Aggregate Heads for CNC routers

Types of Techniks Aggregate Heads

Techniks Aggregate Heads increase the capabilities and productivity of CNC routers by enabling additional machining axis and automating difficult machining applications. Techniks Aggregate Heads mount in the CNC router’s motor spindle and utilize the rotation and torque of the spindle to drive the tool clamped in the aggregate head. When coupled with CNC routers equipped with a C-axis to allow rotation around the Z-axis, Techniks Aggregate Heads enabled the cutting tool to approach the workpiece in directions and orientations not possible with standard tool holding systems. Use of Aggregate Heads offers cutting, grinding, probing, indenting, doweling, gluing, and other processing methods in addition to rotating machining processes such as routing, drilling and sawing. The result is the ability to accomplish more machining in a single setup. This makes Techniks Aggregate Heads ideal tools for machining wood, composite materials, plastics, and aluminum.

Anatomy of an Aggregate Head

An Aggregate Head generally consists of a body that contains a series of gears, and a torque arm also called an anti-rotation collar. The torque arm consists of a collar that fits around the aggregate and a locating pin or pins and is the part that secures the aggregate against spinning while in operation. It also reduces vibrations and supports the aggregate against side-load machining forces. The locating pin is specific to the router manufacturer and engages with the machine’s anti-rotation support ring, stop block, or C-axis.

Techniks Aggregate Head Quality

Aggregate heads are essentially small, high-precision gearboxes running at very high RPMs. During operation, these high rotational speeds combined with torque from the machining forces create heat buildup within the aggregate. Excessive heat can damage lubrication seals, evaporate grease, or oil lubricants, and cause premature failure of the aggregate head. Techniks Aggregate Heads are designed to minimize heat buildup to enable longer service intervals and more aggressive machining operations. First, Techniks Aggregate Heads utilize precision calibrated bevel gears that have been matched to ensure proper fit and smooth torque transmission during operation. Bevel gears have a longer tooth engagement with each other than crown gears and offer superior torque transmission. This is why automobile transmissions use bevel gears as opposed to crown gears. Next, Techniks Aggregate Heads are hand assembled by German craftsmen who know the proper amount of force required between the bevel gears to allow optimal performance without excessive heat buildup. Each Techniks Aggregate Head goes through a testing process of running in a motor spindle where heat buildup and noise are closely monitored. If variances to acceptable levels are discovered during testing, the aggregate is disassembled, adjustments made to the bevel gear assembly, and reassembled for re-testing. Only when an aggregate meets the most demanding quality standards is it ready for packaging and shipping to our customers.

Techniks Aggregate Heads are Industry 4.0 Ready

With the advent of increasing interconnectivity, real-time communication, and smart automation embodied in Industry 4.0, Techniks Aggregate Heads are ready to meet these new standards. Techniks Aggregate Heads are available with our proprietary AC 4.0 computer chip that is mounted to the aggregate and collects process data such as rotational speed, operating hours, temperature, and vibration and transmits this data in real-time directly to the customer. The customer is alerted when critical parameters are reached and can optimize settings on the machine, aggregate, and/or tooling in order to maximize the performance of the aggregate, lengthen the service life, optimize processes, and ensure trouble-free operation. AC 4.o also indicates recommended service intervals and enables timely and planned service preventing unanticipated downtime by means of preventative wear monitoring.

Techniks Aggregate Heads Series and Configurations

Techniks offers three series of aggregate heads and many configurations to meet any application.

SmartLINE Aggregate Heads

SmartLINE aggregates features a compact and lightweight design for operations where clearance or maneuverability is required. SmartLINE aggregate heads are grease-lubricated for long life and deliver a great price-to-performance ratio. SmartLINE aggregates are available in the following models:

SmartLINE DUO

Light weight aggregate heads for standard-duty operations on a smaller CNC router or where space is limited. They can be configured with multiple ER25 outputs, a combination of ER and saw outputs, or even with two S1 saw outputs.

Features:

• Output: two-sided, right angle
• Output options: ER25, saw blade

SmartLINE VARIO & VARIO VISO

Use Vario or Viso Aggregate Heads to cut at any angle from 0˚ to 100˚. Vario aggregates can be fitted with an ER25 output, or the Combi saw output that is compatible with 45mm or 52mm bolt circles. Viso can also accept the modular system.

Features:

• A compact design tool for a smaller CNC router or where space is limited.
• Variable angle single output (0° – 100°)
• Viso features a digital display for easy angle setting

SmartLINE EXTRA Lock Recess

Innovative lockset recess aggregate heads are the ideal aggregates tool for working in tight spaces. Offset design is optimized for cutting lockset recesses, but can be used for other boring operations.

Features:

• Offset design optimized for longer tooling operations
• Output options: ER25

FunctionLINE Aggregate Heads

FunctionLINE aggregates feature a larger body for improved heat dissipation and longer service intervals. Function LINE aggregates are grease-lubricated for long life and are available in the broadest configuration offering including MONO, DUO, QUATTRO, VARIO VISO, FLOATING, EXTRA, SOTTO, VERTI, HORI, and many others.

FunctionLINE MONO & DUO

An affordable was to add 4th-axis capability to your CNC router. An ideal tool that is able to perform routing, boring, mortising, and sawing operations.

Features:

• Single or double, right-angle output
• Output options: ER25, ER32, saw blade, modular

FunctionLINE QUATTRO

FunctionLINE Quattro aggregate heads can be configured with 4 ER25 outputs, two ER25, and two ER32 outputs, or two modular outputs and two ER25 outputs. Modular outputs are required for saw spindles.

Features

• Quad, right-angle outputs
• Practically eliminates time-consuming tool changes
• Output options: ER25, ER32, saw blade, modular

FunctionLINE VARIO & VARIO VISO

Use Vario/Viso Aggregate heads to cut at any angle from 0˚ to 100˚. They can be fitted with an ER25 output, or the Combi saw output that is compatible with 45mm or 52mm bolt circles.

Features:

• Route, drill, saw, or mortise any angle from 0° to 100°
• Viso features a digital display for easy angle setting
• Output options: a combination of ER25 and saw blade or modular system (Viso only)

FuntionLINE EXTRA Lock Recess Aggregates

Innovative lockset recess aggregate heads feature an offset design optimized for cutting lockset recesses. Can also be used for other boring operations.

Features:

• Offset design optimized for longer tooling operations such as mortising
• ER32 output on the front, ER16 on back
• 15,000 RPM tool speed for faster cutting

FunctionLINE SOFT TOUGH Aggregates

The Soft-Touch CNC router aggregate head accurately follows the contours of your material, automatically compensating for up to 10mm of variance for consistent depth of cut. Floating pressure is adjustable from 1/4 lb. to 20 lbs.

Features:

• Up to 10mm of compensation for surface variation
• The optional chip guide directs dust into the machine’s dust hood for a cleaner work environment

UltraLINE Aggregate Heads

UltraLINE Aggregate Heads are oil bath lubricated for continuous operation in extreme conditions and designed for high performance materials. Recommended for sawing using blades larger than 7″, V-grooving, heavy routing operations, cutting MDF, composite materials, or cutting aluminum.

UltraLINE Duo Aggregates

UltraLINE aggregates add fourth axis capability to your CNC router. An efficient tool that performs routing, boring, mortising, and sawing operations faster and easier.

Features

• Oil bath gear lubrication for superior wear resistance during heavy-duty operations
• Dual, right angle output (other different angles available)
• Output options: ER25, ER32, saw blade, Prolock

UltraLINE Vario/Viso Aggregate Tooling

Features:

• Full 200˚ of angle adjustment from -100° to 100°
• Most flexible of any aggregate head
• Faster sizing and grooving than with CNC router bits

UltraLINE Moulder Aggregates

UltraLINE Moulder aggregate heads are used with a variety of cutting tools to shape and form as required. They are also used for gang saw operations.

Features:

• Gear reduction for high torque
• 30mm x 120mm arbor size
• Optional Chip Guide for dust control