Main Machine Configurations:

1. Basic Components

The machine's base, slide, spindle housing, and other basic components are made using high-strength casting technology, resulting in a stable internal microstructure. The casting structure has undergone machine dynamics analysis and finite element analysis to optimize its geometry and ensure high rigidity. The wide and sturdy machine base, with its full-support load design, adheres to advanced material mechanics design principles, ensuring load capacity during machining.

2. High-Precision Spindle Unit

Utilizes a Taiwan high-precision bearing rolling spindle A2-8, configured with a 1PH8137 spindle servo motor (Taiwan servo spindle motor optional). It offers high precision, long lifespan, and easy maintenance.

3. Spindle Rotary Encoder

The spindle coaxially mounts a Heidenhain or Renishaw rotary encoder, providing a TTL signal to the linear servo toolpost dedicated driver for the spindle angle signal. Coaxial rotary encoder installation ensures high positioning accuracy and effectively improves the outer diameter machining accuracy of non-circular parts.

4. Linear Axes

The Z1/Z2/X1/X2 axes all use high-precision ball screw pairs and imported high-precision linear rolling guides. The Z1/Z2 axes use Bosch Rexroth 55mm roller linear guides, while the X1/X2 axes use Bosch Rexroth 45mm roller linear guides. The ball screws utilize a pre-tensioned assembly process, significantly increasing transmission rigidity and eliminating thermal deformation during high-speed movement, thus ensuring the machine's positioning accuracy, repeatability, and stable machining accuracy. A high-precision spindle encoder (synchronous belt drive) is installed on the Z1 axis, providing the Z1 axis position signal to the linear servo toolpost dedicated driver.

5. Linear Servo Toolpost

(1) The new generation flat linear servo toolpost EJX1260A, independently developed, has reached internationally advanced levels. This toolpost boasts extremely high dynamic accuracy, dynamic stiffness, and frequency response. Its output force reaches 1500N, stroke is 6mm, frequency response exceeds 450Hz/-3dB, and servo toolpost repeatability reaches 0.0003mm;

(2) It uses the independently developed high-precision servo driver EHA3020T0S with dual CPU control, with a servo frequency reaching 16K. By downloading data edited by the dedicated data processing software to the dedicated driver, the piston irregular outer circle machining can be controlled and completed.

6. Numerical Control (NC) System and Electrical Control System

(1) Uses the internationally standardized Siemens 828D dual-channel numerical control system, which is simple to operate and highly reliable;

(2) The wiring in the electrical cabinet complies with national electrical safety standards, ensuring that the control system is not affected by external interference during operation. An air conditioner is used for the electrical control cabinet to quickly exhaust hot air, maintaining a constant temperature within the cabinet, allowing for long-term stable operation of the control system.

7. Machine Software

    (1) The "Epoch Piston Surface Data Processing Software" can edit and control various irregular circumferences required for piston machining, including standard ellipses, ellipse-superimposed eccentric circles, eccentric ellipses, rotated ellipses, or discrete data fitting. Its interface is clear, intuitive, user-friendly, and easy to operate.

    (2) Piston surface data input adopts a chart-based interface, making data entry visually straightforward. Cross-sectional shape data is displayed using polar coordinate graphics, providing an at-a-glance overview.

    (3) Upon completing data input, the software automatically calculates and displays the contour diagram, facilitating verification.

    (4) The machining software features simplified parameter input and a user-friendly man-machine interface. It monitors and displays the entire machining process status in real time.

8. Lubrication System

An automated timed and metered lubrication system (with adjustable flow) delivers oil to moving components including guideways and ball screws. This minimizes oil waste while providing an environmentally friendly solution.

9. Tailstock

The hydraulically driven tailstock sleeve moves to extend or retract the center point, with a feed and rapid feed, and adjustable clamping force.

10. Tooling

The piston mouth is used as the positioning datum. The machine provides two methods for clamping the piston: hydraulic tailstock clamping and hydraulic pulling. Users can choose a combination based on their process requirements. An air-injection type rotary cylinder is used, and the piston tooling mouth can be subjected to air tightness testing.

11. Others

The machine is equipped with a fully enclosed protective cover, a high-flow cooling system, and is aesthetically pleasing, safe, and leak-proof. The chip removal device is simple, environmentally friendly, practical, and reliable.