S E R I E S

AL40G AL60G
Linear Motor Drive
High-speed & High Precision Die-Sinker EDM

5 Core Technology
Die-sinker EDM for Precision Moldand Precision Parts Machining
5 Core Technologies

Sodick continually invests in research anddevelopment to provide useful products forcustomers.
We develop and manufacture in-house thebest electric discharge machines by combining five core technologies: linear motors,motion controllers, power supply devices,discharge devices and ceramics.
Our new products AL40G and AL60G are a
new generation of precision die-sinker EDM
that is a fusion of the linear motor control
technology accumulated over 20 years, thelatest discharge control technology, and artificial intelligence (AI).

Linear Motor Drive System
Features of linear motors

Ball screw drive system

Among the many features of our linear motors, the biggest are high speed andhigh response. These are achieved because of no abrasion during movement
and no need to have ball screws. Conventional drive systems use ball screws toconvert rotary motion into linear motion. With this method, however, mechanical conversion errors adversely affect the tracking performance of the highspeed servo. Thanks to linear movement, there are no conversion errors fromrotary motion in linear motors, and direct drive achieves accurate positioning
and quiet, high-speed operation.

TechTech

1 34&High performance linear motors developed and manufactured by Sodick
A high-thrust linear motor developed and manufactured in-house allows stop,acceleration, constant speed, deceleration and stop operations at high speed
and with high response. Also, backlash is eliminated, which is impossible withconventional ball screw drive systems, and accurate axis movement is maintained semipermanently.

Linear motor drive system

Sodick Motion Controller (K-SMC)
Linear Motor Drive Technology

Ball-Screw Drive Technology

NC unit

NC unit
From linear scale

Linear motor

Linear scale

To linear motor

MotordriverDistancedetec�on
Encoder

Motor
Ball screw

Work pieceElectrodeWork pieceLinear motors have an ideal direct drive mechanism. With excellent high-speed
movement and positioning accuracy, because there is no mechanical contact,high responsiveness and long-term stability, maintainability, and reliability
are maintained. The performance of the linear motor used in this drive system
is maximized by combining the motor with the K-SMC motion controller thatSodick has refined over many years.
Since the new AL series of die-sinker EDM does not use ball screws, direct position detection with no axis movement error is possible. Unlike conventional
methods, in which the state of the detected discharge gap is monitored by theNC unit and controlled through a motor driver, the Sodick motion controller
directly monitors and controls the linear motor. Therefore, real-time control
without delay upon gap detection has been realized. This achieves high response and precise control.

Equipped with the New Numerical Control Unit
SP Power Supply+ New Stable Electrical Discharge System
Arc-less 4
The numerical control unit SP power supply is an ideal power supply device
that supports a variety of machining and operations. By adopting the latest
M4-LINK CNC board, the communication speed and processing speed havebeen improved, and the motor control response speed has been more thandoubled.
Equipped with the latest Arc-less 4 stable electrical discharge system, the performance of the die-sinker EDM has been dramatically improved, with higher
speed, suppression of electrode wear to the utmost limit, and realization of awide variety of machining surface finishes, from satin finish to mirror surface.

Tech

Tech

2

5Ceramic Parts
An in-house manufactured lightweight ceramic slider with high rigidity andlow thermal displacement is adopted for the main spindle linear motor slide
part. By mounting linear motors on the left and right sides of the slide part ina well-balanced manner, and offsetting the magnetic attraction force, shifting
and warpage of the slide part is prevented, achieving high straightness andsmooth driving.
Through high straightness and smooth driving realized by synergy with ahigh-speed and high-response linear motor, high-speed and stable deep rib
machining has been achieved. In addition, the high-speed jump effectively
discharges the machining tips, reducing abnormal arcs and machining shape
defects attributed to secondary discharge, and greatly reducing machining

Dynamic brake
Cooling pipe
Air balancer
Ceramic slider

time.

Advantages of ceramics

Magnet■ Because of its light specific gravity, if it is used for moving parts such as atable, light weight can be achieved and eventually the load on the motor
can be reduced.
■ Because of its small linear expansion coefficient, thermal displacement inresponse to environmental temperature changes is suppressed.
■ With its excellent insulation properties, fine discharge energy during fiishing work can be transmitted accurately between electrodes.

Structure of ceramic sliderIn addition to realizing high-rigidity machine structure by an optimal
design created using the latest CAE analysis technology, we pursued
improving operator workability as well.
Since the three-sided automatic vertical machining tank moves up anddown in conjunction with the machining fluid level, the workpiecebeing machined is highly visible. Because of the openness when themachining tank is lowered, the workpiece status can be checked fromleft and right, making preparation easy for complicated jobs.
The fluid level adjustment knob, jet suction adjustment knob, and thejet and suction pressure gauge are all arranged on the front side of themachining tank, enabling efficient setup work.

Sodick-IoT

High-rigidity Structure & Excellent
Workability

AIM (AI Maintenance)

Supports productivity improvement through analysis, investigation and monitoring
AI Maintenance (AIM) monitors and automatically diagnoses each status of the machine, including the operation status, maintenance status, and machine installation environment. This boosts the machine's operation
rate, reduces machining defect rates and improves traceability.

Total Temperature
Control
TH COM
Through sensing, the temperature of each component of themachine is precisely corrected
and the Thermal Commit (THCOM) function, which provides
various diagnostic functions,minimizes thermal displacement due to temperature changes in the installation environment andduring high-speed driving.

S-ViewerThis software inspects each NC unit at a fixed interval to collect data.
The operating condition of the registered NC unit can be centrally managed to improve themachine operation rate.

LN Pro AI
Our new products AL40G and AL60G have a large 19-inch touch panel
with excellent operability. Furthermore, the LN Professional AI (LN ProAI) condition advisor, which continually provides optimum machining
conditions through artificial intelligence (AI) is standard equipment,
and it is possible for beginners to experienced users to take maximum
advantage of the machining performance of the AL40G and AL60G.
Simple four-step operation (shape selection, machining plan, detailed
conditions, position setting) allows the best performance, dependingon the purpose.

SEIKAnet
Sodick's network system uses standard network protocols.
NC programs can be transferred between the machine and a PC, or between machines.

LQ e-mail
Efficient process monitoring is supported, by transferring error and stop information by e-mail,and by checking the operating conditions from a remote location.

Equipped with all the Latest Machining
Circuits as Standard TMM4, TPC4, BSN4
New controls and circuits have been prepared to improve the quality
and speed of all discharge machining areas. Those improvements include high speed in rough machining using short-pulse high-peak current (TMM4 circuit), high speed in the intermediate finishing area byimproving fitness to narrow gaps (TPC4 control), and uniform and highspeed discharge in the finishing area by accurate pulse control (BSN4circuit).

Automation System (Option)
We propose a complete automation system (automatic workpiece/electrode exchange system) that uses articulated robots, etc. By taking full advantage of amachining tank incorporating a three-sided vertical mechanism that takes an automation system into consideration, a system tailored to customer needs can be developed.

Specifications

AL40G AL60G

Machine Tool Weight
Air Pressure
Air FlowTotal Power Input*1 EROWA/TP specification

420

2670

620
400

2440

2150

0~350

2330

750
600

35

1130
1690

385

887

Machine Tool Dimensions (W x D x H)

2645

1550

830

ManualMax Weight of Electrode
Max Workpiece Weight
Distance Between Electrode and Table Top
Distance from Floor to Table Top

AL40G

Z-axis stroke 270
150~420(Erowa/TP-02)
133~403(3R)

Automatic

AL60G

750 x 550 mm (Ceramic)
950 x 740 x 450mm
150 to 400 mm
330 Liters
600 mm
420 mm
370 mm
ER-020025
COMBI
EROWA
ER-007521
ITS
EROWA
3R-460.86-2
COMBI
3R
3R-600.86
MACRO
3R
TP-02
50 kg
1500 kg
200 to 570 mm*1
850 mm1740 x 2785 x 2570 mm(Includes a Power Supply and Dielectric Tank)
5150 kg (Includes a Power Supply and Dielectric Tank)
0.65 MPa*2
100NL/min
3-phase, 50/60 Hz, 10 kVA

1645Clamping Chuck

AL40G

600 x 400 mm (Ceramic)
750 x 620 x 350mm
100 to 300 mm
190 Liters
400 mm
300 mm
270 mm
ER-020025
COMBI
EROWA
ER-007521
ITSEROWA
3R-460.86-2
COMBI
3R
3R-600.86
MACRO
3R
TP-02
50 kg
550 kg
150 to 420 mm*1
830 mm1550 x 2440 x 2330 mm(Includes a Power Supply and Dielectric Tank)
4000 kg (Includes a Power Supply and Dielectric Tank)
0.65 MPa*2
100NL/min
3-phase, 50/60 Hz, 10 kVA

2230

Work Table Size (W x D)
Work Tank Inner Dimensions (W x D x H)
Work Tank Fluid Level (Min to Max)
Work Tank Capacity
X Axis Travel
Y Axis Travel
Z Axis Travel

100

Machine Tool

2440

140

*2 If required air pressure is not met, Pressure Booster (Option) must be installed.

Dielectric Tank

Dielectric Fluid
Dielectric Tank Capacity
Required Amount
Filtration

AL40G

EDM Oil
285 Liters
330 Liters
Replaceable Paper Filters

AL60G

EDM Oil
465 Liters
560 Liters
Replaceable Paper Filters

Unit: mm

CNC Power Supply SP/SP-E

Graphics
IoT
Maintenance

1740

1390
1880

350

140

445

2950

2785

2320

740
550

850

0~450

950
750

ER-020025
ER-007521
3R-600.86
3R-460.86
TP-02Z-axis stroke 370
200~570(Erowa/TP-02)
183~553(3R)

2570

2930

1645

Memory Device
Input Format
Display Type
Character Set
Keyboard
Positioning Command
Max. Input Command
Machining Conditions Storage Capacity
Offset Setting Storage Capacity
Program Sequence Number Assignment
Number of Coordinates
Simultaneous Control Axes
Min. Input Command
Min. Drive Unit
AJC Speed
Max. Feed RateXYZ Axis
Position Detection Mechanism
Drive Mechanism
Compensations

AL60G

2470

User’s Memory Capacity

40A
Optimum Pulse Control [Arc-less 4, TMM 4,TPC 4, BSN 4, SVC]
AC200 V, 50/60 Hz
Multitask OS, K - SMC-LINK Method (M4 - LINK)
Editing: 100,000 Blocks
Saving: 30 MB
SSD Card, Dedicated USB Memory
Dedicated USB Memory, Multi Touch Panel, Keyboard, LAN
19-inch TFT-LCD
Kanji (JIS Level 1 Kanji Characters), Alphabetic Characters, Numeric Characters, etc.
Standard 101 Keyboard, Function Key
Incremental and Absolute±999999.999/±99999.9999/±9999.99999 (switchable)
1000 Conditions (C000 to C999)
1000 Conditions (H000 to H999)
N000000000 to N999999999
60
Max. 4 Axes (SP-E: 6 Axis Specification/8 Axis Specification)
0.001μm
0.01μmXY Axes : Max. 10 m/min, Z Axis : Max. 36 m/min
6 m/min
Full - closed Loop (Linear Scale)Linear Motor
Pitch Error Correction, Plane Pitch Error Correction, Torque Correction for Each Axis
XY/ YZ/ ZX Plane, Graphics Drawing During Machining, Background Graphics Drawing,
LORAN Shape Drawings, Discharge Graphs, etc.
Compatible to S-VIEWER (Compatible to MT-CONNECT : Option)
AI Maintenance100

Max. Machining Current
Discharging Power Supply Unit
Power Requirement
NC Unit2785

Unit: mm

Linear Motor Drive
High-speed & High Precision
Die-Sinker EDM

AL40G/AL60G

Sodick Co., Ltd.
3-12-1, Nakamachidai, Tsuzuki-ku, Yokohama, Kanagawa
224-8522 Japan
TEL: 81-45-942-3111 FAX: 81-45-943-7880● The export of Sodick's products and its related technologies (including software applications)is regulated under Japan's Foreign Exchange and Foreign Trade Control Law. In addition,
because some of these products may be subject to re-export controls under the Export
Administration Regulations (EAR) of the United States; please contact Sodick before offering
or exporting these products overseas.
● This catalogue contains a photographic image that has been generated from 3DCG.
● Options may be included in the photos and the contents of this catalogue.​● Due to ongoing research, specifications are subject to change without prior notice.
● The contents of this catalogue is current as of February, 2020.
Printed in Japan

https://www.sodick.co.jp/en/S2026400.2020.02<02>