THE K5 ECOSYSTEM FOR THE PRODUCTION OF MICROTECHNOLOGY

Picture this: flexible, demand-driven production of customized parts. This is a trend you don’t want to miss if you want to keep your customers happy, whether they’re B2C or B2B. Precitrame Machines can help you meet this goal by offering innovative Swiss-made production solutions for machining high-value microtechnical components.

A quick introduction to Precitrame

Precitrame Machines SA is a Swiss company that specializes in designing and building high-precision machines for a whole range of industrial sectors. The company was originally founded as Precitrame in the 1980s and started out making tooling and micromechanical components. In 1988, Precitrame took a big leap forward by producing its first CNC transfer machine to meet its own needs. This marked the beginning of an era of diversification and innovation.

In 2001, Precitrame decided to split its machine tool production and manufacturing activities. This split led to the creation of two separate entities: EMP SA (Ebauches Micromécaniques Precitrame) and Precitrame Machines SA. This strategic reorganization allowed each branch to focus on its core business, enabling them to become even more specialized and efficient.

Today, Precitrame Machines boasts a broad range of products that include transfer machines, polishing machines, and watch assembly workstations. The company has also recently welcomed Kummer Frères SA into the fold. This move has allowed Precitrame to expand its portfolio with micromachines, strengthening its position as the leading name in the market.

Precitrame is based in Tramelan, has three production sites totaling 14,000 m², and employs around 400 people worldwide. The company is proud to guarantee the Swiss-made quality of its products and also prioritizes working with local suppliers. This approach is in line with an eco-friendly vision, which it puts into practice in many ways, such as renovating buildings, installing solar panels, and using distance heating. Precitrame has always been committed to optimizing its energy consumption, which reflects its commitment to sustainable development.

Precitrame is known worldwide thanks to its subsidiaries, “Precitrame Deutschland GmbH” in Germany and “Precitrame Services (Shenzhen) Co. Ltd.” in China, which provide a global presence and top-quality customer support.

Precitrame is more than just a machine manufacturer. It provides complete, adaptable, and innovative solutions to optimize customers’ production processes. This focus on customer satisfaction and technical excellence helps Precitrame stay at the top of its sector.

From transfer to micromachines

Precitrame, a top company in high-precision CNC transfer machines, has added an innovative machining concept in the form of micro machining centers to its range. With transfer machines, Precitrame covers the needs of customers that produce thousands of parts a day, while K5 micro-machining centers, which produce just a few parts per batch, are ideal for prototype manufacturers. Based on conceptual work done at HE-Arc, Precitrame has adapted and industrialized the K5 machines to help customers use them to their fullest potential.

Rotary transfer machine MTR216

The K5

The K5 range includes a single machine that can be used as a conventional machining center, with or without automation. The K5-4 model is a 4-axis machine that can be used to machine thin components that require multi-sided machining. The K5-5 has 5 axes and is great for making complex parts. Two automation options can make these micromachines more autonomous.

Both variants feature a common, ultra-light axis base. The axis travels (X = 78 mm, Y = 56 mm, Z = 50 mm, B = 270°) offer a standard machining volume of 50 x 50 x 40 mm. The lightweight design of the moving components allows for high speeds and accelerations of up to 2 G, which provide the cutting speeds needed for high-speed machining (HSM). Moving parts are lubricated regularly to guarantee long-term performance. Lubrication is carried out manually and centrally. The 4-axis version features an additional axis (W-axis) to support thin-walled workpieces. It can also be used to hold the part by vacuum to separate it from the blank. The 5-axis version has a C-axis with five air channels and a vacuum channel to position parts. In addition to its positioning function, the C-axis can perform turning operations at a maximum speed of 5,500 rpm. It can, of course, also perform standard turning functions like insert radius correction and constant-speed cutting.

The Precitrame spindle is small but powerful. This Ø 38mm spindle, equipped with an ATC-E15 attachment, can reach a maximum speed of 60,000 rpm and has 10.8 Ncm of torque. For turning, it also has an encoder for chisel positioning and a holding brake. A ring with four nozzles at the end of the spindle orients the jets that distribute the cutting fluid.

The tool magazine has 50 slots for ATC-E15 tool holders and a position for a wireless 3D measurement probe. This means that a large number of individual tools and replacement tools can be stored to avoid machine stoppages. The tool magazine is isolated from the machining area to prevent the tool holders from contamination. To optimize tool changeover times, the machine is equipped with a four-position buffer fed from the main magazine.

The optional wireless probe re-centers and orients the blank after loading, checks the dimensions of the machined parts, and calibrates the machine axes. A laser tool breakage detector checks for tool breakage near the machining area. This equipment can detect tools as small as Ø 0.2 mm

The machining zone is sealed inside an enclosure to keep water out. Other advantages when machining precious metals are that build-up is minimal and the area can be easily cleaned using the spray gun. Swarf is collected in a 17-liter tank that can be fitted with a filter bag. The cutting fluid goes into a settling tank to remove medium-sized particles before flowing into the clean fluid tank. The third filtration stage consists of a cartridge filter to remove fine particles. The oil conditioning system has a temperature-controlled capacity of 45 liters and is built into the machine. The spray pump has an adjustable flow rate of up to 25 l/min and a maximum pressure of 3 bar. The water / water temperature exchanger manages the thermal regulation of the rotary axes (spindles, B and C) and the coolant.

There are several ways to recover cutting fluid vapor. As standard, a dedicated vapor extractor is built into the roof of the electrical cabinet. The collected vapor is returned directly to the watering tank. However, customers can integrate their usual system. In this case, the vacuum cleaner is placed next to the machine. The machine can also be connected to a central vacuum system. Special versions are also available, for example for dry machining ceramics.

If the machine is used for production, it must be fitted with a fixed automatic fire extinguishing system. The Primus system is the standard option, as it offers the best integration. Other suppliers’ systems (e.g., Al-Deco, Kraft & Bauer) can also be integrated.

Although the machine is very compact, well-designed access points make maintenance easy. The chip tray must be emptied regularly, but it is accessible via a lockable door in the precious metals machining frame at the front of the machine. A rail system makes it easy to empty the bin. The door is fitted with a spray gun for cleaning the machining area with cutting fluid. The electrical cabinet can be moved to provide access to the machining unit by separating the machine into two parts. A quick connection system for cables and hoses makes maintenance work on the axis base easy. All electrical components are housed in the electrical cabinet and are accessible at all times through a door at the rear of the machine.

The K5 also offers great flexibility in terms of workshop layout. In fact, the machine can be moved around a single floor using just a pallet truck, which can lift it from the front or from the side.

K5-5 with CK-40P automation

K5 automation

When it comes to producing small batches with long cycle times, the SK44 or SK45 variants can store up to a dozen fixtures with the workpiece mounted on them. The pick-and-place manipulator automatically changes the fixtures as soon as a part is finished.

The CK40-P can produce larger batches thanks to its large storage capacity. It comes with a palletizer for up to 10 pallets (220 x 277 mm). In this version, the raw part is loaded directly onto the machine bed by a polyarticulated robot. It also has space for other operations, such as mechanically or optically centering the blank to be loaded. An integrated drawer allows parts to be deposited for SPC inspection. The latter can also be used for one-off tests, to store pre-assembled blanks on fixtures.

HMI and Factory Dashboard

To provide an ergonomic and intuitive user experience, Precitrame has developed a 100% touch-sensitive Human Machine Interface (HMI) called Precitrame Manager (PMM). This user-friendly interface allows users to focus on production. Each page of the interface is designed to provide a clear view of the operation being carried out. This HMI also provides increased security through user access management. This application can also exchange data with other systems in the background. For example, a standard OPC-UA connector, which provides access to basic production data, is available as an option. A customized interface can also be implemented on request.

A common supervision environment is available to allow customers with several Precitrame machines to group them together, irrespective of the model. This tool, called Factory Dashboard, provides a global view of the machine park and production in real time. Data such as machine status, names of parts produced, quantities to be produced and finished parts are just a few examples of the information available.

Since Precitrame develops its software solutions in-house, they can be fully customized according to customer requirements.

For the micro-factory

For medium-sized batches, Precitrame has designed a range of flexible microcells called the MCK concept. The MCK concept links two to eight K5 machines via a centralized automation system that manages the transfer of parts between machining modules. As with a transfer machine, the workpiece is clamped only once for each machining stage and is removed from its fixture only when finished. This guarantees that the positioning is accurate between the various machining stages. The automation cell can perform pre- and post-machining operations in addition to loading and unloading workpieces onto and off the fixtures. Mechanical or vision-centering stations and part de-oiling stations are just two examples.

The MCK concept allows one or more machining modules to be replaced with a washing station or a dimensional and/or quality control station to ensure the most finished part possible at the end of the process. This micro-factory can be operated in several ways. The most conventional way is to produce the same part in parallel on each machine, multiplying productivity by the number of machines. In sequential mode, each machine performs a portion of the operations before the part is transferred to the next machining module. This mode balances the cycle times of different operations on several machines, just like on a transfer machine. Independent operation is less common. This mode allows different parts to be produced on each machining module. This provides a high degree of flexibility when organizing production, and can even be used to produce customized, one-off parts. The final mode is a combination of sequential and independent operation. In other words, a number of machining modules produce one type of part, while the remaining machines produce another. This mode combines flexibility and productivity.

View of the C-axis K5-5

MCK506

K5-TRIO for bar machining

The K5-TRIO, with three machining units, or the K5-DUO with two machining units, are the most suitable solutions for medium-sized batches requiring the part to be reworked to machine the second side. One special feature of these machines is the direct feed of micro-bars up to 165 mm in length and 10 mm in diameter. Depending on the bar diameter, the bar feeder can store over 3 m of material. However, billet feeding is still possible. If a part requires few rework operations, the K5-TRIO can perform these while other operations are being carried out, saving up to a third of additional production. If the machining time on both sides of the part is virtually identical, the K5-DUO finishes the part without any need to handle it outside the machine. Other features are similar to the K5 unitary concept, as the basic principles are applied to the entire Precitrame micromachine range.

Energy efficiency and more

Precitrame has always aimed to use production resources as efficiently as possible. Despite their large size, Precitrame MTR transfer machines have always offered a highly competitive ratio of “resources / produced parts” for high-volume production. These solutions are also efficient in terms of surface area and energy consumption per m² and kWh per part produced. This is why the integration of micromachines is fully in line with the company’s objectives. It helps to reduce energy consumption while maintaining productivity for small and medium volumes. In fact, a K5 machine consumes less electricity than a vacuum cleaner or hairdryer. For example, a K5-5 with sprinkler and vapor extraction consumes around 1.8 kWh during production. This micromachine also makes it possible to make production halls more compact, thereby reducing floor space requirements. For example, a single K5 requires 1 m², while adding a CK40 loader requires an additional 0.7 m². In terms of multi-station machines, a K5-TRIO takes up 2.6 m² and an MCK506 just under 20 m². Precitrame’s eco-responsible machines are designed to help customers reduce their ecological footprint and cut production costs at the same time.

Fields of application

Precitrame machines are versatile and can adapt to a wide range of industrial sectors. They’re widely used in the watchmaking, electronics, jewelry, automotive and medical sectors. Precitrame’s K5 range, in particular, has specific applications in the jewelry and medical sectors. The units in the range produce complex jewelry and medical instruments with precision and high-quality finishes. This diversity testifies to Precitrame’s flexibility and technical expertise, allowing it to meet the specific requirements of each industry, whatever the batch size.

Online configurator

Precitrame is maintaining its innovative approach with the launch of its new online configurator, accessible from its website. This intuitive tool allows potential customers to configure their K5 machine according to their specific needs. Once the configuration is complete, Precitrame’s sales team takes over. They analyze requests and quickly contact interested parties to finalize details, provide further advice, and draft appropriate sales proposals.

This new tool is perfectly in line with the company’s vision: to offer innovative, tailor-made solutions while keeping a strong focus on its customers and meeting their specific needs.

Precitrame Machines SA
Grand-Rue 5
2720 Tramelan
Switzerland
T +41 32 486 88 50
precitrame.com