Machine Construction

Building the Future One Machine at a Time

A lofty title for a very important function. It's the same advanced computer design system procedure used by leading aerospace and automotive firms. FEA's software technology advantage shortens the time it takes us to develop new models and create machine options.

This software provides 3-D modeling of any structural component of our machines. It allows our engineers to test every element of machine construction in fantastically small detail right on the computer. With it, our engineers can create images, even movies, that show where stresses would occur in various machine components. FEA has significantly and positively impacted Komo's ability to provide you with machines designed with the exact combination of structural integrity and high-speed operation required.

Because our engineers can computer verify and pre-flight frame integrity, material thickness requirements, frame geometries and much more, you are assured of a more durable machine tool investment. That's one reason your Komo will last far beyond the leasing agreement. Our machines hold their value because the are designed for a longer service life.

When it comes to tailoring a machine for a specific production challenge, FEA is critical. Our engineers can select tool plate materials, components and systems to perfectly match machine design objectives, performance goals and future option needs.

While other router builders merely copy what others have done, or guess at machine rigidity after committing to production (meaning you're the guinea pig), Komo KNOWS how our machines will react in real-world production situations prior to making the first weld. They build, we engineer.

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Machine Base Construction

Komo CNC machining centers are highly integrated, modular framed machines. The two-piece construction of the machine means less joint work, which increases overall rigidity.

The columns are an integral part of the base, which increases accuracies by dampening harmonic vibrations. The columns are precision machined as part of the base for absolute parallelism. Frames are all ultrasonic stress-relieved to remove any possibility of frame twist or "settling" over time. Your Komo CNC router has the most rigid frame available.

Trapezoidal Fabricated Columns

FEA analysis by our engineers has resulted in a new column design concept for CNC machining centers that is 15X more rigid than tube-type structures! Our trapezoidal column design allows extremely high cutting axis thrust resistance for optimum cutting power.

Maximized performance is further enhanced by our improved Acc/Dec (acceleration/deceleration) of the drive system. In order to handle higher machine speeds, the frame must be able to take the physics of speeding and stopping the moving parts in a shorter duration of time.

Without corrective structures, traditional tube frames can flex too much to take long-term high-speed production. Komo's trapezoidal frame columns offer superior rigidity to do today's type of high-speed production. This frame orientation also minimizes harmonic vibrations and frame bounce for better part finishes, no matter which tooling is used.

Komo CNC machining centers are also laser calibrated for precision assembly. This extra attention to detail assures you of a more durable, longer-lasting machine tool investment. Komo CNC machining centers are built for reliable, profitable operation over many, many years of use.

The open frame design allows faster, easier cleaning of dust and chips. All important machine systems are accessible for inspection, maintenance and cleaning purposes. The electrical panel is attached to the machine at the back of the machine. This is done to reduce floor space requirements.

Machine guarding is heavy-duty tube with the emergency e-stop clearly marked and positioned opposite the control. Multi-point leveling pads along the lower base allow precise alignment of the machine. Our machines may be bolted to your flooring for the ultimate in vibration elimination.

True Machine Tool Construction

Komo CNC machining centers are built on the most durable machine tool foundations available. Each frame is fabricated from thick-wall structural steel tubing on special fixtures for maximum pre-assembly accuracy. Frames are ultrasonically stress-relieved for superior integrity prior to machining.

Sure, this way of doing things isn't the cheap way; but it's the right way. Your machine investment should last far longer than the lease, perform far better than you expect. Komo CNC machining centers won't let you down when your production changes or you need just that little bit more out of your next run.

Innovative Gantry Construction

Our large gantry-type machines are built with the same drive to provide superior cutting performance as our bridge-type machines. Traditionally, gantry-type machines have a greater challenge maintaining machining tolerances over very long axis travels, not with a Komo.

Our synchronized dual drive systems eliminate any "skewing" as the gantry moves over the table. Part accuracies are held even over extended travels. Additionally, the extra servo motor positioning power allows more tooling provisions on the tool plate, or the inclusion of specialized part processing options.

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The more accurately the component is made, the more accurate the positioning of the machine. Komo uses the best sized components available and matches them to the travel of the parts they are intended to move.

For example, if a ballscrew is too thin, it can "whip", or oscillate, when turned over a long table travel. And, as with any metal object, the stresses applied for rapid changes in speed or direction can weaken a too-small ballscrew over time.

Drives must be extraordinarily sturdy, too. Rapid changes in direction must happen in milliseconds. The drives must be able to handle constant, rapid changes without undue wear or heat build-up. Komo uses the proven Fanuc drive system for long machine life and absolute high-tolerance performance.

Komo uses the Fanuc advanced HVI high-speed servo system for optimum acceleration/deceleration.

The bearing trucks ride on the guideways, and are attached to the moving components of the machine. They feature centralized oil lubrication and recirculating balls, and are matched to the guideway for reliable, precision operation.

Proper lubrication is no small concern. Today's CNC machining centers operate at very high speeds and feature precise components. Let a machine run dry long enough, and you could find yourself facing catastrophic (and expensive) wear or breakdown.

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Komo provides a wide selection of spindles, with capability to machine almost any material. Spindles are available with power ratings up to 30 HP, with speeds up to 30,000 RPM. A Komo CNC machining center can take on any job with extra rigidity and durability in virtually any production environment. The RPM is infinitely adjustable for precise control of part finish. Full horsepower is achieved at different levels, depending on motor winding configuration.

The spindle turns the tool holder which, in turn, holds the cutting tool. Komo CNC machining centers utilize industry-standard HSK 63F tool holders. HSK tooling provides maximum rigidity to ensure superior cut quality. Our VGM and Summit machines use the ISO 40 taper.

Komo CNC machining centers may be configured with a staggering variety of optional equipment. That's why each machine is designed with a massive tooling plate. The plate provides ample rigidity for our engineers to design options with the capabilities required for nearly any application. Multiple spindle configurations are common on our machines, with specially-designed machines in production carrying up to 36 spindles on a tool plate.

Although modern cutter technology does a fine job of helping to cool the tool and extract chips from the cut, some materials, particularly plastics, require additional help in clearing chips and cooling the tool while machining. That's why we incorporate automatic spindle air blast systems in our machines. This simple mechanism has no moving parts, and has adjustable pressure capabilities. Chips are blown clear of the cutting path to the dust extraction system, and the cutting temperature is reduced.

Speaking of which, we pride ourselves on how clean we can leave a cut. Chip extraction is an important concern. You don't want to reintroduce chips back into the cutting path. Our machines use a single dust/chip collection line for extraction from the spindle shroud.

• Centrifugal force increases joint strength.
• Centrifugal expansion of the spindle at higher speeds cannot cause increased shank penetration under drawbar force.
• The contact surface of the tool holder will allow for radial and axial repeatability of 0.0001".

Image courtesy of hskworld.com
For all your HSK Tool questions, visit www.hskworld.com

Standard Taper Tooling

• Centrifugal force decreases joint strength
• Centrifugal expansion of the spindle may occur at higher speeds, causing increased shank penetration under drawbar force. This causes the Z offset of the tool to change.
• When the spindle is stopped, this expansion can cause the tool holder to stick, resulting in tool changing difficulties.
• Axial repeatability is 0.004".

What are the Benefits of HSK Tooling?

• High static and dynamic rigidity

• High tool changing and repeating accuracy

• Low tool runout

• Low tool change stroke and time

• Suitable for heavy duty machining and high speed applications

• Harnesses centrifugal forces to increase joint strength

• Low weight allows for more tool holders in the carousel

• Low load on the spindle bearings

• Adapted for manual and automatic tool changing

• Widely available from multiple vendors, resulting in cost competition and stock items

• Modular systems available (extensions, reducers)

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Komo Machine is an authorized GE Fanuc builder. We've been using Fanuc control systems for more than 20 years. Our machines feature closed-loop GE Fanuc systems where the controls and positioning motors all speak to each other in faultless harmony. This gives you better, faster machining cycles with more reliable positioning.
 

Each machine solution we provide carries the experience and skills of our people as well as the engineering knowledge and digital muscle of GE Fanuc, one of the most trusted names in machine control.

Don't let someone sell you a machine with an outmoded PC solution they've cobbled together, or one based on an out-of-date operating system. Turn to Komo and GE Fanuc for reliable, proven machine control technology.

Your operator can store and retrieve hundreds of programs right on the shop floor. Harness the native power of PC connectivity possibilities with your customers and your internal computer systems.

The control provides network-ready connectivity with your computer systems. Fiber-optic connection of the control to the machine ensures faster, more reliable data transfer.

The front-end PC allows you to integrate emerging machine programming software advances, such as nested-based manufacturing and the latest in design to machine production code software, into your production.

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We do the machining of the vacuum standoffs on metal specification versions of our CNC machining centers. Each vacuum standoff features a gentle chamfer slope to make cleaning of the table easier as there are no ninety degree "nests" for dust collection. Ample area is provided around our worktable perimeters for optional fixturing equipment accommodation.

The multiple ports also act as a redundant system should one or more ports become accidentally blocked by foreign material. A manifold under the table and outside of the machine frame allows easier access to the vacuum system without complicated machine disassembly procedures.

Komo's modular grid table system is standard on the Solution, Mach Xtreme and Fusion series; available as an option on the Mach III series and VGM series.

The operator activates the raising and lowering of the pneumatic pins right from the control unit. The pins allow locating of a spoilboard and the material to be machined. The pins locate the material on two directions (axes). Large or small sheets of material may be located easily. Once positioning is made, the pins are retracted out of the way of the spindle(s).

The Mach III Series offers the ability to relocate the pop-up pins along the edge of the table exactly as needed. In this way, you can still use the location pins whether you have a large sheet of material or smaller pieces.

The pins are locked and unlocked for movement along the table by a simple hand lever locking mechanism. The pins slide along inside of a machined channel and may be positioned at any point on the table. The channel is an integral part of the worktable, so you needn't be concerned about any future alignment issues.

Maintenance of the pop-up system is limited to occasional cleaning of the pins. The whole system is built upon industry-tested components for heavy use over a long service life. The simplicity of the system ensures you years of trouble-free part location.

Pins not enough, talk with Komo about a laser projection system to make quick work of pod setup and locating material in a specific location. Komo has the right solution for your locating needs.

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