UPC 100

Ultra-precise machining of freeform optics

 

Information

Introducing the UPC 100
Compact but powerful, the fully featured UPC 100 offers all the benefits of SCHNEIDER’s larger ultra-precision machines but for smaller workpieces – even software options for corrective freeform machining. It is based on a unique modular platform, developed from scratch, to achieve the highest machine dynamics.

Providing extraordinary accuracy and extremely low surface roughness, the UPC 100 is the ideal choice for producing challenging freeform applications like mold inserts with surface roughness values in the 1 – 2 nm range for polymer optics or ophthalmic applications.

No matter how complex the geometry – highly demanding 3D surfaces for head-up displays, augmented reality, laser applications or Infrared optics are manufactured with ease.

Solid design, great performance
On top of a rigid granite base the UPC 100 combines hydrostatic linear guides and aerostatic spindle technology. Unlike most existing machines in the market, the UPC 100 is a clean sheet design developed to maximize dynamic machining capability. Its perpendicular arrangement of fast tool axis and X-axis allows for direct coupling of dynamic forces into the super rigid hydrostatic guiding. This arrangement offers the best conditions for dealing with dynamic impulses and leads to both superior form accuracy and significantly minimized vibrational effects.

Its hydrostatic guidings guarantee the best damping capabilities and maximum stiffness. This serves as the perfect foundation for delivering outstanding surface quality while achieving the highest processing speed.

Compared to conventional primarysecondary setups using an auxiliary fast tool axis and separate secondary controller, the UPC 100 uses just one single main controller to drive the entire machine, including the optional fast tool. The smart architecture is fully taken into account in the core design of the hardware, software, feedback control, and safety systems. Faster communication speeds and enhanced functionality, such as full override function for touching off on freeform molds or lenses at reduced processing speed, are among the many benefits. The fast tool can process a wide range of freeform geometries at a great pace.

Best throughput, highest productivity
The UPC 100 utilizes a unique motion control system which combines an industry proven PC-based control with highest clock rate digital drives for all axes. With clock rates of up to 100kHz the controls are multiple times faster than today’s standard. This leads to a minimum of control deviation and following errors, facilitating improved high frequency damping abilities not only of the hydrostatic guiding system but also of the regulation system itself. The result is low axis vibration of +/-1nm and ultimately the lowest surface roughness values.

Highest safety standards
All SCHNEIDER UPC machines comply with the strictest international safety standards. The UPC 100 is fully encapsulated, protecting the operator in case of workpiece losses. Functionally safe encoders, RFID encoded interlocks and automated speed reductions during open door activities guarantee maximum safety for the machine operator. In addition, the full enclosure effectively reduces noise and dust emission to preserve a clean working environment.

Option set
The UPC 100 is a unique modular platform machine already prepared for automation and can be connected to existing automation systems.

An optional high-precision full area optical freeform measurement system evaluates the entire lens surface. It can be used for corrective freeform machining, serving as the perfect answer compared to expensive standalone measuring devices.

Ready for the integration of laser-assisted machining technology, even the hardest and most brittle materials can be machined. Increasing ductility at the cutting point, the material strength is selectively reduced, resulting in higher material removal rates, improved surface quality and longer tool lifetime.

An alternative option is the integration of an ultrasonic-assisted machining system that allows for processing steel, titanium and nickel alloys with ease.

Technical Data

work piece diameter

up to 300 mm

axis

3 + optional fast tool

travel X

250 mm

travel Z

150 mm

spindle speed

up to 10.000 rpm

spindle resolution

11.840 lines/rev

milling spindle

60000 – 80000 rpm (aerostatic)

vibration isolation

air springs

machine base

natural granite

controller

64-bit Windows 10 based

power consumption

max. 1.8 kVA avg.

air requirement

min. 8 bar (116 psi)

machine weight

approx. 1600 kg (3528 lb.)

dimensions (width x depth x height)

approx. 1870 x 910 x 1873 mm (74 x 36 x 74 inches)

All data subject to change without notice. Please verify details with SCHNEIDER.

Downloads

  UPC 100
PDF, 3.48 MB