Multi-Tasking Machine Enhances Flexibility, Speed and Automation Integration

Mazak continues its i-H Series rollout with the Integrex i-200H ST Multi-Tasking Machine. Like other Integrex i-H Series machines, Mazak says, the Integrex i-200H ST features a new design that increases flexibility and enhances machine performance for easier automation integration and the ability to process a variety of part types without additional expenses.

The machines within the i-H Series sport new, ergonomic enclosures with compact footprints that require less floor space. In addition, Mazak says it equipped the machines with faster and more powerful turning spindles, space-saving milling spindles and a new parallel-type lower turret with optional live tooling capabilities. The company also expanded tool capacities for lower turrets and for tool storage magazines along with offering a wider range of chuck size options.

Specific Integrex i-200H ST machine changes that ease the integration of automation are the inclusion of front and rear tool setup, a flat-front design to accommodate robots, tool magazine placement at the machine’s rear side and an retrofittable automatic machine door. Other new additions include an integrated automatic jaw changer (AJC) and the parallel-type lower turrets.

Requiring no additional robot system, the AJC quickly exchanges jaws from turning spindle chucks with others in jaw stocker systems located above both of the machine’s turning spindles. These stocker systems have room for up to 10 jaw sets that can be loaded/unloaded while the machine continues to work uninterrupted.

Along with a parallel-type turret (T), the Integrex i-200H ST sports both a main and second turning spindle (S) and a milling spindle headstock for “done in one” part production. The turret design can work with a greater range of tool lengths, eliminates interference when workpieces are held between the machine’s two turning spindles and reduces chip accumulation on the machine’s X-axis covers.

This machine accommodates a chuck size of 8” and boasts an extended Y-axis and X-axis stroke of 8.27" and 21.06" respectively for maximum part diameters of 23.62". The main and second turning spindles operate at 5,000 rpm, while the milling spindle comes standard as 12,000 rpm (24/22 kW), with a 20,000 rpm (24/22 kW) version offered as an option.

Mazak adds that the Integrex i-200H ST also uses the latest Mazak control technology, the Mazatrol SmoothAi CNC, for improved programming, controlled spindle speed for reduced vibration and greater machine thermal stability. These Mazak technologies include Solid Mazatrol, which allows users to automatically generate programs from 3D part models; SMOOTH Ai Spindle, which automatically optimizes spindle speed based on sensor feedback to minimize machining vibration for superior part surface finishes; and Ai Thermal Shield, which adapts to and learns from environmental changes to control the effects of heat on machining accuracy.

In addition to new Smooth Technology solutions and control functions, the new control also provides access to Mazak’s Mazatrol Twins software, which enables shops to create, on a PC, synchronized digital twins of real machines on their shop floors. The digital twins software solutions provide highly efficient machine operation through Smooth Project Manager that ensures efficient job setups and Smooth CAM Ai for an open and interactive interface for CAD/CAM software packages.