KESSLER Milling

Milling Spindles MILLING SPINDLES

The KESSLER milling spindles have a modular design.
 
Configure your own milling spindle model by specifying the installation position, motor,
speed, bearing, lubrication and sensory system – the perfect customized solution for your
individual branch and application needs.

KESSLER offers more: As an internationally successful company with extensive and highly specialized  expertise, we provide comprehensive advice about the design and manufacture of individual components and project management of complex system solutions. We use the very latest technology and analytical processes to test our components under realistic conditions, so that our products help your business to stay flexible and maintain its competitive edge.

Our in-house development division is supported by extensive calculation and analysis skills
and covers everything from drive technology to the construction of all-in-one systems.
Furthermore, optimized production and assembly lines provide the framework for stable processes
and the superior quality of our milling spindles.



 
The V line is all about
  • Vertical machining
  • Suitable for tilting operation
  • Milling spindle for processing of different materials
  • Milling spindle for processing of workpieces with varying geometries
  • Use in small and large-scale production
  • Short duration until reaching the stable Tool Centre Point (TCP)
  • Equipped with shaft clamping for turning operation
  • Option to measure the axial shaft displacement

All advantages of the modular system
at a glance
  • The best matching COOLMOTION® motor for your individual needs:
    With very high torque, very high speed or high-compact design
  • Various bearing lubrication systems available
  • Hydraulic, pneumatic or electric release unit available
  • High flexibility: KESSLER rotary union for the media: Cooling lubricant,
    dry operation, compressed air, minimum cooling lubrication compatibility
  • Process reliability due to extensive sensory system
  • Analog or digital tool clampingstatus monitoringavailable on request
  • Hydraulic clamping for turning operations available
  • High power density due to very compact,
    space-saving design and light weight
  • Reduction of TCO (Total Costs of Ownership) due to the rapid change of the rotor exchange group (KESSLER QCC)
  • High availability with the KESSLER tool clamping system
  • High flexibility: Various tool interfaces available
  • High operational safety with LEDs due to optimal illumination of the tool intervention
  • Bearing preload dynamically adaptable to the machining process
  • Robust: Designed for high load forces in the machining process
Our V line variants
Model V100 V200 V400
Maximum speed (rpm) 24,000 18,000 15,000
Spindle fitting Ø (mm) 202 230 270
Tool interface HSK 63
BBT 40 / SK 40
Capto C6
A 100
SK 50 / BBT 50
Capto C8
A 100
SK 50 / BBT 50
Capto C8
Impress with
  • high flexibility
  • optional shaft clamping
  • tilting operation optional


Milling spindle / V100
  • Spindle fitting: Ø 202 mm
  • KESSLER COOLMOTION® motor
  • Rotary union: Internal coolant supply with high volume flow
  • Cooling: Closed cooling circuit
  • Bearing lubrication: Grease / re-greasing / oil-air

A few of the many KESSLER motors   
Select the right COOLMOTION® motor for your needs from our extensive range

S1 S6 / 40% S6 / 25% S6 max.
Maximum speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
High speed 24,000 70 22 110 35 130 41 190 60
High torque 15,000 130 30 201* 46 217 50 217 67
Bestseller 20,000 87 25 135* 40 150 44 203 60
Entry-level model 14,000 80 15 112 21 129 24,5 141 27

Other synchronous and asynchronous motors available on request

* S6 40% / 25 % 2min DC


Milling spindle / V200
  • Spindle diameter: Ø 230 mm
  • KESSLER COOLMOTION® motor
  • Rotary union: Internal coolant supply with high volume flow
  • Cooling: Closed cooling circuit
  • Bearing lubrication: Grease / re-greasing / oil-air

A few of the many KESSLER motors   
Select the right COOLMOTION® motor for your needs from our extensive range

S1 S6 / 40% S6 / 25% S6 max.
Maximum speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)

High speed
18,000 185 57 205 57 235 57 260 57
High torque 12,000 235 54 265 54 305 54 335 54
Entry-level model 15,000 185 57 205 57 235 57 260 57

Other synchronous and asynchronous motors available on request


Milling spindle / V400
  • Spindle fitting: Ø 270 mm
  • KESSLER COOLMOTION® motor
  • Rotary union: Internal coolant supply with high volume flow
  • Cooling: Closed cooling circuit
  • Bearing lubrication: Grease / re-greasing / oil-air

A few of the many KESSLER motors   
Select the right COOLMOTION® motor for your needs from our extensive range

S1 S6 / 40% S6 / 25% S6 max.
Maximum speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
High speed 15,000 300 48 445 70 535 84 640 100
High torque 10,000 365 46 510 64 630 80 750 95
Entry-level model 15,000 220 35 305 48 350 56 405 65

Other synchronous and asynchronous motors available on request


Modular extensions available
  • Choose the best matching KESSLER COOLMOTION® motor for your needs
  • KESSLER rotary union  
    - Cooling lubricant
    - Dry operation  
    - Compressed air
    - Minimum cooling lubrication capability
  • Sensor monitoring system
    - Face end contact monitoring
    - Vibration sensor  
    - Analog sensor
    - Eddy current sensor
    - Clamping status monitoring
    - Clamping monitoring
    - Leakage monitoring
    - Temperature sensor PT100
  • Hydraulic clamping
  • Bearing preload: Variable
  • Bearing lubrication: Grease / re-greasing / oil-air
  • Closed cooling jacket
  • Clamping spring package is designed for 5 million tool changes
  • Standard cable outlet, connector optional
  • Holding-function for collet chuck: Variable
  • 2-channel rotary union
  • Oil-air lubrication unit
  • Re-greasing unit
  • Direct lubrication: on demand

COOLMOTION® for the V line
  • achieves a very high torque density
  • achieves very short acceleration times
  • performance-enhanced motors for a compact design
The MT line is all about
  • 5-axis machining
  • Very short construction thanks to release unit and rotary union integrated in the shaft
  • Can be used in tilting heads
  • Processing of different materials
  • Machining of workpieces with varying geometries
  • Use in small and large-scale production
  • Short duration until reaching the stable Tool Centre Point (TCP)
  • As an option, can be supplied with clamps for turning operations
  • Option to measure the axial shaft displacement
All advantages of the modular system
at a glance
  • The most suitable COOLMOTION® motor for your individual needs:
    With very high torque, very high speed or high-compact design
  • Various bearing lubrication systems available
  • Hydraulic release unit
  • High flexibility: KESSLER rotary union for the media: lubricant,
    dry operation, compressed air, MQL capability
  • Process reliability due to extensive sensory system
  • Process reliability due to extensive sensory system
  • Analogue tool clamping status monitoring
  • Hydraulic clamping for turning operations available
  • High power density due to very compact,
    spacesaving design and light weight
  • Reduction of TCO (Total Costs of Ownership) due to the rapid change of the rotor exchange group (KESSLER QCC)
  • HSK and Capto tool interfaces
  • High degree of operational safety thanks to LEDs due to optimal illumination of the tool intervention
  • Robust: Designed for high load forces in the machining process
Our MT line variants
Model MT80 MT100S MT100L MT100H MT400 MT500 MT600
Maximum speed (rpm) to 24,000 20,000 20,000 20,000 15,000 10,000 8,000
Torque S6 / 40 % (Nm) to 95 120 210 235 560 850 1,250
Spindle fitting Ø (mm) 170 202 202 202 270 325 395
Length overall (mm) 475 385 475 530 628 TBD TBD
Tool interface HSK 63 
Capto C6
HSK 100 
Capto C8
HSK 125 
Capto C10
Impress with
  • very short construction
  • very short vector length
  • high effective torque at the tool cutting edge
  • Quick Connect Cartridge (QCC)* reduced machine downtimes for servicing
  • optional shaft clamping

*Not with MT80 and MT600


Milling spindle / MT80
  • Spindle fitting: Ø 170 mm
  • KESSLER COOLMOTION® motor
  • Cooling: Open cooling housing
  • Bearing lubrication: Oil-air / re-greasing

Choose the most suitable COOLMOTION® motor from the list of preferred motors

Model   S1 S6 / 40% S6 / 25% S6 max.  
  Max. speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
 
MT80-S24 24,000 55 40 65 40 70 40 80 40 High speed
MT80-S20 20,000 80 45 95 45 110 45 145 45 High torque

Available on request
Not available with Quick Connect Cartridge (QCC)


Milling spindle / MT100 S / L / H
  • Spindle fitting: Ø 202 mm
  • KESSLER COOLMOTION® motor
  • Cooling: Open cooling housing
  • Bearing lubrication: Oil-air / re-greasing

Choose the most suitable COOLMOTION® motor from the list of preferred motors

Model   S1 S6 / 40% S6 / 25% S6 max.  
  Max. speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
 

MT100S-S20

20,000 85 20 100 20 115 20 170 20 High speed

MT100S-S12

12,500 100 36 120 40 130 43 180 48 High torque

MT100L-S20

20,000 130 45 160 45 180 45 200 45 High speed

MT100L-S12

12,500 175 54 210 54 235 54 280 54 High torque

MT100L-A15

15,000 100 24 135 32 170 40 170 40 Entry-level

MT100H-S16

16,000 150 40 180 40 200 40 250 40 High speed

MT100H-S12

12,500 200 54 235 54 265 54 315 54 High torque

MT100H-A15

15,000 115 26 175 40 215 48 230 52 Entry-level

 

Available on request


Milling spindle / MT400
  • Spindle fitting: Ø 270 mm
  • KESSLER COOLMOTION® motor
  • Cooling: Open cooling housing
  • Bearing lubrication: Oil-air / re-greasing

Choose the most suitable COOLMOTION® motor from the list of preferred motors

Model   S1 S6 / 40% S6 / 25% S6 max.  
  Max. speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
 

MT400-S15

15,000 315 87 365 87 375 87 390 87 High speed*

MT400-S12

12,000 500 75 635 75 670 75 700 75 High torque*

 

*Available on request


Milling spindle / MT500
  • Spindle fitting: Ø 325 mm
  • KESSLER COOLMOTION® motor
  • Cooling: Open cooling housing
  • Bearing lubrication: Oil-air 

Choose the most suitable COOLMOTION® motor from the list of preferred motors

Model   S1 S6 / 40% S6 / 25% S6 max.  
  Max. speed 
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)

MT500-S6

6,000 800 67 930 67 1,000 67 1,100 67

 


Milling spindle / MT600
  • Spindle fitting: Ø 395 mm
  • KESSLER COOLMOTION® motor
  • Cooling: Open cooling housing
  • Bearing lubrication: Oil-air 

Choose the most suitable COOLMOTION® motor from the list of preferred motors

Model   S1 S6 / 40% S6 / 25% S6 max.  
  Max. speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)

MT600-S5*

5,000 1,200 75 1,350 75 1,500 75 1,600 75

 

*Available on request
Not available with Quick Connect Cartridge (QCC)


Modular extensions available
  • Choose the most suitable KESSLER COOLMOTION® motor
  • Sensor monitoring system
    - Vibration sensor
    - Eddy current sensor detects axial shaft displacement
    - Clamping status monitoring
    - Clamping monitoring
    - Temperature sensor PT100
  • Hydraulic clamping
  • Bearing preload
    variable
  • Closed cooling jacket
  • Clamping spring package is designed for 3 million tool changes
  • Oil-air lubrication unit
  • Re-greasing unit on demand
  • Direct lubrication: on demand
The H line is all about
  • Horizontal machining
  • Typical applications: Automotive industry, process machines
  • Milling spindle for machining of similar work pieces, with similar working cycles with a high work frequency
  • Milling, drilling, thread cutting, grinding, boring of
    aluminium, castiron and steel
  • Internal monitoring of milling spindles (condition monitoring)
  • Tool clamping system designed for a maximum amount of tool changes
  • High speed: Up to 25,000 rpm
  • High torque: More than 400 Nm

All advantages of the modular system
at a glance
  • The best matching COOLMOTION® motor for your individual needs: With very high torque, very high speed or high-compact design
  • Various bearing lubrication systems available
  • Hydraulic or electric release unit available
  • High flexibility: KESSLER rotary union for the medias: lubrication, dry operation, compressed air, minimum cooling lubrication compatibility
  • Process reliability due to extensive monitoring system
  • Spindle fitting diameter and position: The spindle fitting diameter can be configured accordingly to meet your specific requirements
  • High productivitywith the KESSLER tool clamping system – Clamping spring package is designed for 5 million tool changes
  • High productivity due to short acceleration and braking times
  • Milling spindle with end face contact monitoring
  • Removable assemling flange
  • Variable interface: Full contact plane surface or segmented plane surface
  • Various spindle heads available
    – Individual shapes can be defined as required
  • High operational safety with LEDs due to optimal illumination of the tool intervention
  • 2x or 4x bearings available
Our H line models
Model H80 H100 H200
Speed (rpm)

25,000

20,000 15,000 / 16,000
Spindle fitting Ø (mm)  170  200  240
Tool interface HSK 63 HSK 63 HSK 100 / 63
Impress with
  • very short acceleration times
  • high power
  • low rotor torque of inertia

Milling spindle / H80
  • Spindle fitting: Ø 170 mm
  • KESSLER COOLMOTION®motor
  • KESSLER tool clamping system: Clamping spring package
    is designed for 5 million tool changes
  • Rotary union: Inner coolant supply
    with large volume flow
  • Cooling: Closed cooling circuit
  • Bearing lubrication: Grease / re-greasing / oil-air

A few of the many KESSLER motors
Select the best matching COOLMOTION®-motor for your needs from our extensive range

S1 S6 / 40% S6 / 25% S6 max.
Maximum speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
High speed 25,000 80 33 100 33 105 33 115 33
High torque 20,000 95 33 110 33 125 33 140 33
Entry-level model 24,000 40 16 60 24 75 30 95 38

 Other synchronous motors available on request


Milling spindle / H100
  • Spindle fitting: Ø 200 mm
  • KESSLER COOLMOTION®motor
  • KESSLER tool clamping system: Clamping spring package
    is designed for 5 million tool changes
  • Rotary union: Internal coolant supply with high volume flow
  • Cooling: Closed cooling circuit
  • Bearing lubrication: Grease / re-greasing / oil-air

A few of the many KESSLER motors
Select the best matching COOLMOTION®-motor for your needs from our extensive range

S1 S6 / 40% S6 / 25% S6 max.
Maximum speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
High speed 20,000 120 36 140 36 150 36 165 36
High torque 15,000 170 32 210 32 235 32 270 32
Entry-level model 20,000 60 19 90 28 112 35 172 54

 Other synchronous and asynchronous motors available on request


Milling spindle / H200
  • Spindle fitting: Ø 240 mm
  • KESSLER COOLMOTION®motor
  • KESSLER tool clamping system: Clamping spring package
    is designed for 5 million tool changes
  • Rotary union: Internal coolant supply with high volume flow
  • Cooling: Closed cooling circuit
  • Bearing lubrication: Grease / re-greasing / oil-air

A few of the many KESSLER motors
Select the best matching COOLMOTION®-motor for your needs from our extensive range

S1 S6 / 40% S6 / 25% S6 max.
Maximum speed
(rpm)
 Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
Torque
(Nm)
Power
(kW)
High speed 16,000 160 63 180 63 215 63 231 63
High torque 10,000 350 55 390 55 460 55 500 55
Entry-level model 14,000 200 42 300 62 300 62 300 62

Other synchronous and asynchronous motors available on request


Modular extensions available
  • Spindle heads: variable
  • Bearing: 2x or 4x bearings available
  • Choose the best matching KESSLER COOLMOTION® motor for your needs
  • KESSLER rotary union
    - Cooling lubricant
    - Dry operation
    - Compressed air
    - Minimum cooling lubrication capability
  • Spindle fitting  Ø (position A and B side): variable
  • Sensor monitoring system
    - Face end contact monitoring
    - Vibration sensor
    - Clamping status monitoring
    - Leakage monitoring
    - Temperature sensor PT100

  • Segmented plane surface
  • Bearing preload: variable
  • Assembling flange removable
  • Bearing lubrication: Grease / re-greasing / oil-air
  • Standard cable outlet, connector optional
  • Holding-function for collet chuck: variable
  • 2-channel rotary union 

  • Oil-air lubrication unit
  • Re-greasing unit
  • Direct lubrication: on demand

COOLMOTION® for the H line
  • achieves a very high torque density
  • achieves very short acceleration times
  • performance-enhanced motors enable a compact design

Quick Connect Cartridge (QCC)

Fast replacement of rotor shaft, front / rear bearing and power drawbar on-site

Reduces TCO (Total Costs of Ownership)

Reduces machine downtime

No electrician needed

Keeping up with the beat of the spindle

The KESSLER diaLOG intelligent system for data processing and condition monitoring is our solution for a connected industry

  • Integrated electrical current, temperature and vibration sensors determine the current, frequency, temperature conditions and vibration acceleration.
  • An intelligent digital network system (KESSLER diaLOG) analyses and evaluates process data.
  • Detects and stores exceeding marginal values
  • Interface with the network infrastructure or machine tool
  • Process data is forwarded to control systems in real time. The system for data transmission will be available in 2018 for TCP / IP or ProfiNET interface.
  • Predefined marginal values will permanently be controlled and monitored by the system. The diaLOG App has been developed for the evaluation of the diaLOG data.
  • Its functions are planned to include preventive maintenance and on-going data collection.
  • In future, correction factors will be conveyed from the motor spindle to the user and warning reports will automatically follow to the process control systems.
  • KESSLER diaLOG in the product, supports it being subjected to a complete process visualization.
  • Applicable in the whole product portfolio and other application areas possible.
  • SPINDLE MONITORING
    - Live view of all diaLOG sensor data
    - Analysis of functions by means of individual values
  • FINGERPRINT
    - KESSLER fingerprint
    - Detection of the as-found fingerprint (test bench)
    - Comparison in the case of spindle repairs
    - Commissioning fingerprint in the machine tool
    - Cyclical comparison with the new fingerprint
    - Data export
  • CONDITION MONITORING
    - Display of captured limit value exceedances
    - Transport monitoring
    - Crash detection
    - Overload detection
    - Display of continuously captured data
    - Load spectra
    - Loading conditions
    - Histogram data
  • PRODUCT DATA
    - Display of data on the spindle type plate
    - Display of converter parameters
    - Data export

Availability on request


KESSLER diaLOG - All advantages at a glance
  • Condition monitoring by detecting exceeding marginal values
  • Improved operational reliability in customer processes (Process performance, operation time)
  • Reduces TCO (Total Costs of Ownership)
  • Reduces machine downtime
  • Reduces unexpected downtimes
Very short tool change cycle times
All advantages at a glance
  • Higher accuracy due to reduced heat input into the machine tool, since no hydraulic unit is required
  • Simple and quick to install
  • Designed for at least 2 million tool changes
  • Extremely short tool change time with 0.2 sec.
  • Low-maintenance
  • Energy-efficient
  • Very fast chip-to-chip times possible due to short tool change cycle times
S1 S6 / 40%
[DC: 2 min]
Tool interface Axial force
Torque (Nm) Power (kW) Torque (Nm) Power (kW)    
14 4.5 40 13 HSK 63 / HSK 100 25 kN
Functionality

The InterFace Control System (IFC) is a face detection system for detecting a tilted position of the tool in the tool interface caused by a foreign object such as a chip caught between the tool face and spindle. A sensor installed in the bearing cover of the spindle measures the deformation or deformation of the tool holder on a ring gauge. The measurement takes place either during acceleration of the spindle or at constant speed. The communication between the industrial PC and the controller takes place via ProfiNET. An application especially for machining processes where a particularly high accuracy of tool clamping is required.

All advantages at a glance

o Process safety: High reliability through > 99 % detection probability

o Sensitivity: Chips > 40 µm directly detectable. Small chips, between 20 µm and 40 µm visible with teaching

o 100% detection range: Chip detection over the entire circumference of the flat surface

o High robustness and long service life due to non-contact measurement without the need for rotating parts or rotary transmitters

o Main time neutral: Due to the measuring possibility during the acceleration phase, no interruption of work necessary; alternatively also possible at constant speed

o Speed stability: suitable for speed ranges up to 30,000 rpm

o Evaluation electronics outside the spindle: low integration effort, installation in short spindles possible

o Length growth sensor included, without additional sensor

o Fast switch-off option when chips are detected due to shortest measuring time within only three spindle revolutions (see Kessler Motor Spindle H80 < 150 ms)

o Can be integrated into the H80, H200, V100, MT80 and MT100 spindles and many more on request

o Maintenance/sensor exchange possible with installed spindle


Basic principle

Tools act with a force on the flat surface and on the cone surface and create an individual Deformation. Deformation can be detected by an eddy current sensor on a rotating measuring ring.

Chip between tool holder and spindle shaft produces an uneven deformation


System configuration

Technical data

o Chipsize LxWxH:

      - >7x1x0,04 mm (Steelchip, without reference measuring)

      - <7x1x0,04 bis >7x1x0,02mm (Steelchip, with needed reference measuring) 

o PROFINET connection for PLC communication

o Optional Connection to screen Input device (HMI)


Sensitivity

o   Chips > 40 µm directly visible

o   small chips with a size between 40 µm and 20 µm and left-hand rotating tools require teaching

o Achievable accuracy depends on the spindle and the sensor position

      - HSK 63   è 20-30 µm

      - HSK 100   è 30 µm


Communication/Interface

o ProfiNET

o GSD file describes interface

o industrial standard protocol

o Customer can choose between different measurement Options

  - Ramp, constant, with reference, without reference

o Shaft displacement

o Customer receives status, error message

o Future measurements