Spindles for chamfering and drilling with compliance by Mannesmann Demag for your robot

Spindles with Deflection for Countersinking and Drilling by Mannesmann Demag for Your Robot

Spindles with deflection from Mannesmann Demag are designed for precise countersinking and drilling tasks at robot workstations. They combine robust mechanical construction, high-torque drive technology, and an integrated deflection function that positions the tool axially or radially to reliably process wall thicknesses, installation depths, and inclined surfaces. The systems are designed for continuous operation in manufacturing environments and enable reproducible removal and insertion tolerances in automated processes.

Construction and Materials

The housing typically consists of hardened steel or aluminum alloys with high-precision bearings. Spindle shafts are generally hardened and ground, with bearings provided by angular or cylindrical ball bearings in combination with angular contact ball bearings, depending on the required axial and radial load. Sealing and shaft gland materials are chemically resistant elastomers (NBR, FKM) or PTFE variants to withstand coolants and emulsions. Milling spindles with deflection for countersinking and drilling additionally feature reinforced guides made of ball screws or precise linear plain guides, which ensure the deflection movement with minimal friction and high repeatability.

Drive and Connection Variants

For industrial robot systems, electromagnetic direct drives or brushless DC/EC motors are used. The drives are designed for continuous speed control and high dynamic acceleration. Connections are standardized: power and torque transmission via hollow shaft with flange mounting, electrical connectors with protection class up to IP65/IP67, and optional media couplings for coolants. Tool clamping is usually done via ER collets, HSK, or DIN tool holder systems; for special countersinking tools, impact-resistant quick-change flanges are used. Pneumatic or hydraulic connections can be integrated to support the deflection unit or to supply workpiece clamping and chip extraction.

Mechanics of Deflection

Deflection is achieved mechanically via cam-guided slides, eccentric axes, or servo-driven linear axes. With axial deflection, tools can be pivoted by defined depths; with radial deflection, the drilling position is shifted radially, for example, to create hole patterns on curved components. The mechanics are designed so that the tool position remains stable within hundredths of a millimeter even under variable force influences. Wear parts such as guide rails or ball screw carriages are easily accessible and can be replaced without complete disassembly, reducing downtime.

Performance Parameters and Operating Conditions

Spindles for countersinking and drilling tasks are available in speed ranges from slow deep drilling to highly dynamic countersinking. Typical designs cover constant speeds as well as load control. Temperature stabilization using internal sensors and optional liquid cooling is important. Protection classes and cooling concepts are adapted to the environment: versions for splash water and coolant use meet IP65/IP67 with additional sealing rings and chip concepts, while high-precision variants with air bearings are designed for clean environments. Vibration damping is achieved through integrated isolators to reduce contextual vibrations of the robot and ensure workpiece quality.

Control, Sensor Technology, and Integration into Robot Cells

The spindles can be integrated into robot controllers via fieldbuses such as EtherCAT, Profinet, or CANopen. Built-in sensor technology includes speed, torque, temperature, axis position of the deflection, and collision monitoring. With bidirectional communication, sensitive process steps can be automatically adjusted: lowering speed, feed corrections, and status monitoring are reported to the robot controller in real time. For demanding inline inspections, interfaces for inline measuring systems are available, so that the drilling or countersinking pattern can be immediately validated and rework can be automatically triggered.

Application Areas and Process Reliability

Typical applications include the processing of sheet metal, castings, forged parts, and pre-assembled components in the automotive and supplier industry, mechanical engineering, and plant construction. Spindles with deflection enable the countersinking of screw holes in curved oil pan areas, the drilling of offset hole patterns on body elements, and the creation of through-holes in geometrically complex parts. Process reliability is achieved through combined monitoring of tool wear, chip formation, and coolant supply, as well as through defined tool change strategies within the cell.

Practical Examples

Example 1: In a robot cell, a six-axis robot mounts a spindle with radial deflection to produce several offset holes on a curved support plate. The deflection allows the robot to perform only minimal axis movements, reducing cycle times by 20–30%. Tool holders are ER25, coolant is supplied via an integrated hollow shaft, and the spindle communicates torque and temperature values via EtherCAT to the cell controller.

Example 2: When processing a cast component, a spindle with axial deflection performs the countersinking of screw holes on an inclined surface. The system uses a servo-driven linear axis for depth control and additional force monitoring for automatic feed adjustment with varying casting wall thicknesses. After each countersinking cycle, an inline measurement of the countersinking depth is performed; deviations are logged, and a quality stop is sent to the line controller.

Example 3: In an automated assembly line, a spindle with integrated chip extraction and FKM seals drills into coated aluminum profiles. The spindle has an HSK-A63 holder and integrated coolant recirculation. A collision sensor protects the tool and robot arm, while the spindle temperature is actively regulated to minimize thermal expansion.

Selection Criteria and Selection Process

Choose a spindle based on: performance specification, holder type, cooling, protection class, integration interfaces, deflection range, and maintenance accessibility. Pay attention to compatibility with your robot controller and a documented interface for process data. For series production, modular systems are advantageous as they allow quick replacement of wear parts and easy adaptation to changing workpieces.

• Performance, holder type, cooling, protection class, deflection range, interfaces, and maintenance access

Service, Maintenance, and Spare Parts

Regular maintenance includes bearing inspection, seal control, lubrication of guides, and sensor function tests. Mannesmann Demag compatible systems offer documented inspection intervals, standardized spare part kits, and optional on-site service contracts. Replacement components such as guide carriages, seal kits, and tool interfaces are available as stock items to minimize downtime.

Further technical information, product variants, and specific application examples can be found on our technology page https://maku-industrie.de/technik and in the collection of real application cases https://maku-industrie.de/anwendungsbeispiele.

FAQs

1. Which tool holders are common for spindles with deflection?
Common are ER collets (ER16–ER32) and HSK holders (HSK-A63, HSK-F), less frequently ISO30/40 for special applications. The choice depends on tool diameter, clamping force, and quick-change requirements.

2. How is deflection controlled and monitored?
Deflection is achieved mechanically via eccentric or linear guides, usually servo- or stepper motor driven. Monitoring is done by position encoders, displacement sensors, and force sensors; process data is transmitted to the controller via EtherCAT/Profinet or CANopen.

3. Which sealing and cooling concepts are recommended for use with coolants?
For coolants, FKM or NBR seals in combination with stainless steel or PTFE standard elements are recommended. Additionally, spindles should have chip removal, external coolant recirculation via a hollow shaft, and a defined flushing strategy to minimize deposits and seal wear.