The Road

EDM
GANTRY 400
GANTRY 500
GANTRY 800
GANTRY 1200
GANTRY 1500
GANTRY 2000

> More Productivity

by more efficient EDM

The Course
In the Mould and Die Industry, improving
your efficiency is the only way to secure
your future and your strategy. The
management task requires a comparison
of all the possibilities with the best
technical solutions. We, as a supplier of
technical-systems and equipment, see
our duty and task to develop machines
so that you will be able to reach your
goals.
Our EDM-program features a wide range
of applications, excellent technics and
intelligent possibilities for processengineering.
That is the way to improve your
productivity.
Go for performance

> The nature as Paradigm

Erosion (lat.: erodere = to gnaw off) is the

erosion-production-process which relies on

geological process of removing weathered

electrical discharge procedures between the

stone-material, that creates textures and

electrode and the conductive workpiece. These

sculptures over millions of years.

opportunities and results of the process are

The technical principle spark-erosion

fascinating to the ambitious technician, just like

(EDM = electrical discharge machining) is an

the nature paradigm.

Your Partner
OPS-INGERSOLL is positioned as the
specialist in the market, with expertise in
the total range of machining workpieces.
The combination of HSC and EDM,
our OPS-INGERSOLL-MoldCenter,
was developed and is the positive proof
of the evidence. The GANTRY-concept is
covering the EDM requirements from
small to large. Herewith we are confident
to raise your process-efficiency fundamentally.
The direction is obvious, lets go the
course together.

Rainer Jung, President

GANTRY 400
GANTRY 500 and 800
GANTRY 1200
GANTRY 1500 and 2000
Control
High-Lights
Technical Data
Options
MoldCenter / Automation

GANTRY 400
Plug and Play!
Set-Up, Fill-In, Erode!
And this with highest accuracy on
smallest floor space!
This is possible with our GANTRY 400.
When you got to machine workpieces
with limited dimensions, the GANTRY 400
is the ideal base of operation for efficient
processes, and also offers intelligent
automation technology.

GANTRY 400
Axis-Travel: X / Y / Z
400 / 300 / 300 mm
Work tank dimensions: L / W / H
650 / 500 / 340 mm
Operator friendly machining
with efficient handling

Miracle in floorspace-saving

Highest accuracy at minimum space

Control
High-Lights
Technical Data
Options
MoldCenter / Automation

GANTRY 500
With the 500th GANTRY 500 machine
which was built in 2006, the machine
has proved an allrounder for over a
decade.
Due to the GANTRY-style regarding
accessibility and retrofitting of automation, this makes this machine to be
one of a kind.

GANTRY 500
Axis-Travel: X / Y / Z
525 / 400 / 450 mm
Work tank dimensions: L / W / H
750 / 650 / 420 mm

GANTRY 500 and GANTRY 800 Precision-machines which stand out of

Maximum accuracy due to rigidity and temperature-stability

High-Speed-Jump for fastest machining with excellent image-preciseness

Top performance, by the use of modern generator-technology

More versatility for new applications through modular upgrading

All possibilities and wide scope for automation

GANTRY 800
The requirements and the workpiecedimensions are getting more complex
and demanding.
For this configuration we have conceived the GANTRY 800. The machine
only needs slightly more floor space
than the GANTRY 500, but has the
double working-area. This makes it to
a real Capacity-Miracle.

GANTRY 800
Axis-Travel: X / Y / Z
550 / 850 / 450 mm
Work tank dimensions: L / W / H
800 / 1100 / 480 mm

the crowd
Best quality for machining and consequently for your final product

Highest productivity by saving manufacturing-time and better cost-benefit-relation

Control
Absolute reliability of processing with defined reproducibility

High-Lights
Technical Data

Best future- and planning-reliability for your investment

Options
Optimised flexibility as an assumption for more customer orientation

MoldCenter / Automation

GANTRY 1200
The GANTRY 1200 is unique for its
various possibilities. The experiences
of the large-scale-machines and the
vitality of the small-machines are
combined in the GANTRY 1200.
The machine moves fast with large
workpieces through high-axis-travelspeed and High-Speed-Jump (HSJ).
At the same time the machine is
conceived for large machining in the
Big-mould-manufacturing.

GANTRY 1200
Axis-Travel: X / Y / Z
1000 / 1500 / 650 mm
Work tank dimensions: L / W / H
1270 / 1770 / 680 mm

GANTRY-EDM in big size

Large axis-travel-ways by smallest footprint

Large fluid-tank, lowering totally into the base

Machine in GANTRY-style

Weight of electrodes 1 100 kg, automatically exchangeable

GANTRY 1500/2000
As a result of experiences over decades
for the design, manufacturing and
application of large EDM-equipment,
OPS-INGERSOLL is your qualified partner in the Large-mould-manufacturingindustry.
With GANTRY 1500 and GANTRY 2000
we offer future-oriented and inflective
solutions for large EDM-tasks and
-challenges.

GANTRY 1500/2000
Axis-Travel: X / Y / Z
GANTRY 1500: 1050 / 2050 / 1000 mm
GANTRY 2000: 1550 / 2750 / 1000 mm
Work tank dimensions: L / W / H
GANTRY 1500: 1520 / 2520 / 945 mm
GANTRY 2000: 2020 / 3220 / 1350 mm

Generator, fire-extinguisher, cooling-unit and electrical-control-cabinet

are integrated into the supply-unit
Fluid-level is maintained automatically, means no fill- or drain-time

Best accessibility for loading, set-up and for inspection

Control
High-Lights
Technical Data

Ideal for complete and partial machining of workpieces

Options
MoldCenter / Automation

CONTROL
OPS-INGERSOLL expects to increase
the efficiency of your production.
Control, power-unit and innovative
ideas like HSJ are consequently under
review regarding these requirements.
The 64-bit-PC-NC-control supports the
capability of the GANTRY even to fulfil
complex duties with high discharging
performance, small electrode-wear,
homogeneous surfaces and to accomplish dependable long-lasting-accuracy.

Essential facts of the control:

Windows-operating-system

Adaptable to all common CAM-systems

MultiProg Technology-Selection

Shop-floor oriented operator-guidance

Easy to learn, due to dialog-text

multipulsePRO/MultiProg
multipulsePRO

Current Result 2006

A new dimension in sink-EDM. With

00 %

multipulsePRO you will reach an

improvement of electrode-wear specific

Less wear,
up to 60% with graphite

80 %

for graphite-electrodes of up to 60 %,
and even better metal-removal.
With this you will benefit the full poten-

60 %

40 %

tial of your GANTRY machine, and reach

shorter process-times.

 Graphite

20 %

 Copper
0%
Wear Others

Wear OPS-INGERSOLL

Wear change due to multipulsePRO

Customer conclusions
concerning multipulsePro:
Experiences up to date extremely positive

Very good process-stability

Better wear results

MultiProg

EDM-Times, especially with graphite, definitely reduced

Programming with PC
As complex as any machining-task may

EDM-secondary effects are mostly eliminated

be, with MultiProg the programming will

be very easy.
The input of the most important parameters is sufficient and MultiProg calculates the necessary number of electrodes
for an optimized EDM-result, determines
the complete EDM-technology from
roughing to the final-step.
Whether you have single- or multiplecavities, tunnel-gating, ribbed- or
freeform electrodes, made out of copper
or graphite, whether you have to
machine tool-steel or even exotic
materials, for every task there will be
the right solution in MultiProg.

MultiProg, Programming with PC

High-Lights
With the GANTRY-type-series from
OPS-INGERSOLL you tap the full potential out of the quality, as well as the
efficiency-gain of EDM and utilize for
your manufacturing.
Each machine of the model-range
features in principle:
Enormous dynamics by best
possible rigidity
Long axis-travel-ways at
minimum footprint
Thermo-symmetrical bodywork
for long-life-accuracy
Operator convenience
The constructive base for all these
features is our approved and consequently further developed GANTRY
method of construction.

GANTRY-style-construction
The OPS-INGERSOLL GANTRY-style-construction is providing a high rigidity of all
machine-elements and results in minor deformation compared to C-frame-structures.
This tight machine-concept is characterized by large axis-travel-ways and easy
pick-up electrode-exchange.

OPS-INGERSOLL C-axis
Integrated into the Z-slide the high-performance C-axis is a standard outfit of all
OPS-INGERSOLL EDM-machines.
Rotation-properties, potential moment of inertia and positioning-accuracy
accomplish the highest requirements, which must be made available by the C-axis
for EDM. Even heavy and wide overhanging electrodes are held in exact position.
The high dynamic direct-drive allows the EDM-process in multiple axis.
Every standardized electrode-clamping-system can be adapted.

Mega-Filter
As a standard feature of the machine, a special cartridgefilter is developed especially for EDM requirements. The
filter-surface is 10 respective 20 m 2 (40 m 2 for the big
machines) and the filtering-principle is that the fluid is
running from the inside to the outside, and maintains an
extremely long lifetime.
The exchange of the filter-elements is done via a quickdisconnect-coupler and works clean and fast.

Technical Data
GANTRY 400

GANTRY 500

GANTRY 800

GANTRY 1200

5,100

6,200
200
9.1
25
400 / 50

12,000
17.4
25
400 / 50

Machine
Machine weight
Generator weight
Power input
Fuse protection
Voltage/Frequency

kg
kg
kVA
A
V/Hz

10.3
25
400 / 50

4,400
200
9.1
25
400 / 50

mm

Rise and fall tank

650 x 500 x 340

Rise and fall tank

750 x 650 x 420

Rise and fall tank

800 x 1,100 x 480

Rise and fall tank, filled moveable

1,270 x 1,770 x 680

mm

300

375

450

640

kg

50

100

200

300

mm

105 / 405*

135 / 585*

135 / 585*

150 / 800*

1 20
0.001

1 20
0.001

1 20
0.001

1 20
0.001

kg

50*

50*

50*

50*

kg

10*

15*

15*

25*

kg/m2

0.4*

0.4*

0.4*

0.4*

120

120

Work tank
Type
Clear dimensions (L xWxH)
Dielectric fluid level, max.
programmable/automatic

Work head
max. head load
Distance electrode-clamping
chuck to work table min./max.

Integrated C-axis
RPM (adjustable)
Angle positioning
Loading capacity manual
electrode change
Loading capacity automatic
electrode exchange
Movement
of inertia, max.
Torque

1/min.
degree

Nm

Work table
Surface (L xW)
Load capacity

mm
kg

550 x 470
500

730 x 630
1,000

760 x 1,000
2,000

1,640 x 1,140
7,500

mm

400 x 300 x 300

525 x 400 x 450

550 x 850 x 450

1,000 x 1,500 x 650

675

1,180

1,945

mm/min.
mm

64 bit
Digital AC-servo-drive
max. 10,000
0.001 or 0.0001

64 bit
Digital AC-servo-drive
max. 2,000
0.001 or 0.0001

64 bit
Digital AC-servo-drive
max. 2,000
0.001 or 0.0001

64 bit
AC-servo-drive
max. 6,000
0.001 or 0.0001

m2
ltr

Cartridge (integrated)
10
320

Cartridge (integrated)
10
400

Cartridge (integrated)
20
800

Cartridge (integrated)
20
2,800

Pick-up rotary disk

20

Pick-up rotary disk

20 (30)

Pick-up rotary disk

20 (30)

Pick-up linear magazine

13 (30/50)
2/14

kg
kg

10*
40*

15*
60*

15*
60*

25
150

Switching mode, resistorless

70

Switching mode, resistorless

70

Switching mode, resistorless

70

Switching mode, resistorless

70 / 100

kW

Standard
2.5

Standard
3.9

Standard
3.9

Standard
8

kg

10

20

Travel ways
X / Y / Z inside
work tank
Y (by electrode changing
position)

mm

Control
PC-NC-dialog
Type of drive
X,Y, Z rapid traverse
Digital display (selectable)

Dielectric supply
Filter unit
Filter surface
Dielectric fluid, total volume

Electrode changer
Type
Positions (Option)
Combi-magazine positions optional
Electrode weight
Single electrode
Total weight

Generator
Type
Machining power, max.

Additional features
Automatic lubrication
Chiller, cooling power
CO2-fire-extinguisher,
DIN 14497, size

* Note: The values stated are max. values which may vary according to the clamping system used.

Technical modifications reserved.

30,000

42,000

30
50
400 / 50

30
50
400 / 50

Rise and fall tank, filled moveable

1,520 x 2,520 x 945

Rise and fall tank, filled moveable

2,020 x 3,220 x 1,350

2450

900

1,300

Machine height: 2220 mm

1,500

1,500

200 / 1,200*

450 / 1,450*

1 20
0.001

1 20
0.001

50*

50*

25*

25*

0.4*

0.4*

120

120

1,380 x 2,380
20,000

1,870 x 3,080
30,000

1,050 x 2,050 x 1,000

1,550 x 2,750 x 1,000

2,850

3,555

GANTRY 500

GANTRY 800

1871

2250

GANTRY 2000

2700

GANTRY 400

GANTRY 1500

1625

1420
2050

2460

Machine height: 2653 mm

GANTRY 1500

max. 5000
2950

Machine height: 3440 mm

3690 mm with raised portal

2750
4450

Machine height: 4760 mm

Cartridge (integrated)
40
7,000

Cartridge (integrated)
40
13,000

Pick-up linear magazine

15 (50)
4/18

Pick-up linear magazine

20 (50)
4/18

25
150

25
150

Switching mode, resistorless

100

Switching mode, resistorless

100

Standard
10

Standard
10

30

45

GANTRY 2000

max. 5000

64 bit
AC-servo-drive
max. 8,000
0.001 or 0.0001

6730

64 bit
AC-servo-drive
max. 8,000
0.001 or 0.0001

3440
5100

Machine height: 5250 mm

5650 mm with raised portal

6030

3950

GANTRY 1200

Machine height: 2703 mm

High-Lights
HSJ-Technology

120 %

High-Speed-Jump

Standard

High-Speed-Jump
100 %

OPS-INGERSOLL offers with its HSJ80 %

Technology for the GANTRY-machines

400, 500, 800, 1200 an improvement of

60 %

the eroding-performance, specially for

40 %

difficult applications. HSJ is the high-

ce

an

orm

sed

rf
pe

rea

Inc

 Erosion time

20 %

 Lift-off time

performance-servo-system for the Z-axis

with an acceleration of about 1,2 G.

0%

On the base of scientific researches a

new drive- and technology-concept was
created. This results in a reduction of
the working time of about 50 % for
e. g. deep-slot applications.

Fundament changes of EDM results:

Increase of the effectiveness due to the considerable

improvement of the ratio erosion versus lifting-time

Secure work for unattended actions,

even for deep cavities, without cooling-flush

Guarantee for consistent surfaces

Improvement of Machining-Time up to 50 %
for applications even with deep slot-processing

Options
Application oriented options for the
equipment of GANTRY-machines:
Handling of electrodes and workpieces
RAM-clamping-system
MultiControl remote-monitoring
and diagnostic

Electrode changer
Each of our EDM machines is equipped with a standard
electrode changer. For the network with external pre-setupand measuring-places, including automatic transfer of the
electrode- as well as the workpiece-offset-data, we offer all
different automation levels as customized solutions.
We have drastically improved the flexibility and operator
convenience for our large machines with a combined
electrode-changer. This guarantees a convenient changeover
from roughing to finishing electrodes.
Small electrode changer

The GANTRY 1200, 1500 und 2000 has a combined electrodeclamping-system on the slider and the C-axis. For large electrodes
the full eroding demands are utilized through the big clampingsystem on the slider. With this slider clamping system it is
possible to work and handle pallets up to 150 kg and with the
C-axis clamping-system pallets up to 15 kg.

RAM-clamping-system

With the additional module MultiControl

you have direct access to all functions
of the 64-bit-PC-NC-control of your
EDM-Machine by ISDN connection.
With the OPS-INGERSOLL Teleservice
our service-technician is able to connect
himself online with your machine for
diagnostics and/or troubleshooting.

MultiControl display

Final Destination!
We have built this machine range to meet
your current requirements and future
expectations to achieve shorter development times, wide interest for product
variations and the huge pressure for
costs and competition. We developed and
created an universal machining-strategy,
for all process levels.
All our machines are pre-arranged
for automation. The association of an
MC-Handling-System can also be
installed later.
To combine both technologies, HSC and
EDM, we offer you the possibility to join
the two in the MoldCenter. With this fully
automated MoldCenter you will reach an
efficiency, you never could achieve with
two separate systems.

MoldCenter

Our brochures:

Spark Erosion

High-Speed-Cutting

Automation

OPS-INGERSOLL Funkenerosion GmbH

Daimlerstrasse 22
57299 Burbach, Germany
Phone: +49 (0)2736 | 446-0
Fax:

+49 (0)2736 | 446-510

E-Mail: info@ops-ingersoll.de
Company Profile

12/06

Internet: www.ops-ingersoll.de