Rottler SG100XY Cylinder Head Seat and Guide Machine

Overview

There are two common designs for diesel cylinder heads: large castings for six-cylinder inline engines with 24 valves, and single-cylinder heads with four valves (such as those used on the CAT 3500 series). The single-cylinder heads pose the greatest challenge, as most seat and guide machines can only handle one head at a time, requiring repeated manual loading, clamping, and tooling changes. This leads to wasted time and operator fatigue. Rottler developed innovative fixtures that allow easy loading of four single heads simultaneously. With one-button operation, all heads are clamped at once. The system accommodates uneven or previously machined heads of different thicknesses and non-parallel surfaces. Once clamped, the SG100XY can machine all intake seats unattended, and after a quick tool change, automatically switch programs to cut exhaust seats—also unattended. For large 24-valve castings, Rottler engineered a servo-controlled 360° rollover fixture with power clamping. This enables fast setup and 360° rotation for operations such as valve guide and spring seat repairs, injector tube replacements, and even drilling out broken exhaust manifold studs.

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Key Features

• ACTIV Spindle – Incorporates a spherical spindle design that automatically compensates for misalignment, ensuring perfect centering of the UNIPILOT tooling system with respect to the valve guide centerline.
• Automatic Guide-to-Guide – Lightweight workhead floats on air cushions and moves precisely from guide to guide via servo motor and precision ball screw, clamping automatically with air pressure for rigid machining.
• Quick X-Axis Alignment System (Patent Pending) – Allows fast setup of different cylinder heads by aligning outer valve guides using two pilots and linear slide alignment arms.
• SSV Spindle Speed Variation – Advanced motor control that automatically varies spindle speed during finish cutting for improved surface finish and vacuum sealing performance.
• Windows Touch Screen Control – User-friendly Windows-based touch interface for automatic hole-to-hole operation without complex CNC programming.
• Lightweight Floating Workhead – Enables precise centering and smooth guide-to-guide transition using a servo-driven base plate.
• Variable Speed Servo Spindle Drive – Controls spindle speed and revolutions for superior surface finish and repeatability.
• Multi-Angle Seat Cutting – Precision CNC-ground carbide inserts for single, multi-angle, curved, or radius seat profiles.
• Built-In Cutting Insert Sharpener – Diamond wheel sharpener for quick tool maintenance and extended insert life.
• Electronic Level and Angle Sensor – Touch-screen digital readout allows precise and quick head leveling.

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Standard Equipment

• Special version for Automatic Guide-to-Guide machining in X and Y directions for unattended operation.
• Special Alignment System for fast setup of various cylinder heads (Patent Pending).
• ACTIVE Spindle System – Pneumatic spherical automatic alignment for rapid pilot centering.
• CNC Touch Screen Control using Windows OS and industrial PC with Intel processor.
• Internet connectivity for remote diagnostics and software updates.
• Automatic cycles for seat cutting, guide drilling, reaming, tapping, and housing boring.
• 15\" (400 mm) bright touch screen for full programming and monitoring.
• Electronic handwheel for manual positioning (.001\" / .010\" increments).
• Precision digital readout: .0001\" (.002 mm) resolution.
• Built-in database for storing specifications, tooling data, and parts information.
• Heavy-duty spindle with Rottler R40 taper, 3.70\" (94 mm) diameter, 10\" (250 mm) vertical travel.
• Automatic tightening and quick-release spindle lock nut system for one-hand operation.
• Spindle travel by precision ball screw and AC servo motor for Z-axis movement (10\" / 250 mm).
• Spindle rotation by AC servo motor – variable to 1000 RPM.
• Floating workhead on air cushion for precision centering.
• Servo-driven workhead movement in X-axis (40\" / 1025 mm travel).
• Servo-driven table movement in Y-axis (6\" / 150 mm travel).
• Spindle head tilt ±10° for canted angle valve guide heads.
• Integrated vacuum tester with hose, filter, and pads.
• Dual LED work lights for shadow-free viewing of the seat area.
• Machine paint color: RAL 9002 (Grey White).

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Control System

The Rottler Touch Screen CNC Control uses advanced Direct Motion Control technology and Windows OS. The system includes an industrial-grade PC linked to the internet for worldwide remote diagnostics, updates, and support. The Conversational Touch Interface simplifies programming of all major operations — seat cutting, housing boring, guide reaming, drilling, and tapping. No prior CNC experience is required, and operators can store and recall complete setup information and machining data for future use. Additional manuals, setup charts, and specification files can be stored directly in the machine’s onboard computer.