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FAQ WorkCenter

Machining Center eCAB WorkCenter

Frequently asked Questions

On these pages you will find frequently asked questions with answers belonging to about our machining center eCAB WorkCenter. Leaf thru the questions or choose one of the following categories:

Questions about the technical outfit
Questions about processing of materials
Questions about the software
Questions about efficiency
Other questions

Questions and answers about the technical outfit

Q	Which are the main differences between eCAB WorkCenter and eCAB Giant?
A	Both machines are based on the same approved technologies. The eCAB WorkCenter is the standard machine for panel builders who process dismountable enclosures (like Rittal TS8) up to a size of 2.400 x 1.550 mm (H x W) and non-dismountable enclosures (like Rittal AE) up to 1.600 x 1.000 mm (H x W). For bigger non dismountable enclosures we offer the eCAB Giant. It can handle enclosures up to a size of 2.400 x 1.450 mm (H x W). Both machines offer many unique selling proposition compared to other solutions for panel builders.

Q	Which kind of tools are included in the scope of supply of the machine?
A	The machine is shipped with 12 standard tools: 3 drills for through holes (5, 5.5, 6mm), thread-moulders M4, M5, M6, M8 with pilot drills and one powder metal end milling cutter. If you need another tool outfit we can meet your needs.

Q	We need more than 12 tools. Is the tool hopper expandable?
A	Yes, the tool hopper can easily be expanded up to 18 tools at small additional costs. The tool holders are DIN certified (SK30 tool holder with hardened and grinded full metal ER collets) an can be purchased through Steinhauer or many other sources.

Q	Are tool-type dependent tool-holders needed?
A	No, each tool holder can be used for borers, pilot drills, thread moulders, thread cutters, milling cutters, circular milling cutters or engraving tools.

Q	Does the machine need length compensatory tool holders for the tapping tools?
A	No. Threads are cut with thread pitch over the Z-axis (metric as well as non-metric), so no expensive or outdated length compensatory tool chucks are needed. Each collet chuck is suitable for any type of tool.

Q	What is meant by the "circular milling option" ?
A	The circular milling option is needed for the making of large threads (M20-M63) with only one additional tool, the circular milling cutter. While X- and Y-axis of the machine describe a circle, the Z-axis is driven into the material with thread pitch while the C-axis is rotating with dependent speed. A special circular milling cutter mills a thread during this process.

Q	What is the advantage of a mouldet thread over a cut thread?
A	Normally a panel builder works with thin sheet metal of a thickness between 1-3 mm. In thin sheet metals a thread often ends after 1.5 turns, so no strong carrying capacity can be achieved. To reinforce the carrying capacity of a thread it can be moulded by compressing the material instead of cuting it. A moulded thread offers about 40% higher strength as a cut thread. For thread moulding much higher forces are needed as for regular tapping. Due to it's 5.5 kW NC-Motor with constant high torque of 7.5 Nm at all relevant speeds for thread making the eCAB WorkCenter can form all threads up to M12. A pleasant side effect of thread moulding is a tool lifetime which is about 20 times higher than the lifetime of a thread cutter. Therefor a moulded thread is much stronger and cheaper than a cut thread. Since the algorithm for thread moulding and thread cutting is exactly the same (only the pilot drills differ) both types of tools can be mixed at the users decision.

Q	How are the tools to be changed?
A	The machine has a fully automatic tool changer with SK30 collet chucks (industry standard).

Q	Will the tools be lubricated automatically?
A	Yes, during all processes where this is needed. The automatic Minimum-Quantity Lubricating System lubricates drills, thread moulders and milling cutters with spray oil. Automatic lubrication can fully be controlled by software.

Q	Is there any tool breakage or tool wearing monitor?
A	Yes, already in the standard scope of delivery a tool breakage monitor for the thread-moulders (as the only critical tools) is included. If the thread-moulders are driving into a position where a pilot-drill should have drilled a hole (but could not do so because of tool-breakage) the SPC will generate a tracking error and stop the program immediately. After changing the broken tool the program will continue at the right position. In addition to that it will be monitored if there are suitable tool at all in the tool-bins. As standard there will be no monitoring for the other tools, since the costs for a real tool breakage sensor will be out of all proportions to the advantages. The optional tool monitoring system does not only detect tool breakage of all tools but even tool wear and tool erosion in realtime on a basis of energy-control, power-control and divergence-control. Unlike less convincing optical monitoring systems, which only control the quality of tools after deposition in the tool-bin and which must be measured in after any tool-change our tool monitor has no influence on tool handling.

Q	What are the system requirements for the machine?
A	An industrial PC with TFT/DVI display, keyboard and mouse for the supplied CAD- and control applications is included in the scope of delivery. The industrial PC is mounted in the switch cabinet of the machine and can easily be scaled for future operating systems or applications. The PC is running under Windows XP.

Q	Are there any special tools needed?
A	No. All tools are standard tools - you can order them by catalogue and they are available through many sources.

Q	Is it possible for the tools to drive into the plastic distance bolts on the workpiece seat?
A	Yes, it is. These plastic bolts are designed as expendable parts. They will last for a very long time and they cost about 3.70 € each as spare parts. To prevent the tools from driving in the bolts a bolt-raster overlay can be visualised in the DXF-preview. Bolts effected by tools can be removed or shifted before the machine starts production.

Q	We don't like the security fences on the left and right side of the machine. Can we order it without them?
A	No. The security fences are part of the machine's safety regulations and the attestation of conformity

Q	Why do you use a powder metal end milling cutter instead of a hard metal end milling cutter
A	In principle one can use both types of milling-cutters. A hard metal end milling cutter needs high rotational speed and vibration-free operation, which usually must be guaranteed by use of complex pressing down mechanisms right at the tool-head. There are no advantages regarding lifetime and cutting speed compared to a powder metal end milling cutter. Tool-life of a powder metal end milling cutter (on average 65-85 m milling-distance per milling-cutter) is much better at lower costs as for a fragile hard metal end milling cutter. Noise emission is lower and the range of possible rotational speeds is bigger. Handling is much easier. By firm use of high-quality and standardized industrial components (SK30 steep-angle tapers, high-frequency CNC-spindle motor) radial deviation and therefore vibrations and noise could be minimized, allowing milling speeds of up to 5 times faster than earlier machines at a lower noise level. Even at a milling speed in steel of 1,700 mm/min noise-emission of the machining centers will remain under the legal noise limit to be operated without personal protection devices, like ear protectors. There is no need for vibration reducing workpiece holders since vibrations are reduced by an excellent radial deviation.

Q	Are there advantages of a milling cutter compared to a mechanical press?
A	Yes, in handling of lacquered parts. Punching out cutouts can chip off the lacquer at the edges. This does not happen during milling processes. Besides that a press needs a special and expensive hard metal plunger for any contour needed. The machine can cut any contour without the need for special tools.

Q	Isn't the corner radius of the milling cutter a problem for mounting parts?
A	No, nearly all mounting parts can be mounted in spite of the corner radius of 3 mm. If not, the corners can be filed out to end measures easily or a second milling cutter of smaller diameter can be used. Alternatively the corners of the cutout can be drilled with a small diameter drill to achieve a corner radius of 0.5 mm as part of a CNC program.

Q	Is it possible to install more than one milling-cutter?
A	Yes. The machine supports as many milling-cutters of same or different diameter as you need, up to a total of 17.

Q	Will the milling cutter be worn out only at one spot?
A	No. While milling we move the milling cutter in and out over the Z-Axis and it will be worn out evenly giving a much longer tool life.

Q	Does the machine need compressed air?
A	Yes. It needs 6-8 bar, about 300 l/min. For workshops without compressed air supply just order the compressor-option.

Q	Which influence has the positioning speed on the material-flow?
A	None to only a little. The Steinhauer eCAB WorkCenter machining center has a positioning speed of up to 60 m/min (X- and Y-axis, Z-axis: 45 m/min), which is up to 4 times faster than earlier machines. By means of mathematical methods for distance optimization tools are used optimized. A tool change only happens when all steps with the tool are finished. Time is not an important parameter for a fully automated machine like this - but noise emission and solid machine construction are. The wide experience of all of our customers shows us that the system, which is a fully automated machine, will work only 60-70% of the working hours, even at companies with a strong material flow. If we increase the speed of positioning, which is easily possible, we would increase the noise dramatically. The increase of noise would have a large and negative impact on work ergonomics since employees usually have to work in close proximity to the wiring of switch cabinets.

Q	Other machines do use toothed rack drives for the positioning of X- and Y-Axis. Why does Steinhauer AG use ball screw drives for positioning?
A	Chips can end up everywhere - it's a miracle how they find their way to the strangest places of the machine. For example by means of the compressed air people use for cleaning the machine. As long as chips are made of soft material, like f.i. wood, this usually is not a problem for a toothed rack drive since the gear-wheel will walk over it. Other with metal chips who end up within the teeth of the toothed rack drive, sticking onto it due to grease or oil dust. If the gear-wheel walks over one of those metal chips the gearing might be seriously and instantly damaged. The use of toothed rack drives is an absolute no-no in mechanical engineering. Positioning travel is realized in principle by means of ball screw drives which are resistable against any kind of chips.

Q	Which CNC/SPC and motive power engineering is used within the Steinhauer Machining centers?
A	The CNC/SPC as well as the motive power engineering and the frequency-converters are made by Beckhoff and meet the latest technical standards. All active components are wired using Realtime Ethernet (EtherCAT) and controlled by TwinCAT environment. Therefore the machines are fully capable of remote management and service. The CNC-kernel understands DIN-code and has a full-contour editor which is capable of cutting any contour, even true-type fonts. Besides CNC/SPC an industrial PC running under Windows XP Pro is shipped with the machine. It is used for the control of the machine as well as for running the Steinhauer software (CAD and postprocessor for automated CNC program generation).

Q	How many programs can be held in the CNC control of the machining center?
A	The number of production-programs in the CNC/SPC is only dependant on the size of the hard-drive in the industrial PC. Usually this means a couple of thousands of ready to use programs.

Q	Are the machines remote maintainable?
A	Yes, all active components up to the last bus-terminal are remote-maintainable through Internet. Remote maintenance uses a highly encrypted connection and only needs a suitable IP-stack on the industrial PC. Remote management can be used for training purposes or user-guidance too. Remote maintainance assures a very low cost of ownership.

Questions and answers about processing of materials

Q	Which materials can be machined on the eCAB WorkCenter?
A	The machines can process steel, special steel (V2A, V4A), copper, aluminium, PVC, GRP and other plastics. Depending on the type of material the machine will work with different forward feeds and rotational speeds according to our material parameter database.

Q	Is it possible to machine Aluminium?
A	Yes. It is possible to machine all types of Aluminium used in switch-cabinet making and electronics with the eCAB WorkCenter.

Q	Is it possible to machine Copper current bars?
A	Yes, it is possible to drill, tapp or mill Copper current bars up to a thickness of 10 mm. See picture

Q	We need oversize mounting-plates to be machined. Is it possible to do that with the Steinhauer machines?
A	Yes, the eCAB WorkCenter allows machining of oversize workpieces up to 2,400 x 1,550 mm.

Q	Up to which size can we process complete enclosures?
A	The machine allows processing of all surfaces of non-dismountable enclosures up to a size of 1,600 x 1,000 mm (H x W) Therefore you can process the complete Rittal AE-spectrum including oversize measures. Front doors are usually detachable and can be machined on the front side of the machine.

Q	How can we machine complete housings and cases?
A	Beside the regular workpiece seat for flat workpieces, like mounting plates, the machine has a door in the machine front for complete housing assemblies. By opening this door the machine gets converted for case processing. The case will be fixed on the machine by means of pneumatic fixtures. It is easily accessible from the rear and front of the machine.

Q	Is it possible to mill channels (i.e. non through channels) and do engravings?
A	Yes, it is. With the engraving option it is possible to mill channels and engrave arbitrary contours, even on bent surfaces.

Questions and answers about the software

Q	We need more than one software workstation. Is this possible and how much does it cost?
A	It is possible and the costs are really low. Our software base is AutoSketch, a CAD software for something around 180 €. Together with the machine you will get the first license and our extensive symbol- and component libraries. You may copy these libraries freely and use them on as many systems in your company as you like. All you will need are additional AutoSketch licenses.

Q	Can we use the software on a network?
A	The AutoSketch CAD-software, like most other CAD software, must be installed on the local PC, but you can install the libraries and the drawings on a network server and use them from as many PCs as you like.

Q	Is it possible to connect the machine's software to a cable confection system?
A	Yes. We provide approved interfaces for all major cable confection systems (like Metzner Triathlon or CadCable CabinetLayout).

Q	Must we take tool radius into consideration?
A	No. You are planning in the CAD software with end-measures. The software will apply a tool-radius offset automatically.

Q	Is the change of position of tools in the tool-magazine critical if we want to process older jobs?
A	No, all projects are absolutely independent from tool location in the tool-bin. After changing a tool's position in the tool-database all programs will continue with the tool from the new location.

Q	Can we plan multispan switch-cases in one drawing?
A	Yes, and even more. In the CAD software you can plan multispan assemblies in one drawing together with all additional housing components. For instance you can place a door next to the mounting plate to ensure that elements placed on the door (like mains-switch) are in true alignment with elements on the mounting plate. During export to the postprocessor the drawing will automatically be separated to the right number of machine programs, which can be run as a sequence or selective afterwards.

Q	Why don't you use your own CAD-kernel for your layout software?
A	Well, to design and maintain an own CAD kernel many software developers are needed. We wanted to concentrate on a suitable design tool for switch cabinet planning and we wanted a perfect CAD environment as a base for it. So we use a CAD product from the world market leader Autodesk and concentrate on add-on programming to optimise the product for the needs of switch cabinet makers. Our own programming always will be compatible to the most recent version of AutoSketch. It allows bi-directional data exchange with our Postprocessor and many third-party E-CAD applications and provides a functionality and integration depth no competitor can offer.

Q	Do you supply only sample libraries?
A	No. Our machining centers ship with component libraries with more than 1000 detailed symbols, corresponding to a couple of thousand real parts from switch cabinet manufacture. Since many parts have identical mounting borings or cut-outs we can use a one-to-many interface to keep data administration easy.

Q	Are the symbol and component libraries extendable?
A	Of course they are. You can create new symbols using AutoSketch and new database entries using our comfortable component generator (in the scope of supply of the machine). New parts can be defined in AutoSketch or in the database. The corresponding entry will be generated automatically.

Q	Which databases are you using for the component libraries?
A	We are using open standard databases from the Microsoft Office suite (i.e.: MS-Access, MS-Excel). The user can access these database directly to change component-, tool- or geometrical data. Alternatively one can use other databases, like SQL-databases from PPS-systems.

Q	Should we archive finished projects as machine programs or as a CAD-drawing for further use?
A	In principle both methods of archiving are possible. If saved as a CAD drawing one can always add or change details to use the drawing as a base for variant construction. If a project should always be machined in an identical layout it could be saved as a finished machine program in the control of the Machining Centre. In both ways you are free to use your own naming conventions for the project archive, like project-, part-, or order-numbers.

Q	Can we use the machine with another E-CAD software?
A	Sure. Our postprocessor (the software which converts the CAD-data to a control programme for the SPC) can cope with any E-CAD software suitable for CNC-manufacture. In this case the other E-CAD software will replace our AutoSketch solution. You can even use a PPS system and replace our standard components database with it. We would be pleased to show you all connected planning phases of your customer-orders: Our software enables you to make all the drawings of mounting plates, doors or other components of the switch case and use named components from your preferred E-CAD (like EPLAN etc.) application's part-list. The typical way through your company's departments will be supported by the STEINHAUER software: The electrical drawings with named components will be made in the construction office with the application you are used to (like EPLAN). The workshop receives the drawings and changes them according to the needs of the workshop. An additional drillhole here, an over-current cut-out there - just as necessary. The resulting data will be used seamless for the machining center. After finishing the job in the workshop the modified drawing data will be returned to the construction office electronically for being merged with the other data for a complete customers documentation. You will receive a software system which will enable you to fulfill all your duties without gaps and very user friendly. None of our competitors meets this perfection in CAE production.

Q	In which languages is the Steinhauer software available?
A	At the time being the Steinhauer software (Postprocessor and Control-desktop) is available in German, English and Dutch language. Other language versions can easily be realized. The CAD software AutoSketch is available in German, English and French.

Questions and answers about efficiency

Q	From what quantities will the machine to be used efficiently?
A	If we use a leasing model with 54 month term and calculate with selfcosts for a qualified craftsman of 28,- € per hour the machine will be cost-efficient from 15 fields (or mounting plates) per month. The additional possibility of machining outer case components like doors, roofs or side panels as well as complete cases will improve the efficiency dramatically.

Q	What are the tool life times and costs expectable?
A	The service life of the tools depends on the type and thickness of material (steel, special steel or synthetics). At regular use one can expect about 65-85 metres from the milling cutters, between 5,000 and 6,000 drilled holes per twist drill and a nearly unlimited endurance for the thread moulders. By means of tool optimization and automated driving the endurance of tools is bigger than in any way of manual processing. The average price of a suitable milling cutter is between 10 and 15 €, the short twist drills and thread moulders are, depending on the diameter, between 3-16 € (drills) and 11-25 € (thread moulders).

Q	Are there any efficiency aspects not taken into consideration in the efficiency calculation?
A	Yes, plenty. Let's start with the fact, that qualified specialists for switchcase manufacture have to drill holes, cut threads and cutouts by hand, which is expensive. The whole locksmithery, which is an unpleasant experience for humans, can be taken care of by the machine. Besides that all manual processes with hand tools are extremely noisy, unhealthy and demotivating, especially for employees who have to do concentrated work nearby. Another aspect is the reduction of stockholding- and financing costs for material to be used within the switchcase cabinet. Planing a mounting plate often means to place all the components on it, arranging them manually. They have to be in stock to do that. Using our software you don't have to have one piece in stock. The last aspect is the reduction of human mistakes.