence for complex and large size workpieces.
The carriage and beam travel on properly dimensioned recirculating roller guideways to ensure machining accuracy and stability. Linear axis speed can reach 60 m/min thanks to the digital drives with brushless servomotors and the ground ball screw and double preloaded ball nut assembly
.

Properly sized structure
An interesting feature of Breton machines, and of the Matrix 1000 Dynamic in particular, is represented by the strong shoulders produced using innovative Metalquartz technology: a sandwich structure made of stabilized arc welded steel, with ribbing  embedded in a quartz polymer matrix composites.
This exclusive technology ensures a very high structural rigidity and vibration damping, which guarantees a better surface finish and a longer service life of the cutting tools. In addition, this composite material has the same thermal expansion coefficient as the steel parts of the structure, thus preventing dimensional changes in the structure.

Power and torque
The spindles installed on the Matrix 1000 Dynamic are mounted on a cast iron dual fork head that guarantees high structural rigidity and excellent vibration damping capacity.
The direct drive twist head, positionable at any angle of its operating field thanks to powerful hydraulic brakes, makes it possible to use spindles with a continuous power output of up to 40 kW and torque of 51 Nm (28,000 rpm) or 100 Nm (18,000 rpm), to the benefit of the chip removal capacity and surface finish quality, also on complex profiles.


Identity card
Name: Matrix 1000 Dynamic
Occupation: 5-axes machining centre with moving bridge
Manufacturer:
Breton Spa
Via Garibaldi, 27
31030 Castello di Godego (TV) – Italy
Tel. +39 0423 7691
Fax +39 0423 769600
E-mail: mail@breton.it
www.breton.it


Technical specifications:
Work area

X” axis travel
2,200 mm
Y” axis travel
2,500...6,000 mm
Z” axis travel
1,000 mm
Table surface area
2,000x4,500 mm
Table load capacity
15 tons/m2
Spindle

Power
40 kW
Maximum torque
100 Nm
Maximum spindle speed
28,000 rpm
Spindle taper
HSK - A63
Ram travel
1,000 mm
Ram section
400x400 mm
Axes performance data

Linear axes feedrate (work)
30 m/min
Linear axes feedrate (rapid)
60 m/min
Tool magazine

Number of magazine tool locations
30
Max. tool diameter
140 mm
Max. tool length
300 mm
Max. permissible weight (tool + tool holder)
10 kg
Numerical control

CNC
Siemens 840D solution line
Dimensions and Weights

Footprint
50 m2
Dimensions (LxWxH)
6,800x5,700x5,000 mm
Machine weight
58 tons

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