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
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
Tuesday, May 18, 2010
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