C.R. Onsrud 2016 CNC Catolog

products, materials, parts, or processes prevent the effective use of Roller-Hold-Down
technology. When this occurs, the machine can be operated with rollers disengaged, or even
removed, using only the high flow vacuum for part holding.

The Roller-Hold-Down option is available in either twin table moving gantry design,
continuous triple table moving gantry design, or our fixed bridge moving table design.
All of these models can be equipped with, or without, a number of optional material
handling systems. All are available with a special double plumbed vacuum table system with
twice the vacuum plumbing found on other machines. Thus, they handle the highest flow
vacuum pumps available, at over 50HP, and up to an amazing 120HP per 4X8 table! On RHD
models, we offer our heaviest duty perimeter pop-up positioning for quick and reliable
sheet(s) placement. All machines come standard with an 18HP, 4-pole spindle with
an unsurpassed in-the-field track record for longevity, durability and serviceability.
Increased HP, liquid cooling, multiple heads, multi-spindle drilling blocks, and automatically
adjustable servo head spacing are easy upgrades on any Onsrud RHD.

With a C.R. Onsrud Roller-Hold-Down CNC Router, your company can get more machining
capacity out of less investment, and with less footprint than ever before!

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The Onsrud - OSAI Control

The OSAI combines T he OSAI CNC controller option from C.R. Onsrud is a feature packed controller upgrade
the ease-of-use, designed with the sophisticated power-user in mind. To deliver this power, the OSAI
flexibility and is based on Multi-Platform software architecture. The real time multi-task operating
connectivity of a system offers accurate and safe axis control that can be completed with the system’s own
fully equipped technological algorithms. Additionally, a standard Windows operating system provides a
Windows PC. friendly and familiar operator interface.

Because the PC functions of the OSAI and the machine controller portion are actually
separate, both can be repaired or replaced separately and easily in the field. The OSAI
combines the ease-of-use, flexibility and connectivity of a fully-equipped Windows PC, with
the power, durability, reliability and serviceability of a true CNC machine controller.

OPENcontrol PRODUCT FAMILY ALLOWS TO REACH HIGH FINISHING
QUALITY, HIGH PRODUCTIVITY AND OPTIMIZED MANAGEMENT OF
MACHINING CENTERS THROUGH FEATURES LIKE:

• Complete management of 5 axes by using Tool Center Point (TCP)
• Algorithms for High Speed Cutting (HSC)
• Complete 3D roto-translations.
• Gantry and dual axes management
• Look-ahead with 1024 pre-calculated blocks
• Velocity Feed Forward (VFF) calculation
• Jerk control using advanced algorithms
• Management of tool magazine, tool life, random tool, multi-pocket tool
• Multi-axes electronic cam
• Cross compensation
• Volumetric offset compensation of both mechanical asymmetries and machine

misalignments

CUSTOMIZATION IS FULLY SUPPORTED BY A SPECIFIC CONFIGURABLE
GRAPHICAL HMI AND AN EMBEDDED ISO 6-1131-3 PLC OFFERING:

• Multi-tasking real time execution
• Up to 250 tasks with 10 priority levels
• Cycle tasks with 250 µSec. minimum scheduling
• More than 450 functions available
• Possibility to interpolate axes from logic
• Possibility to include external software algorithms
• Multi-head dual process option included on all multi-head models.
• 1-3ms block processing time, even in fully 5-Axis motion.
• Up to 164 block look ahead.
• Ballscrew Error Compensation available.

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OSAI front end

OPERATOR PANELS FOR OPENcontrol WHY OSAI?
•Open Architecture Hardware and
Each control unit of the OSAI OPENcontrol CNC family can be combined with different
operator interfaces, from the simple Touch Screen monitor for General Motion applications Software-OSAI can work with any
to OPENconsole, a modular High End operator panel for Machining Centres. CAD/CAM available.
•This is a fully customizable control but
OPENcontrol is designed to meet many different application requirements, the modules maintains a common operator interface.
can be combined in order to create a customized and complete front-end suitable for Operators see the same screens even on
different types and complexities of machine tools. entirely different machine models.
•Same software on ALL CNC’s-Software
OPENconsole modules are even interchangeable.
• 17” or 19” Industrial Monitor with Touch Screen option •Common NC process core-Modular and
• OEM panel Scalable product structure that allows
• OEM panel extension many features, options and axes to be
• Keyboard with touch-pad added later.
• Keyboard with track-ball •A controller from a company that is
• Junction element with USB port flexible and responsive and that is run
like a family business vs. a
OPENconsole COMPACT conglomerate.
Also called “All-In-One” it is the operator panel for all the OPENcontrol CNC range which •OSAI is dedicated to the advancement of
optimises features, prices and dimensions without sacrificing design and ease of use. their CNC control, over 14% of product
• Customizable OEM Panel with 2 rotary selectors sales revenue invested in R&D.
• Customizable OEM Panel extension •More standard features than any other
• Keyboard with touch-pad CNC control manufacturer for unequaled
• Emergency push-button performance.
• 2 Custom push-buttons •Spare parts normally shipped within 24
• 1 USB port hours for unequaled service.

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The Onsrud - FANUC Control

C .R. Onsrud offers the FANUC controller system on nearly all 3, 4, and 5-Axis CNC
Vertical Machining Centers. FANUC CNC systems are known throughout the world
for their unmatched reliability, high-speed motion, and world class support. The
FANUC Series Oi - Model F CNC controller option from C.R. Onsrud, has been developed
for the newest generation of high performance machines. The enhanced functionality
and superior performance of this system allows us to extend the potential capabilities
of your machine to a new level. Through advanced software algorithm analysis of part
geometries and machine capabilities, the FANUC system will adjust trajectories and feed
rates, to provide the smoothest possible tool paths, the highest processing speeds, and
exceptional high precision results. The FANUC "open architecture" combined with the
Windows embedded interface, known as the "Panel I;" have allowed our development
team to create user friendly interface HMI screens, that are common across our various
controller system options. This commonality results in a shorter learning curve for new
operators, as well as operators who are more familiar with other control systems. In
addition, the design of this controller allows users to operate in a traditional mode
utilizing familiar FANUC screens; or, they can use the Onsrud HMI touch screen
functionality depressing large on-screen buttons to perform common tasks that once
required deep knowledge and understanding of machine code.

Downtime on any CNC machine can be very expensive. This is especially true when you
factor in the cost of repairs, lost production capacity, and potential revenue and goodwill
lost from missed customer deliveries. When you order an Onsrud machining center equipped
with a FANUC control system, it includes not only the controller and machine interface from
FANUC, but, also every servo motor, power supply, drive and even the wiring will be original
FANUC hardware. Thus, FANUC offers an optional, additional extended warranty package,
covering all FANUC components for as many as 10-years beyond the already exceptional
C.R. Onsrud standard 2-year warranty.

Naturally, on-line remote diagnostics are included on every C.R. Onsrud. Support for
Onsrud machines equipped with a Fanuc controller is available not only from deep bench of
C.R. Onsrud technical support personnel, but also from over 200 FANUC technicians located
throughout the country. With FANUC’s commitment of a 25-year parts availability
guarantee, convenient local parts inventories, and economical repair and return services,
you can look forward to decades of trouble-free operation with the confidence that your
machine will be available for production when you need it.

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FANUC SERIES Oi MODEL F - FEATURES

• Servo technology with the highest performance in the world
• Achieves both high accuracy and smoothness with easily adjusting steps
• Provides the convenience of PC on CNC
• Loader control commanded by G code meets the request of automation
• Nano CNC system combined with precise nanocalculation and leading-edge servo technology
• AI Contouring Control effective for high-speed and high precision machining
• Smart Overlap enables a shorter cycle time for machining parts
• Servo HRV provides high-speed and high accuracy
• Spindle HRV has high acceleration and high response
• FANUC SERVO GUIDE with quick and smart tuning
• Increasing the number of controllable axes makes it ideal for a wider range of machines
• Support of various industrial networks and field networks
• Direct editing and operation of the CNC program on memory card
• Integrated Operation & Programming Guidance with extremely simplified operations
• Safety achieved by the Dual Check Safety embedded into CNC
• Customize functions for each unique machine
• Various types of enhanced diagnosis functions improve maintainability so that the

cause of trouble can be identified quickly

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The Onsrud B&R
Controller System

The STANDARD mobile The Onsrud B&R, is an open-architecture control system that is designed with
handpad controls all simplicity, reliability, and ease of use in mind. This is a fully-functional, stand-
functions of the alone, complete machine control system made entirely from standard, off-the-shelf,
machine. plug and play components that are readily available worldwide. It is manufactured by
Bernecker & Rainer Automation, which is one of the largest international private control
companies in the world today, with over 220 engineers in R&D, 300 application
engineers, and another 125 engineers in their sales department.

Standard on all Tech Series, Pro Series, and Super Duty and Single Table Series
machines, the B&R is much more than the mobile handpad interface that operates the
machine. The B&R is a complete electronics, motion, and control system. With a blazing
1ms block processing time, a super-fast dedicated processor, and 128 multi-block
G-code look ahead, the B&R provides smooth and reliable machine motion without
compromising power or capability. It utilizes an intuitive, easy to understand, easy to
integrate, and easy to learn interface via single labeled keys that are used to select any
of the possible machine functions. The simple conversational intuitive menu structure
allows almost all of the many features to be selected using only three soft keys.

PC FRONT OPTION

If you prefer to use a PC as your machine interface, the Integrated VNC-PC Front Link
allows for a quick hook up to any user provided PC, which will then have complete
control over machine operations. This provides all of the benefits of PC connectivity,
with the robustness and trustworthiness of a proven machine tool controller built from
uniform standard plug and play components. And, if you change your mind later, then
simply switch the machine back into handheld mode, unplug your PC, and all standard
machine functions transfer back to the handpad. This innovative and unique design
eliminates the potential for obsolescence of the PC hardware or the PC’s operating
system that other traditional PC fronts with static PC interfaces will inevitably face. As
long as your next PC has an Ethernet connection, it has what it needs to connect to your
B&R controlled C.R. Onsrud machine.

This should be especially important if you intend to program using CAD/CAM or design
packages on the shop floor, or at the machine. Any computer or PC front that is powerful
enough to run today’s cutting edge software, will soon find itself not powerful enough to
run tomorrow’s. If that happens, your company would be stuck having to use yesterday’s
dated and/or incapable software because of an obsolete PC or out of date operating
system. The B&R control system’s innovative and unique design illustrates our belief, that
all that is complex is not useful, but all that is useful is simple.

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B&R CONTROLLER SYSTEM FEATURES

• Easy to Read, Feature Rich, and Fully-Functional Display which often eliminates
the need for a PC at the machine.

• The necessary software and interface for Integrated VNC-PC Front is onboard and
included on every B&R.

• Standard with 4 port Ethernet Connection, USB connectivity,
and Serial connectivity.

• All axes can be incrementally jogged using a Hand Pulse
Wheel for quick and precise manual machine positioning.
•Cutting Feed Rates, Rapid Traverse Feed Rates, and
Spindle Speeds are adjustable on-the-fly from the
hand pad.
• Manually control the state of inputs and
outputs with status indication for all.

• Single Source Accountability because entire
range of automation hardware and
software is from only one source.
• Multiple Jobs can be stored
inside the flash memory up to 4GB of G-code
(64MB standard).
• Ring Mode from your PC for any job that standard
memory can not already accommodate.
• Upgrading and/or backing up the standard memory is as inexpensive and easy as
the purchase of a larger compact flash card.
• Resume Function in most cases allows the operator to pick back up in the middle
of a program without a re-datum of the machine.
• Search Function allows the operator to start or resume in the middle of a job, or
at the start of any tool, even after an E-Stop and re-datum.
• Table Modes and Pendulum Processing are all handled by the controller.
• System is based on a true rugged machine control, built for hot, harsh, and dirty
environments with a link to a PC as an interface; instead of using a PCI motion
controller card plugged into this month’s current PC.
• Digital drives, amps, and servo motors are all connected to the control and I/O
using B&R’s market leading real-time network ETHERNET Powerlink interface which
allows for much more extensive system monitoring or diagnosis, and for plug and
play in-the-field serviceability.

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High Productivity Options

24,000 RPM SPINDLES

Maintaining the proper chip load during high-speed machining is crucial. The latest
spindles from Onsrud are 24,000 RPM as standard, and are available at speeds up to
30,000 RPM, to take full advantage of the time savings and increased productivity
possible with today’s fastest machines.

EXTRA RAPID TRAVERSE - 6,000 IPM RAPIDS AVAILABLE

High-pitch ballscrews combined with powerful brushless servomotors provide rapid
traverse rates up to 6,000 ipm. This reduces the amount of non-cutting time during
the machining process resulting in faster cycle times and reduced cost-per-part.
Available on “Extreme Series” twin table models. Super Duty Series rapids are 4,800
ipm and Pro Series rapids are 3,500 ipm.

4TH AND 5TH AXIS OPTIONS

A fully integrated 4th or 5th axis creates a supercharged machining center package that
boosts your flexibility and capability. Onsrud offers fully synchronized 4th and 5th axis
configurations in fixed bridge, moving gantry, compact high rail, and high rail designs.

12 POSITION AUTOMATIC TOOL CHANGERS

More tools, more workspace and faster tool changes: we have put these advantages
together to increase your productivity and reduce setup times. Locating the tool
changer outside of the work envelope is a sure way to free up additional space while
adding greater flexibility. Combine this with the added bonus of greater tool capacity
in a flexible, high-productivity machining center like an Onsrud, and you are ready to
tackle the toughest machining jobs, with larger diameter tools. Onsrud-built side-
mount tool changers feature rapid tool changes, and when used in conjunction with
macros, tool-life management and tool-load monitoring, extra pockets can be
dedicated to back-up tooling for un-attended operation.

24-TOOL OPTION

Nearly any Onsrud can be outfitted with this expanded tool option, which can make
complicated parts and operations like in-process inspection or lights-out
manufacturing much easier to program.

24-TOOL OPTIONAL RAPID DATC

The Rapid Dual Arm Tool Changer option can replace the standard tool changer on
select models and will decrease the tool change time to just a few seconds per change.

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PROGRAMMABLE COOLANT AND/OR AIR BLAST NOZZLE ISO-30 vs HSK-63-F

Programmable Coolant and Air Blast Nozzles can provide either coolant or air blast or
both to the cutting tool during the machining process, helps to clear chips and/or
cool the cutting tool. Activated by M code, and fully integrated into the machine,
these nozzles can be programmed to automatically turn on whenever the spindle is
turning, or off at the end of a cycle.

MQL - MINIMUM QUANTITY LUBRICATION

Also known as Near-Dry machining, MQL replaces flood coolant with a minute amount
of high efficiency lubricant applied precisely to the cutting tool. MQL produces near-
dry chips that yield higher prices for recycling; plus saves money, time, and clean-up.

HSK TOOL HOLDERS

Standard on all Onsrud CNC Routers, HSK-63F Tool Holders have 5 times the holding
power of the ISO-30 style. HSK provides 2.5 times the clamping force and can
accommodate 2.5 times the diameter compared to older ISO or BT designs. This
translates directly into less vibration, greater precision, and longer tool life.
HSK-63-A Option available for even more demanding applications.

TOOL LENGTH AND TOOL DIAMETER PROBE

This Onsrud tool probe option incorporates our easy-to-use tool probe with macros. This
package enables an Onsrud router to automatically define tool length and diameter
offsets. When combined with our powerful macro capabilities, it allows operators to
automatically update tool offsets (length and diameter) and check for broken tools
while in-process.

WIRELESS INTEGRATED PART PROBING

Auto-Finds the Edge, Center, or Top of a workpiece or fixture. This compact standard
design was engineered to withstand harsh dirty machining environments. Fully
compatible with high speed, single touch, or double touch probing routines and can
Reduce Set-up times up to 90%.

LINEAR SCALES AND ROTARY ANGLE ENCODERS
ACCURACY ENHANCEMENT

We use Linear Encoders that are specially designed for high-speed, high-precision
applications with a frictionless design that eliminates wear while reducing potential
lagging for higher precision at high speeds and rapid acceleration. Non-contact sensing
delivers increased reliability and higher accuracy.

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1) Onsrud High Flow
2) Vacuum Tables and Options
3)A
3)B 1) ONSRUD’S UNIQUE HIGH FLOW VACUUM INLETS (PATENT PENDING)
3)C Increase the flow of vacuum from the vacuum pump to the High Flow Vacuum Tables by lowering
4) restriction and allowing the air to transition smoothly from the oversized vacuum plumbing lines to
5)A the High Flow Vacuum Waffle Table.

2) C.R. ONSRUD ALUMINUM HIGH FLOW VACUUM TABLE SYSTEM
Features 45mm wide, extra deep vacuum channels on 90mm centers, in both the X and Y directions.
These extra deep channels allow the vacuum to flow restriction free all the way out to the edges of
the tables. This allows as much vacuum holding to be produced out at the edges, as can be created
directly over the vacuum inlets, so optimum part holding is provided everywhere in the entire table.

3) ONSRUD / NEMI COMPATIBLE HIGH-PRECISION ALUMINUM VACUUM GRID CONVERTIBLE
TABLE SYSTEM
A. Ready for your choice of either a Spoil Board, Pods and Pins, Clamps, or Dedicated Fixtures.

B. Shown with round closed cell vacuum tape sectioning off a small portion or the Grid Table, where
the NEMI “penny plugs” are removed, ready for use with either a Spoil Board or Dedicated Fixture.

C. Shown with Vacuum Controlled Pop-Up-Positioning Pins and NEMI Slider Pods.

4) C.R. ONSRUD PHENOLIC HIGH FLOW VACUUM TABLE SYSTEM FOR MATE, TECH
AND PRO SERIES MACHINES
Features the same 45mm wide, extra deep vacuum channels on 90mm centers, in both the X and
Y directions as their aluminum counterpart. These Inch and a half thick phenolic tables are
mounted directly to the Thermal Heat Treated, Stress Relieved, and Normalized One-Piece Steel
Frame Base for lasting, machined-in accuracy.

5) ONSRUD / NEMI PHENOLIC VACUUM GRID CONVERTIBLE TABLE FOR MATE, TECH AND
PRO SERIES MACHINES
A. Shown with Vacuum Controlled Schmalz Frame Clamps for holding small work pieces.

B. Shown with Vacuum Controlled Pop-Up-Positioning Pins and NEMI Slider Pods.

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5)B

Aggregate and C-Axis Options

• For special or unique applications.
• Adds additional capabilites.
• Inexpensive and effective.
• 100% continuous duty cycles.
• Retro-fittable on many models.

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CNC Router Investment
Considerations

1) Company Focus We only build CNC Machines at C.R. Onsrud. Rather than try

inadequately to build many diverse industrial products, Onsrud uses its unrivaled experience
in successfully building production machining equipment, only for building CNCs. Because we
concentrate our efforts on only one product line, our engineering staff, production staff,
support staff, sales staff, and managerial staff can all be cross-trained in machine operation,
troubleshooting, applications engineering, tooling selections and recommendations, multiple
CAD/CAM software solutions and multiple part fixturing methods. Our “deeper bench” provides
you with easier access to more fully qualified and more readily available technicians per
machine installed when you need it the most.

2) Machining Experience The Onsrud family has been building production routers and

machining centers longer than nearly anybody in either industry today. We use over 80 years
of experience, earned through 5 generations of Onsruds that have been manufacturing
machines, when designing the structural components of our machinery. We use our extensive
experience, advanced engineering principles, and our understanding of the physics of
machining, rather than relying solely on our advanced computer programs, models, and FEA
analysis to construct our machines. Thus, we produce machines that are designed for the real
world that will work hard everyday.

3) Standardization C. R. Onsrud does not employ any proprietary systems on our

machinery. By manufacturing only standard equipment utilizing only off-the-shelf industry
standard components, we assure the highest possible level of service, support, and parts
availability. We have been able to deliver over 98% immediate shipping of all replacement
parts requests for over 30 years. Your Onsrud machine will be producing parts, instead of
waiting for parts.

4) Machine Performance We engineer our CNC’s to run 24 hours per day, high-speed,

continuous duty cycle if necessary. We choose only the top shelf suppliers of the highest
quality production duty components available, such as Colombo and HSD Spindles, INA
and Bosch Rexroth Linear Profile Guides, B&R, FANUC, and OSAI drives, amps, and digital
brushless servos, and INA and Star Linear Precision ball-screws. By spending a little more on
the best components available, we ensure you the highest possible production speeds, a long
machine life, plus low operating and maintenance costs.

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5) Made Domestically Our engineering staff, production staff, support staff, sales staff, and managerial

staff are all based here in the USA, in Troutman, NC. This allows us to be far more responsive to any unforeseen or
recurring problems than any machine importer could ever hope to be. Sure their sales staff may all be here in the
US, and they may even have a good technical staff here also, but their engineers and designers are not. Any design
changes must come from China, Italy, or Germany with many of our competitors. If there is ever a problem or
deficiency with an Onsrud machine’s design, the appropriate design changes can be made immediately, put into
place that day, and the next machine that comes off of our line is fixed. There are no language barriers or time
zones between us and some overseas design and engineering staff. Because our machines are built in the USA, the
owners manuals, troubleshooting manuals, and other directions are all written originally in English and are not a
loose translation from another language.

6) Open Architecture Software Our routers can operate from virtually any CAD/CAM system available.

We are not locked into just one homemade software package like some of our competitors. Now you have multiple
avenues and options to choose the correct CAD/CAM system based on your individual needs, rather than being locked
in or pushed into some weak and overly complicated proprietary system offered only by, and supported only by, a
router manufacturer. If you have an existing CAD/CAM, or if the MasterCAM and AlphaCAM we provide are not the
correct fit for your needs, our open architecture controllers allow you to use ANY other industry standard software.

7) Direct Software Support We can offer both MasterCAM and AlphaCAM software and support directly

through C.R. Onsrud. Specializing in metal and non-ferrous, MasterCAM is the most widely used CAD/CAM system
in the USA and in the world today. AlphaCAM sells more copies to the woodworking industry than any other CAD/CAM.
These are easily the most advanced, powerful, and user friendly systems available. All of our technicians are
cross-trained in both systems, so we can offer you prompt help with both systems.

8) Factory Machine Support Included in the price of every machine we sell is C.R. Onsrud factory advanced

technical, tooling, and machine support. All series include free advanced phone support and remote diagnostics to
the original purchaser, and access to our 24/7/365 Emergency technical support line. This helps keep the total cost
of ownership of an Onsrud much lower for you than other seemingly comparably priced machines.

9) Factory Integration Included in the price of every machine we sell is onsite machine integration

directly by a C.R. Onsrud applications engineer. There will not be some shade-tree CNC mechanic employed by a
local vendor that works on CNC Routers only part-time, or some mercenary-type CNC install outfit. Nearly all of our
machines ship fully assembled, so we do not have to send somebody to finish putting it together onsite. We
instead, send a machine integrator to your facility, whose only job is to train you thoroughly and help you
start running your parts, from your drawings, on your machine, using your material, using your tools, to your
specifications, and to your satisfaction. Our commitment is to help you be able to use your machine immediately!
You do not have to worry about being stuck with a machine that does not work, or that you are unable to oper-
ate, and you can be assured of the fastest and lowest possible learning curve.

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Simple Set-Up

SHIPS FULLY ASSEMBLED Most of our machines ship as one piece, fully assembled, and nearly ready to
AND FUNCTIONAL run. All you will need is a large enough forklift to take the machine off the
truck and put it into its final place. Leveling the machines is as simple as
This is all included adjusting the leveling bolts. It does not have to be bolted down to the floor like many
in the price of the lighter machines, and the frame is far too rigid and solid to twist or flex. Just set it
down, level it and it is already square! You will be responsible for a few simple things
machine. such as: any floor preparation necessary, any power supply connections, providing
acceptable dust collection, any necessary pneumatic connections and supply, any
labor and handling equipment (crane, forklift, etc.), and any materials and tooling
needed for machine testing, training, or adjusting. Since your CNC Router will ship
fully assembled and nearly ready to operate, having already been run and tested at
our facility before shipment, C.R. Onsrud expects the machine to be in place and all
of the necessary utilities to have already been brought to the machine when the
technician arrives. The technician will then finish the installation and prepare the
machine to run, plus instruct any machine operators on proper maintenance and
operation. Best of all, our technician’s time with you is included in the price of the
machine. Most of our customers find they are actual in production before the
technician even finishes their on-site training.

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