5 Axis Pro+ 4.0 Machining Center

Optimization of production costs

The 5AXIS PRO+ 4.0 automated machining center is new in SERON’s offer. It was developed in response to the needs of the carpentry industry. The configuration of the machine allows it to be implemented into an extensive, automated machinery park managed in the Industry 4.0 concept, but it will also be perfect equipment for a developing carpentry workshop. The center allows integration with a robot, thus enabling comprehensive optimization of production costs by reducing human resources and minimizing production errors.

Machine management in the Industry 4.0 concept

Well-thought-out technological solutions are based on a professional system for comprehensive machinery management. The control uses the OPC UA communication protocol for Industry 4.0, which is used by leading IIoT software providers. Thanks to the use of this protocol, this control allows remote monitoring of machine operation, control of machining parameters, analysis of downtime, and sending and queuing executive files.
The control system used is intended for advanced industrial machines operating in fluid multi-axis applications. The interpolator is based on a real-time clock with advanced dynamic trajectory analysis. The interpolator used with a cycle time of less than 1 ms guarantees the dynamic implementation of complex shapes while maintaining the highest quality of processing.
The control is equipped with intuitive solutions that make operation simple, while the interface is friendly and clear. The operator can track the progress of the process in real time and correct machining parameters. Additionally, there is a “tool life” management function available, which allows us to control the wear of the tool over the time it has been working and the distance of work in the material. The control also controls the gantry axis and, in the case of machines with rotary axes, has TCP functions.

Automation of production processes

The 5AXIS PRO+ 4.0 series of machines can be fully integrated with an industrial robot. This combination allows you to fully automate the production process. The robot arm, synchronized with the processing unit, places details (e.g. door leaf, stair stringer, body, furniture front and many others) in the working field with excellent precision, which are then processed. After completing the operation, the device takes the detail from the machine and puts it in the designated place, and then repeats the set cycle.

Remote management of key components

The 5AXIS PRO+ 4.0 machining center is equipped with an efficient HITECO 17KW ORBITAL K PLUS tilting and rotating electrospindle. High power of the electrospindle and efficient liquid cooling ensure effective work in the most demanding materials and types of processing. This is particularly important when we process details with tools with a large cutting surface (milling heads for the production of doors, windows, stairs or furniture). The built-in multi-axis accelerometer allows you to capture overloads or dangerous resonance velocities and transmit a signal to the control, which automatically corrects the machining parameters or signals such a need to the operator. In addition, the use of the EtherCat module enables data transfer from the valve terminal to the control, as well as controlling and supervising the machine’s pneumatic system, including counting the number of work cycles, monitoring compressed air consumption (compressed air is the most expensive energy carrier, its production is expensive, only one is used once, there is no possibility of re-use, large pressure losses in the systems). The use of valve islands with a module also allows for the determination of the machine’s overhaul time, assuming a specific number of operating cycles of a given element (valve, actuator), so the user can prepare for the overhaul in advance – he does not have to wait for the delivery of parts, saving time and reducing downtime.

Energy saving with maximum efficiency

The 5AXIS PRO+ 4.0 Machining Center uses OMRON AC servo drives based on Ethercat communication. They ensure high dynamics, significant accelerations and fast journeys. The high-speed Ethercat connection gives us the ability to have even greater control of operating parameters in real time. Synchronization of the control system with the drive installation allows you to control, among others: loads, speeds and accelerations occurring on the engines, which optimizes their operation and increases their service life. In addition to the traditional functionality, the 1S servo drive offers a multi-turn, 23-bit, high-resolution absolute encoder ensuring greater precision and no need to re-home the machine, and is not battery-powered, which eliminates discharge and loss of the base position. The implemented drive system was designed to increase the energy efficiency of the machine tool, thanks to the use of a common DC bus in which the energy given off by the braking drive can be used by the currently accelerating drive. This solution generates savings.

Remote technical support

The communication protocols used enable remote software update as well as service access and correction of parameters not only of the main control, but also of all key components of the machine such as the electrospindle, controllers, drives, inverters and valve islands. In addition, technicians can monitor the status of main components in real time and have access to reporting histories. This allows you to reduce service visits by as much as 90%, which also minimizes machine downtime.

Innovative construction

The 5AXIS PRO+ 4.0 machining center is an innovative machine created for entrepreneurs with a diversified production profile. It was designed based on the structure of the highest series machines, the PRO+ line. The machine body is made of welded steel profiles, ribbed and enriched with composite additives, then subjected to the process of stress relief and machining in one mounting. The innovative design of the machine’s running support based on a steel, also ribbed structure, combined with elements made of light metals and composites allows for high dynamics and working and travel speeds, resulting in maximizing the machine’s efficiency. Linear guides with increased load capacity while maintaining the same dimensions as standard guides were also used. The structure prepared in this way is a key element influencing the long-term precision and accuracy of the machine tool, which in turn is a basic condition for the implementation of innovative solutions.

Flexible configuration

Many years of experience of Seron as a manufacturer of CNC machine tools allows us to tailor advanced technologies to a specific industry. Although we have developed ready-made solutions for clients from specific industries, we remain flexible in relation to the client’s needs, preferences and financial capabilities. The 5AXIS PRO+ 4.0 series machines can be prepared for further expansion, so that the machine can expand its capabilities as the company grows.

The presented technological innovation solutions make the 5AXIS PRO+ 4.0 series Machining Centers manufactured by Seron boldly compete with machines from leading global brands, leaving the customer with the possibility of flexible configuration. Although the capabilities of these machines perfectly fit the needs of large production plants, they remain an affordable solution even for small, developing entrepreneurs just entering the market.

Main Advantages

• Implemented control system based on Industry 4.0 concept
• Innovative 5-axis electrospindle and Z-axis design
• Automated loading and unloading capability
• Comprehensive monitoring of key components
• Energy efficiency with maximum performance
• Remote technical support
• Innovatively designed construction
• Flexible configuration

Dedicated Materials

• Soft and non-ferrous metals: brass, copper, bronze, aluminum
• Composites: dibond, alucobond, etc.
• Plastics: polycarbonate, PVC, plexiglass, Teflon, polyamides, Gambit, rubber, etc.
• Solid wood and wood-based boards: plywood, chipboards, MDF, OSB, etc.
• Paper, cardboard, foil, etc.
• Foams, extruded materials, etc.