Making the tool spin: Swiss motor spindles for energy milling

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The bearing layout with three and four bearings in another version respectively results in high stiffness of the rotating axis. This allows for the working of long and heavy tools for milling deep cavities in one go. This spindle model is aimed at application in the aerospace industry, where structural components such as housings and cross members made of aluminium or titanium are machined. A new bearingless rotary union suitable for all media makes it possible to bring coolants and lubricants into the rotating spindle shaft for cooling tool and workpiece. High-pressure cooling or low-dosed minimum quantity lubrication is just as possible as air-in-rotation. At the same time, the service life of these wear parts has been increased significantly thanks to an enhanced sealing technology within the rotary union.

Building such a short spindle with an extremely powerful induction motor with high-power density speaks well for Step-Tec's innovative power. The moderate spindle mass of less than 230 kg makes it possible to have a compact and highly dynamic swivelling head with a great mass-to-power ratio.

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Technical data:

Power S6) 46 kW

Torque (S6) 366 Nm

Speed 15’000 min-1

Acceleration 2 s (8,000 rpm)

Lubrication DLS oil – air

Cooling COOL-CORE fluid

Tool interface HSK-A100/T100 DIN69063

opt. Big Plus,ISO-SK50, Capto C8

Dimensions 290 x 665 mm

Weight 233 kg

Rotary union Coolant 14 MPa, minimum quantity lubrication, air in rotation

Drive module Siemens, Heidenhain, Fanuc, etc.

Integration into CNC via Profibus

Intelligence „Digital Spindle, Industry 4.0 ready“ Integration of intelliSTEP sensorics for monitoring and process control Remote maintenance, e.g. rConnect

Options: Shaft locking system SSL 1’300 Nm

AMS Axial Movement Sensor

Shaft cooling CCS (CoolCore)

CO2 cooling through shaft possible

The power to machine hard materials

For machining titanium, where a lower speed but high torque is needed, Step-Tec offers the 8,000 min-1 model with 55 kW of power at a torque of 440 Nm. The spindle easily handles the increased lateral forces induced from milling titanium because of the static stiffness of the massive shaft on one hand, and the highly robust bearing layout with three preloaded front bearings (four in total) on the other. A Cool Core variant with 120 kW of power at a speed of 20,000 min-1 will soon complete the 290 platform.

The unique character of the motor spindle, to be fitted with a Spindle Shaft Interlock (SSL) that locks forces of up to 1,300 Nm, makes it very versatile, especially for turning operations in mill-turn applications. With its 290 platform, Step-Tec offers power spindles for complete machining in large milling centres, where structural components can be milled efficiently and economically. The platform combines surface quality with durability. In addition, the spindle is Industry-4.0-ready, enabling direct access to the spindle's status and even its condition with regard to planning preventive maintenance.

At the heart of many machining centres around the globe is a high-performance Step-Tec spindle. As an essential core component stemming up to 7,000 hours a year, the spindles ensure that machines can handle everything from heavy-duty roughing to fine-finishing operations. To ensure reliability, Step-Tec also offers a Spindle Exchange Program (SEP) as well as preventive services. To prevent downtime and unproductiveness, which generate unwanted costs, the Spindle Diagnosis Module (SDM) is able to analyse operating parameters to propose preventive services and thus optimise production.

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