Generation X

This is the Royal Master GENERATION X, extreme profile grinder. Since its introduction it has been successfully implemented into production in most of the top medical device companies in the world.

The machines basis is from our High Accuracy system which is used in Aerospace and Automotive industries where robust equipment is paramount for 24/7 production environments.

The Generation X machine is very versatile where it can make complicated micro-machining wires or conventional wires at up to 1.25 inches per second. Grinding intricate shapes on your product through CNC interpolating includes flats, threads, shoulders, radii, balls etc..

The Gen X Grinder:

  • Replaces Regulating Wheel and Blade with Stationary Wire Support
  • High Accuracy Ram Bed Axis
  • Linear Motor Travel of Servo Driven Work Head
  • Both axis coordinate with 4 millionths (0.0001mm) resolution
  • Interpolate Profile Grind with Programmed CNC Movement
  • Capable of Conventional and Super-Abrasive Wheels
  • Available with CNC dresser with rotary disc or single point diamond

In the Micro Machining Mode

  • Intricate shapes including radii, steep angles, grooves, and flats
  • Guidewires with Paddles
  • Guidewires with non-linear tapers and ellipses
  • Hold linear tolerances to +/- 0.005"
  • Dental Instruments

In the Centerless Mode:

  • Conventional Guidewires at up to 1.25 inches per second
  • Hold linear tolerance to +/- 0.020"
  • Wheel Width up to 3 inch wide

New For 2010:

  • Granite Machine Bed Available
  • Automated E-mail Run Time Analysis for Machine Status reporting
  • 3-D Parts Wizard provides 3-D Modeling to see your part before you grind
  • The ability to Import Solid Models from other CAD programs and have the Wizard generate the Gen X tool path
  • Spin, Rotate, Pan And Zoom on your part for details
  • Improved automatic feeding system
  • Convert to a conventional centerless grinder
  • Programming a CNC machine has never been easier than importing your 3-D Solid Model to define the part shape and use the New Parts Wizard to translate that into a Excel Sheet Recipe.

Advantages of the Gen X wire profile grinder are:

  • reduced down time
  • fewer consumables
  • more flexibility of product to be ground
  • reduced changeover time
  • less maintenance

MICRO-MACHINING

Micro-Machining is a relatively newer form of machining very small parts. Royal Master has developed the Generation X with its 5 axis of motion and its sub-spindle making the machine’s profiling capabilities limitless. Machining as small as .010" raw material, as large as .100", and lengths as short as .030". The Generation X uses a high speed CBN grinding wheel at 9000 sf/m and is unique to any other system that takes raw material from a spool and automatically feeds it into the machine.

This machine like small Swiss screw machines, has a sub-spindle so when the part has a profile or feature on both sides of the part, the machine will hand it off, and finish machining it, thus eliminating the need for secondary operations.

This machine has the capabilities to make helix’s on parts by controlling the rotational speed of the work spindle. The ability also exists to stop rotation to create flats on the parts or plunge in to make notches.

The Generation X machine sits on the TG-12x4 platform and uses a Linear Actuator with encoder resolution of .0001" for lengths and a .000004" glass scale on the ram position for extremely high accuracy on diameters.

ANTENNAE GRINDING

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Antennae Grinding

WIRE GRINDING

Guidewire grinding has taken on a whole new dimension with the Generation X. The Gen X is a parallel machine to the Generation 5 machine as conventional guidewire grinding can be done as quickly as the Gen 5 machine. Using a 3” ( 75mm) wide grinding wheel and a 9000 rpm workhead, material removal rates are upwards of 1” per second.

With the elimination of the Work rest insert blade, and regulating wheel, changeover times are lower as well as consumable costs.

Tolerances capabilities are superior since cut to length accuracies are not needed. Length tolerances of less than .001” are achieved since the wire is ground in only one workholding, not multiple which can introduce error with slippage. Diameter accuracies are identical to the Gen 5, with better than 1 micron ( .000040”)

Generation X Close-up
Generation X Close-up

With the machine built on our Hi-Accuracy machine platform, the ram position that controls the diameter of the wire is controlled by a .1 micron glass scale, and the linear axis is a linear motor also with a .1 micron glass scale. The linear motor which is maintenance free unit is capable of over 5 million cycles without maintenance.

The 15” touch screen control with integrated NEMA rated keyboard and trackball make o[operation of the system as easy as your desk-top PC.

The features of the Gen X are numerous, the Programming is easy and can be done off or on-line using excel wizards. The generation of a tool-path and programming the profile are all done in one easy step. The machine’s functions are all manipulated by the wizards so the maximum system’s flexibility is reached.

Main Operating Screen
Main Operating Screen

The Generation X’s modular design is unique as any feeding system can be plugged into the machine at any time, giving the system future flexibility as needs change. Other feeding systems include a

  • New cut to length vacuum feeding system,
  • An efficient sliding unloading system,
  • Patented Spool feeder for NiTi,
  • Magazine Feeder for longer Material
  • Wire Straightener

Other Unique Features include

  • Exit side chopper for short Length wires
  • Exit side Laser Gauge system for full 24 hour unattended operation
  • Short Wire Unloader
  • Exit Side Coining

Program in a Taper
Program in a Taper

General machine features Include

  • Programming in Absolute or Incremental
  • CNC Dressing
  • Multilingual Control
  • Custom password protected screens
  • Lights out system capabilities are standard. Operate your machine via the Internet, PDA or Blackberry. "At a Glance" updates are available for your internet ready Cellphone or PDA
  • Limitless storage of profiles in Excel format

The Generation X machine is not limited to just guidewire grinding. Built on a standard machine platform, the machine can be used as a conventional centerless grinder with the addition of a regulating wheel dresser and housing. Switching over to INfeed or thrufeed grinding is a 30 minute task.

Part Examples
Part Examples

Accessories

Spool Feeder Vacuum Loader
Spool Feeder
Vacuum Loader
CE Approved Covers including Machine Clamshells Short Wire Unloader
CE Approved Covers including Machine Clamshells
Short Wire Unloader
Part Chopper Magazine Loader
Part Chopper
Magazine Loader
Integrated Laser Gauging Integrated Laser Gauging
Integrated Laser Gauging
Integrated Laser Gauging