Vollmer unveils limited edition wire erosion machine

Vollmer has launched the VPulse 500 1000 Edition, a new wire erosion machine that the company says represents a significant advance in the manufacture and maintenance of PCD-tipped tools. Building on the established QWD series, this limited-edition model offers both high precision and efficiency.

The VPulse 500 1000 Edition commemorates the installation of more than 1,000 Vollmer wire erosion machines worldwide. Available only for a limited time, this exclusive machine is equipped with the company’s EDM generator, the HR automation system for increased tool capacity, oscillation eroding technology, PCD residue detection and a host of further enhancements.

At the core of the machine lies the new VPulse EDM erosion generator, which delivers either higher material removal rates or higher surface quality to meet a wide range of machining objectives. An integrated technology database simplifies operation by providing preconfigured parameters to enhance user-friendliness. Operators can quickly select suitable material-specific machining programs, while the database can be expanded to accommodate specific customer requirements.

Comprehensive machine concept drives flexibility

The VPulse 500 is a complete solution for manufacturing and maintaining PCD-tipped tools. Its advanced control technology achieves optimum machining performance via simultaneous path interpolation across five CNC axes, enabling measurement and erosion within a single clamping operation.

The machine supports machining with unsupported clamping and offers an optional counterpoint unit for machining between centres. Multiple interfaces ensure flexibility for varying workpieces.

Vollmer has developed an operating concept that places human–machine interaction at its centre. A flexible, height-adjustable and tilting control panel allows operators to maintain clear visibility of both the display and the work area. Operation is intuitive via touchscreen or mouse, with user-friendly menu navigation enabling complex tasks to be performed with minimal training. Straightforward information retrieval ensures rapid access to essential program and machine parameters, while new documentation and analysis options support faster process optimisation.

Advanced software integration

The VPulse 500 1000 Edition integrates the established ExProg programming system, combining its capabilities with new enhancements. The intuitive interface allows simple application, while profiles can be divided into any number of sub-contours, offering machining flexibility.

Vollmer says the machine delivers fine contours and exceptionally sharp cutting edges cost-effectively, ensuring maximum process reliability. In metalworking applications – particularly in the automotive and aerospace sectors – manufacturers benefit from its ability to produce complex tool geometries reliably and productively. For woodworking tool manufacturers requiring outstanding profile accuracy, the VPulse 500 1000 Edition consistently delivers dependable results, reports Vollmer.

Thanks to the intelligent HR automation system, the machine can operate unmanned for extended periods, including over weekends. The internal automation accommodates up to 16 tools, each weighing up to 20 kg, with a maximum diameter of 300 mm and a length of 500 mm. For those requiring greater capacity, the HC5 automation solution offers 28- and 64-tool storage options.

According to Vollmer, the VPulse 500 1000 Edition embodies three core advantages: high precision through its five-axis kinematics, enhanced productivity via high-performance control systems combined with the new VPulse EDM erosion generator, and simplified operation through innovative design and improved human–machine interaction.