Archive | May, 2010
The starting point was a partially functioning sheet metal notching machine made in 1970, obviously without CNC and totally manual.
A full mechanical overhaul was performed on the notching press, including replacement of the motors with new, more efficient, EU Energy Class A motors with CE certification.
Machine performance was significantly increased with the development and installation of a new Siemens CNC and software capable of converting a CAD drawing into a series of machine instructions.
With these innovations, today the notching machine can perform the integrated, fully automated operations required by the customer, guaranteeing time savings for machining and programming, as well as allowing the notching machine to perform complex shapes that otherwise would be almost impossible to handle.
Galbiati Group has a unit dedicated to the complete reconditioning and retrofitting of presses. Experience, production capability and a complete fleet of machine tools allows us to perform all types of machining in house.
Reconditioning involves the complete strip-down of the machine, inspection of each individual part; restoration of the parallelism of the surfaces by milling, grinding, boring, and lapping
where necessary; replacement of worn parts; overhauling the hydraulic and electric systems to the latest technology in order to comply with current safety regulations.
You can see the difference in the Minster PM3 300T press from the before-and-after pictures taken on its arrival in our plant and after refurbishing, milling, boring, lapping and all final quality and safety tests, checks and inspections.
In mint condition, the machine is delivered to the customer with certification and warranty. The overhaul also includes recertification of the machine and upgrading of the electric equipment according to CE norms.
Piovan high speed precision press with parallelism between the bolster plate and the upper slide, fully balanced and suitable for hard metal progressive dies.
FRAME: The press frame consists of 4 fabricated steel parts (crown, 2 uprights and bed).
DRIVE MECHANISM: belt driven flywheel
CLUTCH/BRAKE UNIT: Hydraulic actuated multiple disc clutch/brake unit by Ortlhinghaus.
CRANKSHAFT: Made from top quality steel, U.S. tested, and nitrided
CRANKSHAFT HOUSING: The crankshaft rotates on four large surface bearing bushings. Lubrication is hydrodynamic, with a continuous oil flow.
SLIDE GUIDES: The slide moves along two, hydrostatic oil lubricated bronze gibs. The clearance along the entire length of the guides is calibrated.
The G30 cast iron gibs are attached to the side frame and are surface-hardened.
BALANCING: Mechanical balancing of the forces is obtained using a counterweight controlled by a connecting rod shifted by 180° with respect to slide motion.
SLIDE: The G30 cast iron slide structure is driven by two cast steel rods.
Slide adjustment is performed by electric motor. A steel T-slotted plate is screwed onto the lower die shoe.
BOLSTER PLATE: The bolster plate is made from G30 cast iron with “T” slots for die assembly.
LUBRICATION CONTROL UNIT: Lubrication is achieved by a control unit separate from the press to facilitate inspection.
The lubrication control unit is fully automatic and includes two main pumps:
- One for auxiliary devices (variable flow rate)
- One for lubrication
MACHINE LUBRICATION: All shaft and slide guides are oil injection lubricated.
DIE AREA PROTECTION: The die area is protected by photoelectric barriers.
MAIN MOTOR: The AC variable motor is driven by an inverter.
ELECTRIC EQUIPMENT: Central electrical cabinet made in accordance with current regulations.
Electric power: 380 V/50 Hz
The main control panel is located in a dedicated cabinet.
All the main machine controls are located on a mobile control panel .
Other stop buttons and emergency buttons are located on the columns.
There is an additional control panel on the press side that includes a two-hand control unit with start and jog buttons, a selector switch, and automatic operation start button.
TECHNICAL DATA:
Rated capacity: 4000 kN
Slide Stroke: 35 mm
Slide Adjustment: 70 mm
Quick Lift no. mm
Bolster Thickness: 250 mm
Shut Height (stroke down): 445 – 515 mm
Upright Opening: 600 mm
Speed: 100 – 350 strokes/min
Main Motor Power: 100 kW
Total Weight: 90,000 kg
The notching machine are designed for applications in the electric machine industry for the stator and rotor laminations by notching single or multiple slot patterns. Ideal for the production of laminations in small lots (including prototypes), or large diameter laminations (for example, wind turbine generators). In these cases, they can replace mechanical presses for progressive or compound blanking. The notching machine can cover a large range of diameters and working cycles by adjusting the spindle/slide unit on the fixed frame, adapting it to the size of the blank to be machined.
Galbiati Group has designed and manufactures an innovative notching machine for blanking laminations with the spindle directly driven by the crankshaft. This provides high precision over time as there is no backlash induced by transmission gears. The fixed spindle center guarantees maximum efficiency thanks to the automation of loading and unloading operations, regardless of lamination diameter .
The machine is controlled by a Siemens Sinumeric 4-axes Numerical Control which provides maximum flexibility for machining cycle management resulting in higher productivity. The CNC can set and control the mechanical release of punch penetration from 2 to 4 mm.
The notching machine’s control panel has a simple, user-friendly interface and allows the user to set a series of parameters for quick custom machining. The following parameters can be set on the control panel:
* Notching speed
* Number of slots
* Slide position with respect to the centre of the indexing spindle
* Angular position for cycle start
* Blank centering adjustment
* Angular compensation to offset blank thickness variations
* Speed reduction at end of the notching cycle
* Machining cycles can be stored and recalled
* Activation of special machining cycles, such as conical or skewed stacks, enlarged slots, etc .
* Alarms and diagnostics
Galbiati notching machines are equipped with advanced alarm and diagnostic systems that are extremely user-friendly. Generally speaking notching machines are preferred when the production volumes of laminations do not justify the investment for a mechanical press.
* Notching speed
* Number of slots
* Slide position with respect to the centre of the indexing spindle
* Angular position for cycle start
* Blank centering adjustment
* Angular compensation to offset blank thickness variations
* Speed reduction at notching cycle end
* Machining cycles can be stored and recalled
* Activation of special machining cycles, such as conical or skewed stacks, enlarged slots, etc.
* Alarms and diagnostics
EP3 Press for High Speed Blanking Magnetic Laminations
EP3 Press for High Speed Blanking Magnetic Laminations
Full blanking force under any condition
The flywheel is anchored to the side frame by means of a bushing in order to avoid stressing the shaft. Oversized, it allows blanking operations to be performed with the rated machine tonnage at very low speeds, lower than those allowed by other presses of equal force. The stiffness of the press bed also guarantees increased die life, a feature particularly advantageous when using hard metal dies.
Die Inspection
The quick lift, standard on all EP3 presses, allows the upper half of the die to be opened, very useful for inspecting dies and releasing jams eliminating the need for heating the tie rods. The bottom plate of the slide can be removed, leaving the slide in position.
Hydrostatic Lubrication of Bearings
In EP3 presses, bearing lubrication is guaranteed by introducing pressurized oil inside the shaft and allowing it to exit at the bearings. This system allows the hydrostatic support of the shaft with consequent reduction in backlash.
Dynamic Balancing
The crown of the press houses a machine balancing device that allows the press to operate without being anchored to the ground.
In the EP3 press, the bottom plate of the slide can be removed, leaving the slide in position. This allows the bolster plate surface to be ground for reconditioning.
The hydraulic clutch/brake unit is equipped with its own power pack and dual clutch valve for control and maintenance of the operating pressure
The flywheel is supported on the press frame by a bearing assembly and not by the shaft thereby reducing the stress on the crankshaft.
The crankshaft is nitrided to extend its lifetime.
.
Control and Supervision System
User friendliness is basic feature of high production efficiency.
The EP3 press features a highly reliable, user-friendly but fully comprehensive supervision system. The diagnostics applied guides the user through troubleshooting down to the smallest details, also with the remote assistance, standard on all Galbiati machines.
The EP4 press for high speed lamination blanking is the natural evolution of the EP3 press. A few significant innovations improve production quality and productivity. In particular, dynamic penetration control and overhead shaft assembly have been introduced.
Dynamic Penetration Control
During blanking, the penetration of the slide can vary due to the elongation of the connecting rods (resulting from heating of the machine). This is particularly critical when stacking laminations. The EP4 press allows you to adjust the penetration during blanking in total safety for both product and die. This provides a significant increase in productivity, eliminating all machine down time for stroke adjustment. Finished product quality benefits from this function as it remains constant.
Overhead Shaft Assembly
Overhead assembly of the shaft dramatically reduces maintenance times. It is no longer necessary to disassemble the machine. When the press stroke must be changed, only the shaft needs to be replaced. This is a limited investment in terms of resources and time; other presses require that additional machine components be changed.
Accessibility is made easier for maintenance of the bushings.
Other Features:
Full Blanking Force Under Any Condition
The flywheel is fastened to the side upright by means of a bushing in order to avoid stressing the crankshaft. The oversized flywheel guarantees blanking operations to be performed within the rated press capacity, at very low speeds, lower than those allowed by other presses of equal force. The stiffness of the press bed also guarantees increased die life, a feature particularly advantageous when using hard metal dies.
Die Inspection
The quick lift feature (standard on all EP4 presses) allows the upper half of the die to be opened, very useful for inspecting dies and for unsticking the press without heating the tie rods. The bottom plate of the slide can be removed, leaving the slide in position.
Hydrostatic Lubrication of Bearings
In EP4 presses, bearing lubrication is guaranteed by introducing pressurized oil inside the shaft and allowing it to exit at the bearings. This system allows the hydrostatic support of the shaft with consequent reduction in backlash.
Dynamic Balancing
The crown of the press houses a machine balancing device that allows the press be operated without being anchored to the ground. In the EP4 press, the lower plate of the slide can be removed, without requiring the slide to be removed entirely. This allows the bolster plate surface to be reconditioned.
The hydraulic clutch/brake-unit is equipped with its own power pack and dual clutch valve to control and maintain the operating pressure.
The flywheel is supported on the press frame by a bearing assembly and not by the crankshaft thereby reducing the stress on the crankshaft
The crankshaft is nitrided to extend its lifetime.
Control and Supervision System
User friendliness is basic feature of high production efficiency.
The EP4 press features a highly reliable, user-friendly, fully comprehensive supervision system. The applied diagnostics guides the user through troubleshooting down to the smallest details, also via remote assistance, standard on all Galbiati machines.
Galbiati Group has a dedicated area and all technical knowledge needed to recondition presses. We have gained vast experience in this field thanks to the professionalism of our engineers and a full machine tool fleet that allows us to perform all types of machining.
Press revamping involves:
* Complete strip down of the machine
* Inspection of the wear of each individual part
* Remachining of the surfaces by milling, grinding, boring, and lapping.
* Replacement of damaged components
* Refurbishment/upgrading of the hydraulic and electric systems according to the new CE norms for quality and safety.
Following are some of the steps performed during the revamping of a Piovan 125T press, at Galbiati Group’s facility
In mint condition, the machine is delivered to the customer with certification and warranty. Overhaul also includes machine recertification and upgrading of the electric equipment according to CE norms.
Reconditioning this large press was a highly stimulating challenge for the engineers in the Galbiati Group. The objective was to modify an old deep drawing Weingarten press, used in a large factory in Germany, and adapt it for blanking lamination. Our engineering department designed the required changes, updating the technology of the machine by adding an automatic extraction system for the blanked disk. The press was completely overhauled in our plant. Once reassembled in our factory pit (13 m high), the machine was thoroughly tested to ensure that all functions performed to the customer’s specifications.
At this point, the press was dismantled and transported to the end-customer’s plant in Hungary. Here, all large dimension parts had to be moved in through the roof as they could not fit through the normal access to factory premises. Then the press was reassembled, commissioned, and the final tests performed for customer acceptance.
Photo of the press prior to revamping
Photo of the press after revamping
Wednesday, May 19, 2010
0 Comments