Top technology
With a clearance of 7,200 mm between the uprights and a maximum distance between the spindle nose and the work surface of over 6,600 mm, the machine is able to machine the entire range of large pieces produced in the Belleli factory. «In this case - explains Stefano Lodolo, Sales Director of Innse-Berardi and Camozzi Manufacturing - the solution features an oversized machine structure in electro-welded steel calculated through finite element analysis methods, to ensure maximum stability and overall rigidity. Given the large size of the moving parts, to achieve maximum vibration damping, long life, minimum maintenance and, therefore, lower operating costs, the linear axes and the RAM are hydrostatically supported.
The machine was also equipped with a 5-axis universal head to be able to work very complex pieces, often machined from the solid billet. A large automatic magazine with accessory heads and a high capacity chain tool magazine give the machine great flexibility of use both for applications with large material removal and for machining where great precision is required». The movement of all linear axes is achieved with pre-loaded systems; a double rack and pinion system with electronic backlash recovery is used for the X and Y axes.
«With the same principle, the polar axes of the 5-axis universal head - Lodolo highlights - also use a multiple pinion system on a toothed wheel to obtain maximum rigidity and high dynamics of movement in the absence of backlash
The solution adopted, with electronic backlash recovery, guarantees constant preloading of the system without the need for periodic adjustments and with minimal maintenance requirements».
«Furthermore - Tosto adds - this machining center has been conceived to be able to integrate a 6 meter turning table with a capacity of 250 tons: it is easy to understand that with this configuration our Atlas Hydro reaches maximum levels of flexibility: an extremely important aspect for us that construct single pieces».
Advantages
The mobile gantry machining center, now in full production, offers significant advantages: first of all, high productivity thanks to the high material removal rate and the level of automation implemented on the machine.
The automatic tool change and accessory head change, the use of electronic probes to measure the pieces, the ability to remotely control the machining with the use of video cameras in fact reduce downtime and ensure maximum machine productivity.
«No less significant - adds Tosto - are the advantages deriving from the technical solutions adopted: limited tolerances maintained over time, optimized tool life with the same mechanical property constancy of the component to be machined, optimized energy consumption thanks to constant monitoring of utilities, optimized chip evacuation system for easy cleaning of the work area and mobile operator cabin to allow close control of the machining operations performed, guaranteeing maximum operator safety».
The machine - Lodolo adds - equipped with the latest generation Siemens 840D sl numerical control, is also completely digitalized to meet the Industry 4.0 requirements, to maximize the utilization factor of the machine.
In fact, it also integrates the IBRM (Innse-Berardi Remote Maintenance) system, the digital platform equipped with algorithms patented by our company in collaboration with Camozzi Digital, which allows tangible predictive maintenance and continuous monitoring of vital machine parameters.
In addition to continuous real-time control of a series of machine operating parameters, the IBRM platform, which works in the cloud, allows the automatic diagnosis of the condition status of its critical components.
This is performed by continuously monitoring the working conditions and process parameters by means of sensors installed on the machine. When the limit thresholds of some physical quantities established by the algorithms are exceeded, an alert signal is automatically generated so as to be able to intervene on the machine in an immediate or programmed/predictive manner».
"We are very satisfied with the investment - concludes Tosto - because we are recording exceedingly high machine performances. And it is also an Italian manufacturer: they are good, quick in the realization of the machine and with the desire to experiment some innovative solutions with us".