HELLER H 2000 CNC horizontal machining center

HELLER H 2000 CNC horizontal machining center was built in 2022 by Heller Maschinenfabrik GmbH. The machine represents the fourth generation of the H series, specially designed for use in demanding production conditions. It is distinguished by its extensive equipment and the use of a number of state-of-the-art technical solutions that ensure reliable operation throughout its service life.

The HELLER H 2000 is used for precise, 4-axis machining of workpieces with a maximum weight of 800 kg. The design of the machine provides the foundation for high productivity and machining accuracy. All structural components made of cast iron have been carefully topology optimised to ensure the highest stability and excellent force damping. Kinematics in all 4 axes, in turn, allows precise positioning of the tool in relation to the workpiece. Movement in the X-axis is carried out by a column, which supports the machining unit. The machining unit moves in the Y axis and is well integrated into the column. The rotary table, on the other hand, moves in the Z and B axes. All linear axes are driven by ball screws and move on low-friction roller guides. A direct measuring system in the form of glass scales ensures maximum precision and low positioning tolerances.

The machining process is performed fully automatically by a reliable spindle and cutting tools taken from the 80-position magazine. The spindle is distinguished by its carefully designed, compact design of high rigidity and slim neck, which provides excellent reach into the workpiece. A reliable cooling system and temperature compensation ensures that the spindle does not thermally deform and maintains a constant temperature during heavy-duty, high-speed operation. The machine also has a solution for quick spindle replacement without time-consuming calibration, which reduces repair time as well as operating costs.

All the tools required for efficient machining are stored in a capacious, 80-position chain-type tool magazine. Together with it, a tool changer with two NC axes works, which ensures maximum precision and optimised motion sequences. Combined with the high axis dynamics, this results in short chip-to-chip tool exchange times.

To increase efficiency and reduce downtime, the HELLER CNC machining center is equipped with an automatic pallet exchange system. The system, which consists of, among others, a powerful hydraulic drive and a lifting/swivelling system, ensures accurate and repeatable pallet exchange even under the heaviest loads. It is also compatible with other automation systems. All this makes the offered HELLER H2000 milling center the perfect choice for continuous operation in series production.

Technical specifications of the HELLER H 2000 CNC milling machine

General data

• number of axes: 4 (X,Y,Z,B)
• feed in the X/Y/Z axis: 630/630/630 mm
• rapid traverse in the X/Y/Z axis: 80/80/90 m/min
• acceleration in the X/Y/Z axis: 10/10/12 m/s2
• feed force in the X/Y axis: 10 kN
• feed force in the Z axis: 15 kN
• linear axis positioning tolerance: 0.005 mm
• operating hours: 11505 h
• compressed air pressure: 5-6 bar
• compressed air dew point: 3°C
• compressed air purity: < 5 µm
• maximum oil content in compressed air: 0.1 mg/m3
• total machine power without coolant filtration system: approx. 31 kVA
• permissible ambient temperature: 10-45°C
• power supply: 3x 400 V; 50 Hz
• dimensions of the HELLER H 2000 machine with coolant filtration system and chip conveyor (L x W x H): 6300 x 2950 x 3400 mm

Spindle

• cutting unit SC 63i Speed Cutting
• maximum spindle rotational speed: 16000 rpm
• minimum spindle rotational speed: 5 rpm
• spindle taper: HSK-A 63 (DIN 69893)
• spindle drive power: 45 kW
• spindle torque: 103 Nm
• spindle bearing diameter: 80 mm
• possibility of attaching angular heads

Automatic pallet exchange system

• maximum workpiece weight (double-sided loading): 800 kg
• maximum workpiece weight (single-sided loading): 600 kg
• maximum workpiece diameter: 720 mm
• maximum workpiece height: 850 mm
• pallet dimensions (L x W): 400 x 500 mm
• pallet change time (with hydraulic clamping): 10,5 s
• pallet change time (without hydraulic clamping): 10 s
• pallet exchange accuracy in the X/Y/Z axis: 0.01 mm
• maximum moment of inertia of the pallet in relation to the B axis: 36 kgm2
• loading station with manually swivelling pallet (4x 90°)
• pallet with DIN hole pattern (2 pcs)
• pneumatic control of workpiece support
• reduction of hydraulic pressure to 60 bar for existing devices
• media interface for workpiece attachment (5 circuits, hydraulics up to 80 bar)
• control of additional hydraulic line in work space

NC rotary table

• B axis rotation range: 360°
• B axis rotation speed: 40 rpm
• B axis indexing accuracy: 0,001°
• B axis angular positioning tolerance: 8″
• maximum tangential torque (NC rotary table): 5000 Nm
• maximum tilting torque (NC rotary table): 8000 Nm

Tool magazine

• number of positions: 80
• maximum tool diameter (adjacent positions empty): 160 mm
• maximum tool diameter (adjacent positions occupied): 72 mm
• maximum tool length: 410 mm
• maximum tool weight (adjacent positions empty): 12 kg
• maximum tool weight (adjacent positions occupied): 3.5 kg
• tool change time (chip-to-chip): 2,2 s
• tool holder: HSK 63
• control panel at the tool preparation station

Coolant filtration system

• paper filter
• filtration accuracy: 40 µm
• tank capacity: 1200 l
• IKZ 50 bar
• IKZ capacity at 50 bar: 33 l/min
• maximum power of coolant filtration system: 14 kVA
• workspace flushing

Equipment of the HELLER milling machine

• CNC control: SIEMENS SINUMERIK 840D SL

– integrated tool monitoring (IPM)
– tool breakage control
– automatic production preparation and finishing cycle
– operation time and quantity of produced parts counters
– production data recording (BDE)
– interface in Polish and German

• 24″ operator panel with touch screen: HELLER Operation Interface
• SPEED package – NC rotary table, increased speed of rapid traverse, increased speed of tool change, AutoSet, tool extraction, surface transformation (CYCLE800 – Siemens)
• NC rotary table
• spindle with cooling system and temperature compensation
• 80-position chain tool magazine
• automatic pallet exchange system
• servo drives with incremental encoders on all axes
• direct measuring system in the form of glass scales
• coolant filtration system: KNOLL VRF 250
• belt chip conveyor for wet machining
• chip collection tray with leakage detector
• HELLER BLUE energy management system
• oil mist/emulsion extraction system
• coolant system with SMC components
• water-air cooling unit for spindle and control cabinet
• coolant cooling unit with compressor system
• integrated air and water gun
• pneumatic system based on FESTO components
• central oil-air lubrication system
• low-friction roller guides in all linear axes
• lamp indicating machine status
• OPC UA interface (read-only, in combination with production data recording)
• vibration-damping elements to support the machine
• working door glass blower
• special marking in Polish and German
• marking of concealed devices on guards
• technical documentation in Polish + digital version (PDF, CD)
• safety documentation (LOTO – Lockout/Tagout)
• service documentation, spare parts lists and inspection components
• extended list of spare parts and consumables