3 axis rotary table factory

Rotary table in market mainly includes 4 kinds of mechanism that is worm gear, roller cam, DD driver and harmonic structure. The following is the introduction:

1. worm gear: it’s one of  the most popular structrue in NC rotary table  because of its irreversibility and costs.The worm is generally made of bronze, but the wear resistance is poor. In order to improve the service life, some manufacturers use the alloy steel.

3.DD motor: it’s the most efficient rotary table with the highest precision. It has the highest precision because it has no mechanical structure, which is directly driven by motor , no reducer. It has high technical difficulty and high price. It is generally used for five axis machine tools.

TJR’s standard tilt rotary tables offer several options for turning your traditional 3 axis milling machine into a 5 axis machine for a portion of the cost of a new full 5 axis machine.

The FAR-Series pneumatic brake tilt rotary table line and is offered in multiple sizes and configurations and is available in single arm or dual arm type.

The FHR-Series is a dual arm, hydraulic brake tilt rotary table line offered in multiple sizes and configurations. This series has (3) independent braking systems, and max tilting angle +/- 110 degrees.

The FAR and FHR Series standard tilt rotary tables are capable of being fully integrated into your current machine control so you can utilize as a full rotating and tilting axis for true 5 axis work. It is also capable of being used as a full 4th and 5th axis connecting to TJR’s DAC (Dual Axis Controller) in the event that you need to utilize the unit on multiple machine tools. All are manufactured with large-diameter radial-axial preloaded bearing system for high rigidity that can perform light or heavy cutting.

Eight-spindle rotary dividing table with a faceplate with a diameter of 36 mm. In use, a workpiece with a maximum weight of 1 kg per spindle can be machined.

* pL SOLUTIONS Shanghai Co. Ltd is part of a network of locally owned, independent representatives and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS India/SEAis part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS Italia is part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS Japan is part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS USAis part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS India/SEA is part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS USA is part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS India/SEAis part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS South Korea is part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS India/SEA is part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS USAis part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

* pL SOLUTIONS India/SEAis part of a network of locally owned, independent distributors and service specialists dedicated exclusively to the sales, service, and support of CNC rotary tables designed and manufactured by the Swiss firm Peter Lehmann AG (pL)

Rotary Tables allow machine shops to increase their production and meet their customer’s demand for quicker lead times while manufacturing increasingly complex components.

Production of a machine shop is restricted by the limited floor space the facility has. Due to this issue, Hyfore Workholding has seen an increase in customers looking to invest in 4th axis and 5th axis rotary tables.

A typical customer would be a CNC machinist who already has a 3-axis machine but is looking for greater flexibility, without having to spend a considerable amount of money on a 5-axis machine. For example, the software, motors, cables and rotary table could cost between £25k and £30k, compared to a new machine starting from £140K.

UCAM’s CNC Rotary Tables are renowned for their quality, reliability and performance. The tilting capability allows components to manoeuvre 360 degrees, so that the cutting tool can machine on all five sides, reducing secondary and third operations in the process.

CNC Rotary tables arean effectivecomponent for increasing production machine shops. Adding an extra dimension to your capabilities at a relatively low cost.

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The same Stallion Trunnion Table, up to eight times the productivity. ​Built for the highest production jobs. Available in 3 to 8 sided configurations.​ Complete solutions available to maximize your VMCs throughput.​​ Also made for any rotary table and machine tool on the market.

A CNC rotary table is the precision positioning accessory that can provide a reliable 4th axis or even 5th axis for modern machining centers. Utilizing a computer-controlled rotary table can turn the original 3-axis machine tools into 5-axis CNC machines, expanding the accuracy as well as decreasing the costs while performing complex machining operations at one time.

A CNC rotary table is the precision positioning accessory that can provide reliable 4 or even 5 axis cutting operation capabilities for modern machining centers. Utilizing it can turn the original 3-axis machine tools into 5-axis CNC machines, expanding the accuracy as well as decreasing the costs while performing complex machining operations.

Rotary tables typically have rigid frames and coatings, and also excellent torque capacity, which makes the small device flexible and effective for a wide variety of turning, milling, drilling, and more metalworking operations. The easy setup and seamless interface allow the operators to easily add the rotary table to fit their 4-axis or 5-axis applications. .

The working principle is similar to the basic rotary tables, which is to support the workpiece by accurately rotating the workpieces on the axis in order to locate the parts for high precision tooling. Under rapid rotation, which is driven by CNC instructions, the cutting tools of larger machine tools or machining centers can remove the material and add the feature to the products at exact intervals. On rotary tables, there are vertical and horizontal axes for various tools to perform these high-performance metalworks. To enhance the accuracy and flexibility, there are models that employ additional dividing plates and come with additonal material handling mechanisms and features.

Since 4-axis and 5-axis machining is increasingly popular today, adding the CNC rotary table as the 4th axis is an ideal solution to easily open up more complex machining options at a lower cost. Due to the arrangement, they are widely also called the 4th or 5th axis or tilt rotary. The 4th axis, which is the rotational operational direction, is added to the original three linear axes which are known as X-axis, Y-axis, Z-axis. In some cases, there are two rotational axes add to the original 3-axis machining center, achieving utmost accuracy as well as effective multiple face cutting to reach the difficult area on the surface. Rotary tables are usually mounted parallel to the ground or the bed, with the platter rotating around the vertical axis, for example with the most common vertical milling machine combination. Sometimes the machining application requires an alternative setup with the table mountet on its end so that it rotates around the horizontlal axis. Often, a tailstock is used in this configuration. Virtually all models today come with a clamping kit to mount it onto the bed of your machine tool.

The function of the high precision rotary table is also to rotate the workpiece so the cutting tool can create the contour we desired out of the workpiece. However, a rotary table with higher precision has the ability to achieve great accuracy just as its name implies. There is also a major misconception between the resolution and the accuracy.

A common example is that if a digital readout displays to four decimal places, then the high precision rotary table must also be capable of achieving the accuracy to that same value. Even though for higher accuracy to be achieved, the resolution has to also be high, but there is no guarantee that the accuracy is going to be high. The accuracy is the concept which is the difference between the actual position and the position measured by a reference measurement device. The feedback mechanism such as the rotary encoder, and the drive mechanism can influence the accuracy of the advanced rotary table.

A CNC rotary table can provide great rigidity for stable machining operations. It consists of the worktable where the metal parts are held, the rigid bearing that withstands the forces and loads during the rotation, the solid base which is used for attaching the rotary table to the machining center or other equipment, the motor, and the CNC system.

The worktable is the tooling surface where the workpieces are machined after accurate positioning. The worm gearing is the core mechanism of the table, which mesh with the steel worm which is submerged in the lubricants. Both the rigid bearings and the worm gears have large diameters. Excellent concentricity is the key to smooth operation, durability, and most importantly, accuracy. Driven by a computer and electric motor, the worktable can position the materials at exact intervals. For more flexible or critical operations, dividing plates can be added to this component.

A CNC system regulates the simultaneous 4-axis motion of the rotary table. The instructions are programmed and transmitted via CAD software, reducing the time for adjustment and monitoring by human workers.

There are currently several different types and models available in the industries. Each of them possess its own traits and abilities. Let us take a look at the most common ones other than standard three axis tables

The 4 axis CNC rotary table will process the workpieces by holding them in the same position while the cutting tool performs along the XYZ plane to trim away the unwanted material. In general, a 4 axis model is very versatile equipment that can be used for several different industrial processes such as engraving curved surfaces, continuous cutting, and intermittent cutting. Besides, people can also add other devices such as cam machining, blade machining, and helical grooves to the 4 axes rotary table. Such a feature is simply impossible to achieve with the machining center which has only 3 axes.

Besides the 4 axis ones, there are also 5 axis models. They have the ability to allow the workpiece to be processed automatically from five sides at one time. people usually utilized the 5 axes rotary table in the industries such as the automobile, the aerospace, and the boating industries. The reason that the 5 axes rotary table is commonly used in heavy industries is that the 5 axis machining is an important technique to be used when the components need better intricacy and quick precision. All of these have more than three axes are called the multi-axis rotary table.

The installation method of the precision rotary table can be horizontal, vertical or inverted. When installed horizontally, the workbench surface is in a flat, vertical and horizontal position. When installed vertically, a rotary table is installed so that the surface of it can run up and down. In the reverse layout, itcan be rotated upside down in a horizontal position. The location of the drive of the rotary table can depend on the mount. The drive can be placed on the back, below, on the top or on the side.

When mounted horizontally, the spinning table top drive is positioned above the table floor. When the rotary table is horizontally placed, the side-mounted drive is located on the edge of the table board. The driving mechanism of the rotary table may be manual, electrical, pneumatic, hydraulic or non-driven. For manual revolving workbenches, release the workbenches and manually spin the workbenches with the crank.

Workpieces are gathered and machined through PC and fully programmed instructions. The 5-axis simultaneous operations will be measurably more reliable than products machined via different technologies. Also, the setup is simple and provides an indistinguishable process in every production cycle, the consistency of the quality of the metal products can be ensured under critical control and precision cutting.

Since the metalwork is driven by software, the preferred frameworks can be programmed and adapted by the rotary table. Saving both the cost and the room makes themis the ideal solution for potential users who don’t want to install larger equipment and new machines which may take up a great room for a wide variety of machining applications.

Another benefit is the utmost movements can be completed precisiely and faster. There are more favorable positions, operation angles as well as accessible machining that can be achieved through the technology. The complex operations are suitable for blade, helical grooves production, and other applications required to add complex features or require critical inspection in machining processes like the manufacturing of aerospace, automotive parts, and scientific equipment.

Addding a rotational table saves time because the extra finishing jobs or other sub-operations can also be performed at one time in the machining center.

A rotary table can be used in many applications including manufacturing, inspection, and assembly. Indicators are used, for example, for assembly, manufacturing, and bottling equipment. They typically use a single item in workspaces or move relatively small layouts of items around stations for sequential work or assembly.

In automated assembly machines, the rotary tables implementation is widespread, and choosing the right mechanism is important for both improving efficiency and reducing the cost of this vital component. This guide discusses two common devices for rotating indexing and offers guidance on the right range. There are several ways to get mass mobilization when it comes to the development of rotary indexing tables. Regardless of whether the load or load in centuries of thousands of kgm2 is incredibly light. When choosing a robust rotary index solution that will match or meet your standards, there are several factors to take into account when spinning, elevating, or pushing.

When determining the influencing factors on the postitioning accuracy, the first thing to look at is the mechanical properties of the table itself. A rotary table contains six degrees of freedom. Each of these movements increases the total risk of positioning errors. Usually, a rotary table is driven by a worm gear, which is connected to the motor through a rotary encoder on the back. The position of the table can be determined by the number of pulses transmitted from the encoder to the control device.

The four main sources of error due to the semi-closed position loop are geometric errors, thermal deformation, elasticity, and wear. The sum of these errors is called angular positioning error. To greatly reduce the angular positioning error, the ideal position for installing the angle encoder is on the rotating shaft under test. The angle encoder is installed under the rotary table, and the rotary encoder is installed under the rear motor, the position loop is now considered a closed-loop system.

In the actual test, by selecting specific components, motion index drive, servo rotary indexer, the measurement accuracy is as high as 5-6 microns. These are not the results approved by Motion Index Drives, but the results of customer certification. When starting and stopping large amounts of data, it is important to know how fast it takes to stop the application with large amounts of data.

Backlash in the positioning process is a big issue – when it comes to the beginning and stopping volumes, it"s crucial to know how quickly you need to avoid the mass of your rotary indexing table applications. In a less rigid system or where there is an increased backlash, quicker start-ups and stops can cause a lot of control issues. When shifting a mass, whether rotary or linear, starting and stopping in a system with several minutes of backlash arc will create a lot of back-and-forth motion within the gearing system. The effect is a power that can be difficult and probably hard to quantify. In comparison, as the gear head is used for rotational applications, the more the mass is from the axis of rotation, the further the backlash is magnified.

The backlash may not be a concern in systems where deceleration times are incredibly long. In the case of cam indexers, there is " Zero Backlash." The cam indexer and rotary table dynamics give an incredibly rigid, highly regulated framework. A modern cam indexer system is capable of withstanding short cycle times with stop times in milliseconds.

So you want to get the smart manufacturing going but are not sure of what to look for in rotary tables. The information provided in this section may be able to help. The primary factor is to determine the mass snapshot of inactivity. This is often overlooked when measuring a rotary table for the machine.

Another significant factor is the size of the workpiece being rotated, including how big it is and how substantial it is. You want your rotary tables to be large enough to handle enormous pieces. This is where tilling rotary tables may become handy so that the pieces can be handled without causing interior harm. They allow the quickening and decelerating of machining at appropriate rates.

The last factor is accuracy, the applications for which, for instance, pivoting a gigantic part to allow welding highlights on it where the individual stop positions can be genuinely free. On an additional note, when choosing direct drive rotary tables, factors that you should consider when selecting a rotary table for your CNC machinery include accuracy, backlash, mass moment of inertia, acceleration and deceleration, speed, and environment.

Cam indexers are an omnipresent tool used for several decades for rotary indexing tables. They are suitable for applications that often index the same angle and need a high degree of accuracy at a relatively low cost. To place the load, a cam indexer uses a mechanical cam. A math curve is pushed onto the cam and provides incredibly smooth and repeatable movement.

Another popular alternative is a fully programmable rotary index table. A rotary table is advantageous in two different situations. Firstly, a versatile movement pattern is important. An example is if two components are running on one computer, each of which requires different index patterns. For incredibly fast placement accompanied by a long period, another condition that matches the servo pointer is. The need to accelerate the camshaft while the cam indexing mechanism was operating before starting the output movement reduced the on-demand cam indexer. Acceleration of the camshaft is possible, but there is a delay before the movement begins. There are realistic restrictions.

With an indexing table, the output rotates as soon as the servo starts moving. This is not difficult for a continuous cam indexer or a zero-backlash servo indexer, but it can also be difficult for an on-demand cam indexer. For applications with high-speed servo indexing, smooth movements are crucial. A zero-backlash preloaded reducer can achieve this. The ideal alternative for correct positioning with high dynamic response would be the zero-backlash reel drive system.

Application parameters, like a moment of inertia, indexing angle, indexing period, and residence time, are required for each indexer style. The rotary indexing table for the application should also be sized correctly by a reputable manufacturer.

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About UCAM: We offer a wide range of CNC Rotary Tables and custom-built rotary tables which can be used vertically and horizontally based on the application. Our differentiation lies in cutting-edge technology, unceasing product innovation, and proactive customer relationship, making UCAM the most preferred brand in the Indian machine tool industry. UCAM"s product line lays stress on quality, reliability, and performance while machining the needs across industries - Automobile, Aerospace, Medical, Mining, Defence, Power Generation, General Engineering and Others.

We’ve all heard the argument. An expensive, highly adaptable machine tool can be less expensive to run, in the long term, because higher productivity will lower costs-per-part. However, getting over that initial sticker shock can be daunting for many manufacturers.

Soukup’s group was one of several participating in Okuma Partners In THINC’s Winter Showcase in Charlotte, North Carolina, in December 2017. The group used the products and expertise of Okuma (machining centers), Hainbuch, Kennametal (tooling), Haimer-USA (shrink-fit toolholders), MP Systems (high-pressure coolant and chiller systems), Lyndex-Nikken (5-axis rotary tables), Blaser Swisslube (ester-based coolant), Siemens PL (systems software), and VMH International (systems integration).

“Success can be achieved when companies that are leaders in their fields work together to solve customer challenges,” says Wade Anderson, Okuma product specialist and tech center manager. “As the aerospace, medical, and energy sectors have increased the demand for complex, high-precision parts in relatively limited quantities, original equipment manufacturers (OEMs) and their suppliers are faced with the problem of justifying the expense of a dedicated 5-axis machine.”

To lower system costs, the partners created a discrete, 5-axis module that could be mounted on a 3- or 4-axis machine. To demonstrate the idea, they used an Okuma GENOS M56O-V machining center featuring a 1,300mm x 560mm table; X, Y, and Z travels of 1,050mm x 560mm x 460mm; a 15,000rpm spindle; and a 32-tool magazine.

At the base of the group’s system is an 8" Nikken, 5-axis rotary table equipped with a wear-resistant carbide worm screw and an iron-nitride worm wheel. The table will hold up to 150 lb and is actuated by servo motors linked to the machine control. Rotation is a full 360°, and tilting extends from 0° to 105°.

“In 5-axis applications, the tolerances are invariably tight,” says Bob Berongi, regional sales manager at Lyndex-Nikken. “The use of carbide and iron-nitride in the worm screw and wheel is essential to maintaining those parameters and to extending the life of the table.”

Soukup adds, “All of us who worked on this project are extremely happy with the results. Thanks to our combined efforts, we evolved a cost-effective system that puts top-line 5-axis performance within reach for our customers. And that is our goal.”Blaser SwisslubeHaimer-USAHainbuch America Corp.Kennametal Inc.Lyndex-Nikken Inc.MP SystemsOkuma America Corp.Siemens NXVMH International

It doesn’t take long after you put your first 5-axis machine into production to realize that you can do more with less, and wish you had done it sooner. While the initial cost of investing in 5-axis machining and programming software may seem daunting and out of reach, it’s important to look at the bigger picture. Some good hard number crunching on your current 3-axis machine performance is an absolute necessity. You’ll need to determine the cost of multiple setups to finish a part, cost of fixturing, cost of scrap and labor, wasted time in re-orienting parts and the lost quality due to having to move the part around multiple times. Sure, the maintenance on a5-axis machineis a little more cumbersome, but in the end, 5-axis machining will help you remain competitive allowing you to expand your markets and take advantage of new opportunities. And, you can expect a quicker ROI due to reduced setup, less part handling, less errors and scrap, shorter cycle times.

Industries and processes that can benefit from 5-axis machining include, but not limited to, automotive, aircraft structural parts, military, highly precise and complex medical devices, energy, firearms, die mold, prototype manufacturing and more. What was once impossible to make on one machine or a single setup, is now a possibility with 5-axis.

A 3-axis machine, the most common type of CNC machine, moves the tool in three linear axes – X, Y and Z. They are easy to program and operate and are a perfect low-cost option for simple geometry parts. However, with only three axes, these machines have limitations. For instance, simple, complex workpieces, or parts requiring a quality surface finish, might require multiple setups or need to be repositioned and clamped into custom-made fixtures, in order to get all features completed, making them more susceptible to errors and economically unfeasible.

With 5-axis technology, you can easily machine all sides of a simple or complex part in a single setup on one machine. Without having multiple setups or reorientation of the tool as is the case on a 3-axis machine, a part can be machined faster with less chance of errors.

The logical assumption is that you’re in business for the long haul. So, if your machine shop is spending more time on setups than on machining, or you’re having trouble increasing production times to meet customer requirements, or if you’re trying to bridge the skills gap,it may be time to consider 5-axis machining.

While you can survive these drawbacks, not investing in 5-axis could prevent your machine shop from new business opportunities not only within your marketplace, but in more lucrative parts manufacturing industries.

Take the medical device industry, for instance. Small medical device parts are intricate in nature and usually require more intensive milling and finishing. While this can be performed on a 3-axis machine, the time for additional setup for the milling and surfacing might be cost prohibitive, and more handling increases the chance for error, possibly resulting in lost opportunity.

Or, what about rapid prototyping? You don’t do that because of the multiple setups on a 3-axis? Well, now with a 5-axis workhorse on your floor, you can provide your customers with prototypes quickly.

Another area for improvement is in the use of the highly reliable hole making process – interpolated holes – which can be refined on a 5-axis. This would eliminate the need to use a tooling hole for component alignment prior to boring as it would be on a 3-axis.

Maybe you’re going through tools on your 3-axis like a hot knife goes through butter. Five-axis’ ability to tilt the tool or table to maintain an optimal cutting position and consistent chip load as well as the fact that 5-axis reduces cycle times, leads to extended tool life.

Maybe you don’t think you have room for a 5-axis. Think again. One 5-axis machine can do the work of several 3-axis machines. Think of the floor space saved for other technologies, or for more 5-axis machines.

As lead times become more critical and as jobs become more complex in their geometries and multi-sided parts, awkward angles, intricate features, and complexities, having a 5-axis machine could be your new best friend.

Reduced setups for simple and complex parts alike increase not only your production time but increase the quality of your parts significantly. With the done-in-one approach, you save time and money and get better utilization of all your production equipment. It’s not uncommon to go from five setups to one with 5-axis.

With more angles to position the workpiece and therefore more access to it, 5-axis machining allows unique tool path operations and the ability to machine more complex shapes with a great degree of accuracy.

With 5-axis machining, you can use shorter tools because now with 5 axes, you can tip the tool away from the workpiece. This produces higher cutting speeds and less tool vibrations, better surface finishing and less tool deflection.

With less vibration due to shorter tools , there will be a better surface finish. Also, since 5-axis machines have a rotating table or spindle, more consistent cuts can be made for a smoother surface.

With 5-axis machining, the cutting tool is perpendicular to the cutting surface and therefore can more easily remove more material per pass, resulting in lower cycle times and therefore faster removal of material.

If you’re not machining 5-axis parts, then your competitor is, and most likely getting bids that your shop is not equipped for. Besides giving you a technological advantage, a 5-axis will open up doors to compete for more contracts in more markets. With 5-axis you can make nearly anything in less time, less operations and at a lower cost per part.

It is true that 5-axis machines are more expensive. You get what you pay for though. For one, to ensure high precision and accuracy, these machine tools are solidly built to withstand forces created by the cutting process and continuous movement of the axes. In addition, they are equipped with highly responsive servo drives to enable the machine to respond to thousands of commands simultaneously, they include high accuracy rotary tables to precisely position the workpiece, and they necessitate high processing power to process data fast enough, to name a few. The value of these benefits by far outweigh its cost, as they will enable your shop to more cost-efficiently produce a wider range of work.

Unfortunately, old 5-axis machines of yesteryear have given 5-axis machines of today a bad rap. The modern 5-axis machines of today often include easy-to-use programming software, and if you need something more robust, the most popular CAM software programs have bridged that gap.

While the motion of multiple axes does increase the incidence of collision, most 5-axis machines come with or can be fitted with collision avoidance software which simulates the cutting process prior to running the machine. Not only does this control crashes, but it can also help reduce setup times.

In fact, the opposite is true. With reduced setups, a 5-axis machine has become more accurate than a 3-axis that requires multiple secondary setups which ultimately increases the likelihood of error.

As 5-axis is more complex, there is no doubt that more skilled operators are required. There needs to be a good understanding of machine motion, good 3D visualization skills, the ability to create appropriate tool paths and more extensive knowledge of CAM software. Of note, while having a skilled machinist will help you maximize the capabilities of 5-axis, the control and software of the machine is equally important. And, with good training from a reputable and knowledgeable machine tool partner such as Productivity and MMT Productivity, this obstacle is easily overcome.

While 5-axis machining may seem daunting, it is a great way to differentiate your shop from your competitors, and it will pay back huge dividends. With 5-axis machining you’ll produce parts more efficiently, faster and with higher accuracy, increase the range of work you can do, and open up areas of production that you didn’t even consider possible. With the done-in-one approach, your machine operators can spend more time managing additional machines. You can count on 5-axis to reap benefits for years to come.

If this information has piqued your interest in and appeased some of your fears of 5-axis machining, then we can help get you on the right path to 5-sided machining. At Productivity and MMT Productivity, we understand that moving to five-axis machining is a big investment. We’ll work with you to assess your manufacturing operations, and with multiple lines of high quality 5-axis machines, we’ll match the correct machine to your application. All this supported by applications and service staff who are highly skilled in 5-axis technology. We’ll make sure you get the right machine, and get it into production quickly, with strong support and machine training. Check out our lines of 5-axis machines –  Haas,Matsuura MX, MAM72 and CUBLEX Series, Makino Vertical and Horizontal 5-axis, Hwacheon.

We have a great archived webinar entitled “Maximizing Your 5-Axis Machine – Part 1: Considerations to Meet Expectations” that will give the info you need to get your facility ready for 5-axis Machining. Sign up here to watch this pre-recorded webinar.

SOLPOWER, established in 1995, is a Taiwanese manufacturer of machine tool components such as Direct-Drive (DD) rotary tables, integrated spindle motors and linear motors.

SOLPOWER has been actively developing a number of high-performance direct-drive (DD) rotary tables for the precision machining industry that greatly enhance efficiency and yield. Renishaw"s RESOLUTE absolute optical encoders are compatible with a variety of industrial serial protocols and provide high-performance feedback control of the DD mechanism.

DD rotary tables eliminate mechanical linkages, for example as required for traditional worm-drive stages. Benefits of a gearless rotary table include higher speeds (RPM), faster response times, zero backlash, low noise and space saving. This amounts to an overall reduction in processing times and costs for the end-user.

With the recent drive to enhance processing technology in recent years, many machine shops are supplementing their traditional 3-axis machines with additional 4th and 5th axis rotary tables. Mr Bergan Peng, General Manager at SOLPOWER, shares his view of the rotary table market:

“A direct-drive rotary table is like a low speed integrated spindle motor with operating speeds in general of 200 RPM or less. Manufacturing cost control is vital to success in the machine tool industry. SOLPOWER has a wealth of mechatronics experience and the requisite wound-rotor motors and other components are manufactured internally, while the remainder are sourced from well-established Taiwanese manufacturers. Our rotary tables are frequently employed in 24-hour machining operations and we are a well-respected brand in this sector.”

All of these directly affect the system; generally, the smaller the encoder scale pitch, the better the interpolation cyclic error. The net effect of a reduction of encoder errors is to improve positional control and reduce velocity ripple, which allows a DD rotary system with smoother speed control and higher resolution. Clearly, these features are important for machine tool rotary tables in high-precision applications. RESOLUTE series encoders use 30 micron fine-pitch scale, have a cyclic error of less than 40 nm and jitter of just 10 nm RMS. When combined with generous installation tolerances and advanced scale types, there are few absolute encoders on the market that can offer this outstanding performance.

Encoder errors can be divided into repeatable (non-accumulative) or cyclic errors and random noise contributions. In enclosed-type encoder designs, cyclic errors are made worse by large contributions from bearing backlash, mechanical hysteresis and torsional motion resulting from insufficient stiffness. Error compensation, in this case, is only partially successful due to the presence of noise components. Open-type encoders, in contrast, do not rely on mechanical coupling between the scale and the encoder and, therefore, the vast majority of precision rotary tables specify open optical encoders.

In the current market, PC-based controllers for low-end machine tools are on the rise, but still mainstream traditional controllers by FANUC, SIEMENS, MITSUBISHI and the like, remain popular because customers generally prefer the quality assurance of these brands. Mr Peng continues: “High-speed cutting is the future direction of machining. Our business focuses on providing rotary table solutions in accordance with customers" needs.

An essential requirement is direct interfacing with the customer"s controller, which impacts the choice of encoder. Renishaw"s RESOLUTE series encoders offer compatibility with many popular industrial serial communications protocols including BiSS (to the PC-based controller), FANUC, MITSUBISHI, PANASONIC and SIEMENS. RESOLUTE encoders also offer a wide range of rotary (angle) scale diameters providing greater flexibility in product design.”

SOLPOWER takes full advantage of its years of experience and market position in the field of DD motors and continually develops its product offering to meet the needs of a highly-competitive industry. Mr Peng explains: “We developed the most cost-effective rotary table possible, which means that cost must be strictly controlled from design, parts procurement to production. Renishaw as a major supplier is an important part of our cost-efficiency strategy.”

SOLPOWER"s SDRT series rotary tables have a single rotational axis and are designed to be compact with a high-torque and high-speed response. When integrated into the SDRT rotary table design, the RESOLUTE RESA absolute rotary encoder series offers 23-bit resolution; positioning accuracy and repeatability after compensation of ±10 arc seconds and ±4 arc seconds, respectively; maximum speeds up to 200 RPM and IP67 protection - sufficient to meet the requirements of the vast majority of precision light machining applications.

Mr Peng continues: “These rotary tables have limited space and so the encoder readhead volume, in particular, needs to be small; ease of installation is another important consideration.

Renishaw"s rotary encoder has a unique patented taper mount that effectively reduces installation errors and improves our assembly-time efficiency. Renishaw"s support engineers provided training to enable our staff to install the scale.”

Product sales strategy in a competitive market is important, but the key in the final analysis is the quality of the product itself. Mr. Peng concludes: “Prior to leaving the factory, each of our SDRT rotary tables undergoes a strict quality testing regime. We currently use Renishaw"s XR20-W rotary axis calibrator with XL-80 laser. The XR20-W calibrator features a measurement accuracy of ±1 arc second. Renishaw"s calibration equipment is well respected in the international measurement community and greatly enhances the confidence of our customers.”

SOLPOWER is a Taiwanese manufacturer of machine tool components such as Direct-Drive (DD) rotary tables, integrated spindle motors and linear motors. Renishaw’s RESOLUTE absolute optical encoders are compatible with a variety of industrial serial protocols and provide high-performance feedback control of the DD mechanism.