DSP series products are innovative spindle products tailor-made for lathe spindle by REALLAND TECHNOLOGY. Compared with the two solutions in the current market, DSP series has its unique advantages and effectively avoids disadvantages that other two solutions has. REALLAND believes it is a revolutionary solution that can make positive progress to the machine tool industry.
Before introducing the DSP Series, let's first look at the problems of the two solutions in the market.
Machine tool Configuration —
The spindle system of NC machine tools connected by belt disc can not achieve high speed, high dynamic and high precision positioning because of the defect of belt driving mode, which restricts the further improvement of the performance of NC machine tools. Therefore, the development trend of the industry is bound to move towards motorized spindle.
Unable to achieve high speed
The accuracy of spindle positioning can not be guaranteed
Poor servo dynamic response
Unable to realize the miniaturization of machine tool structure
— Built-in Electric Spindle —
At present, all the existing motorized spindles are built-in motorized spindles, that is, the stator and rotor of the motor are placed in the inner cavity of the spindle box, but this kind of built-in motorized spindle has the following defects:
Machine tools can not be maintained after sale:
Once the stator and rotor fail, the whole spindle box must be dismantled. It is obviously difficult to install the high precision spindle box on the customer site, which restricts the mass promotion of the built-in spindle.
The structure of the original machine tool needs to be changed, and there is a validation period:
Because of the embedded motorized spindle, the length of the spindle box will inevitably be lengthened, which will cause the installation size of the original machine tool to change, and the bearing support spacing of the spindle box will change, which will affect the rigidity of the spindle. This change is technically feasible, but after all, it needs to be verified by rigorous mechanical simulation and actual verification. For machine tool products, it is not easy.
Motor torque is limited:
Because the stator and rotor are built in the spindle box, the dimension is limited, so the torque capacity is restricted, which results in the limitation of the force and energy index of the machine tool.
Heat causes loss of spindle accuracy:
Because the stator and rotor are built in the spindle box, the heating of the stator and rotor will affect the accuracy of the spindle, leading to a certain degree of thermal expansion and contraction of the spindle box in the cold and hot state, resulting in the loss of accuracy of the spindle box.
Complex structure and difficult production
Because motor technology and spindle box technology belong to two fields, it is feasible to combine them, but the accuracy of the original spindle box is high, and the structure of the stator and rotor is complex, making it difficult.
The original mechanical spindle can not be used
At present, there are a large number of machinery spindles in the market, as well as a large number of manufacturing companies of machinery tables.After using the motorized spindle, it will face the risk of being eliminated, which will lead to a lot of waste of resources.
— DSP External Disk-type Structure —
REALLAND has developed a DSP series of external electric spindle products for the drawbacks of the built-in electric spindle. It completely overcomes the pain points of the built-in electric spindle and has the following features:
1. Use only the original belt disc mounting space
The size of the machine tool is not changed, the structure of the spindle housing is not changed, and only the position where the belt pulley is originally installed is used.
2. Easy installation
The DSP is designed to achieve an integrated mounting structure that can be directly mounted on the transition flange seat of the machine headstock. It is simple and convenient, and does not change the machine installation size or the size and rigidity of the mechanical spindle housing.
3. Ultra-thin Structure, Ultra-light Weight
Because of the super-thin structure and super-light weight of the DSP (even lighter than the belt disc), it is possible for the motorized spindle to be externally mounted, which ensures the rigidity of the spindle.
As the core of machine tools, the spindle needs high rigidity and stability, so there are requirements for the span between bearings.Because the outer disc-type super-efficient motorized spindle of DSP is outside the bearing spacing, it does not affect the high rigidity and stability of the mechanical spindle, and is easy to realize the optimal design of the spindle spacing, so that the machine tool manufacturers do not have to worry about the unreliability brought by the new structure, and greatly shorten the pace of the machine tool manufacturers to launch new products.
If the traditional motor structure is adopted, the additional bearing force will be brought because of the long and heavy motor, and the spindle vibration will be large when the tail shaft is swayed at high speed.
4. Realising C-Axis Function
DSP motor adopts the direct connection mode, which can effectively avoid the transmission chain gap brought by the belt connection mode, realizing the function of C-axis with high rigidity and high precision.
The installation structure of the built-in encoder can effectively solve the signal deviation caused by the naked exposure of the traditional spindle encoder in the occasions of oil fog and processing, and realise the function of C-axis with high reliability.
DSP motor can achieve 2.5 times overload at low speed, which means it can effectively realise C-axis zero speed shaft lock function. In some cases, it can replace the function of a brake disc.
DSP motor's large inertia mechanism design effectively ensures the stability of machine tool processing.
5. Higher energy density and output torque
This DSP motor is an ultra-high energy density motor. Its output is far beyond the traditional structure and its torque characteristic is high. It not only has huge cutting force in the low speed section, but also has a very good acceleration characteristic at the high speed end. It can greatly improve the productivity of the structure and expand the processing range of the machine tool, and effectively solve the problem of insufficient output of the original built-in motorized spindle.
6. Special Cooling Structure
The special cooling structure effectively blocks the influence of the heat source on the accuracy of the machine. The heat source is moved outside the spindle system and the motor heat does not affect the spindle bearings. The water-cooled plate is placed between the heat source and the casing, and can also be cooled by the spindle case to extend the life of the bearing.
7. Easy after-sale service
When you are after-sales service, just remove the motor and replace it with a new one. The on-site maintenance is very convenient.