NEW PRODUCTi-TOPCENTER Horizontal Spindle Machining Center
The TOPCENTER series has been highly evaluated as
mass production machining equipment for domestic andoverseas automobile components, with over 2 000 units
installed and operating at customer production sites.
Recently, customer demands such as ① high equipment
efficiency, ② improved operational availability (highreliability) and ③ improved space productivity havebeen increasing. The i-TOPCENTER Horizontal Spindle
Machining Center responds to the needs of customers andreduces initial costs through standardization (package)suited for automobile engine machining.

1. Features

2. Structure(1) Support for high efficiency machining• To support high-load machining, spindle tool clamp
force was strengthened to maintain tool chucking
force, and feed rigidity was raised to ensuremachining accuracy.
(2) Improved reliability*1• High reliability (MTBF 13 000 H: trial calculation)and stronger maintainability maintenance forecast)were obtained by the thorough analysis of operationand maintenance information for conventional
production lines.
• A side filter system (filter with a structure that is
not easily damaged) was employed and activities toraise MTBF were conducted in order to reduce valve
clogging caused by filtration accuracy defects in thecoolant supply unit and machining defects caused byclogged piping.
• A forecast function was added to notify about
replacement periods of component parts, etc. before
equipment breakage occurs, and actions were taken toraise MTBF (using the JTEKT CNC unit MC70).
*1 MTBF: Mean Time Between Failure

2. 1 Spindle
Cylinder block processes were integrated, and a highoutput spindle was developed which supports high-loadmachining.
2. 2 Base unit (column, slider)Cast material wall thickness and rib arrangement of
the main machine component parts (column, slider) wereoptimized using CAE, ensuring sufficient rigidity formachining loads. The linear guide used is the same roller
type used in conventional models, which has high rigidity
and high damping performance. The ball screw selected
has a screw diameter able to maintain sufficient rigidity
against machining loads at 60 m/min. This combination
has enabled the integration of cylinder block processes.

(3) Space-saving• To increase space productivity, the installation area
was minimized to the smallest level for class #40
machines by optimizing equipment layout at themachine rear side.

Analysis diagram

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NEW PRODUCT
2. 3 Reliability(1) As a result of the knowledge obtained throughproduction line information analysis and*2“MAST･ZERO” activities at production sites, thefilter layout has been changed from a center drum
system to a side filter system as a drastic measure forthe coolant unit. Whereas the filter in the center drum
system is easily damaged by passing chips, the side
filter system allows no contact between the chips andfilter, giving the filter a structure that is not easily
damaged.
*2 “MAST・ZERO” activities: Activities based in
production lines at customer plants which aim
to eliminate machine stops by raising the rate ofoperation.

Preventative maintenance function

Forecast function for component replacement periods

Integrates usage performance ofcomponents with life expectancies
and gives notification of estimatedcomponent replacement period
Displays warning when set
value is reached
NC warning

Forecast*3(2) In addition to the visualization of the SFC and otherparts through the installation of a JTEKT CNC unit
(MC70), a forecast function effective in preventativeand scheduled maintenance has been adopted as part of*1
the efforts to improve MTBF . This function enables
notification for component replacements by monitoring
the functional decline, number of operations, and timeon the machine.
*3 SFC: Sequential Function Chart: Visualization ofelectric circuits using a flow chart

Side filter system
FilterCoolant liquid (dirty)
Chips
Filter

2. 4 Space-saving
Minimum space usage in device layout was achievedby amassing the hydraulic and pneumatic hoses and cablerouting on the rear part of the machine together at thetop part, thus securing space for filter and coolant pump
maintenance.
This resulted in a shorter total machine length and thesmallest layout area in class #40 machines.

(Rear)

Filter is not easily damaged as large chips aredischarged without coming into contact with the filter.

Side filter60

Lamp lights up if set value is reached
Air pressure
lower forecast

Coolant liquid (Clean)(Side)

Gives notification for inspection ifvalues exceed those forecasted
prior to reaching abnormal values

3 865
3 805

535 (opening dimension)

475

100Top view

1 190 (bed width)
925 (opening dimension)
1 520
515

330595595

8060
Tilt center

Layout(Machine Tools Development Dept., Machine Tools & Mechatronics Operations Headquarters)

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JTEKT ENGINEERING JOURNAL English Edition No. 1012E (2015)