Fives OTO Magazine March 2010

n° 2 · March 2010
NEWS & UPDATES
OTO GAL 8016
cutoff TOAC 254
tube line oto 40616 etc
mangwana: our support
the parma university project
MISSION
Oto Mills guarantees to their customers the achievement of great productive
and business targets and the creation of high-quality products, thanks to their
know-how, the leadership and the experience gained in designing, assembling
and studying of the performances of tube mills up to 24”. The excellence in the
processes and in the performances of tube mills is the base of the excellent
reputation the company has accumulated in 30 years.
our values
· Business and personal ethics
· Helping and sharing
· True interest for collaborators first of all as men and then as co-workers
· Excellence as lifestyle
· Positive and motivating approach
· Constant care in reaching great goals
CONTACT
WHAT WOULD YOU LIKE TO READ ON OTOMAGAZINE?
Please tell us the topics you wish to read or simply tell us your opinion writing to
[email protected]
our vision
Change the meaning of the word COMPANY in the dictionary.
Wikipedia
An entity that manufactures or sells products (also known as goods), or provides
services as a commercial venture. A corporation.
Oto Mills
A company is a valuable network of relationships, actions, ideas shared and respected,
in order to find out the economic resources to invest on every collaborator and to make
them reach their own personal success, which will turn in success for our customers.
4 EDITORIAL
6 TECNOLOGY & PRODUCTS
OTO GAL 8016
9 TECNOLOGY & PRODUCTS
CUTOFF TOAC 254
10 TECNOLOGY & PRODUCTS
TUBE LINE OTO 40616 ETC
11 INTERNATIONAL SERVICE NETWORK
INDEX
n° 2 · March 2010
12 MADAGASCAR:
OUR SUPPORT
14 THE PARMA UNIVERSITY PROJECT
15 ELLETRE: Achieves ISO 9001:2008 certification
EDITING: Stefano Mora, Manuela Bigliardi
ART DIRECTOR: Stefano Mora
PHOTO and COORDINATION: Stefano Mora
Thank you to everyone who contributed to this magazine
3
EDITORIAL
Dear readers, this year Oto Mills celebrates 30 years of activity. 30 years of hard
work, huge efforts to keep on improving our products and staying a step ahead
of the technology in progress. 30 years of enormous investment of energies.
Nevertheless 30 years of critical times, tough periods of the world economy
which forced us to further concentrate our resources, but we have always
successfully overcome such obstacles and each time strengthening our identity.
As a matter of fact, we would have never achieved all these goals, we would
have never attained such a technological progress without our Customers: since
the beginning, they have actually played an essential role by believing in our
products, by placing their unconditional trust on us, by helping us making better
machines thanks to their suggestions, experience and priceless collaboration.
Therefore, in this occasion, we thank whoever took part to Oto Mills history
throughout this 30 years: the Oto Mills staff, our Customers, our Suppliers, and all
our collaborators. We wish to continue the path in the future together.
12-16 April 2010
Düsseldorf, Germany
We exhibit at Tube 2010 Düsseldorf:
Halle 06 – Stand 6 E30
Halle 06 – Stand 6 F29
5
OTO GAL 8016
AUTOMATIC straight strip joiner
The strip joiner model “OTO GAL 8016” welds the incoming strip with the outgoing
one. A single blade shear (the same for the tail end of the strip being outlet and
for the front end of the strip on the inlet of the line) cuts the ends of the strips
exactly, preparing the edges in the best way possible for the subsequent welding
phase. The welding bead is not removed because it does not interfere with the
subsequent accumulation and forming phases of the strip. The joining and welding
cycle can be selected in one of the following ways:
- Automatically.
- Semi-automatically (for each phase, the strip joiner stops automatically and
continues its cycle only after operator confirmation).
- Manually.
The automatic cycle can be interrupted at any time to carry out any manual
operations required and can be started again automatically, semi-automatically or
manually. An independent control panel is used to select the cycle required and to
check correct execution.
ADVANTAGES
-
Compact transversally because the strip joiner develops longitudinally,
parallel with the strip infeed.
Possibility to join very thick strips.
High alignment precision following automatic correction of feasible
positioning errors.
Less strength required to move the units thanks to the use of ball
bearing runners with low friction coefficient.
Possibility to manage the welding phases automatically, without
operator intervention.
WORK CYCLE
1)
2)
3)
4)
5)
6)
7)
The strip being processed is at a pass-line height of 1300 mm, born by
special rolls. The tail end of the strip is positioned under the shear blade
automatically by end-of-coil photocells on the mobile vice and on the
pinch-roll. Upon completion, the support rolls lower to a pass-line height of
1250 mm., which is the working height of the strip joiner.
The fixed vice on the outlet of the strip joining unit, by means of hydraulic
controls, centres the tail end of the strip axially by means of straighteners
and blocks it with its clamps.
The shear, which at the beginning of the cycle is already in the tail end
cutting position, blocks the tail end of the coil by means of its strip press.
The strip width is measured by dedicated pneumatic sensors.
After this operation is completed, the tail end of the coil is cut and the
strip press opens so that the shear unit can move towards the coil inlet to
prepare for the joining phase of the new coil.
The front end of the new coil is inserted in the strip joining unit and its
position is controlled automatically by the beginning-of-coil photocells on
the mobile vice and on the pinch-roll.
The mobile vice on the inlet of the strip joining unit, by means of hydraulic
controls, centres the front end of the strip axially by means of straighteners
and blocks it by means of its clamps.
In the same way, the shear strip press lowers and blocks the strip.
The mobile vice opens and moves towards the coil inlet after the
overtaking table has lowered.
The mobile vice closes again on the strip, blocking it with the straighteners
and the clamps. The shear sensors measure the width of the strip and
define its position transversally. Once the shear strip press raises, the
mobile vice, by means of a hydraulic command, aligns the two strips
(leading and trailing edges).
The shear, after lowering the strip press, cuts the front end of the new
coil. The strip press then opens again and the shear unit remains in this
position.
The welding unit moves to the strip joining position and the mobile vice
pulls the strip of the new coil to the welding position.
A slight off-set is left between the edges, whose value can be adjusted by
means of a mechanical limit switch that acts on the movement of the shear
unit. At the same time, the overtaking table rises again, which is thus ready
for the following coil insertion phase.
8)
9)
The strip presses of the welding unit close on the strip and the edges to be
welded are born by a copper plate with forced water cooling system.
The two torches are adjustable in all directions and are driven by an electric
motor with variable speed.
The starting position of the torches is defined by the values read by the
feelers of the shear. A number of different welding cycles can be selected
from the control panel.
Once welding conformity has been checked, the operator gives the
enabling signal to continue the cycle, which consists in positioning all the
units so that the coil can be completely unwound.
Trims left after cutting the tail end and front end are collected by a
dedicated container under the strip joiner.
7
DESCRIPTION OF THE UNITS
1. MOBILE VICE UNIT
This structure is made entirely of welded steel. The guide rolls are made of
tempered and cemented steel. The guides and the welding vice are born by
bases that run on ball bearing guides longitudinally and transversally compared
to the line. The unit is positioned longitudinally by a pair of hydraulic cylinders.
Transversal positioning with hydraulic control and position transducer means that
any misalignments of the edges to be welded can be straightened-up. The rolls of
the vertical guide are adjusted by means of an electric motor and encoder. Their
function is that of keeping the strip aligned during shearing and welding. During
the stand-by phase, they open automatically with a hydraulic quick-release system
so that the strip can pass through. On the inlet, the vice is equipped with a mobile
horizontal roll at the bottom that lowers during the shearing and welding phase,
plus a fixed roll at the top. The vice is closed hydraulically.
4. FIXED VICE UNIT
It consists of the same elements as the “MOBILE VICE” but is fitted on a fixed
base. It has two mobile rolls at the bottom (one on the inlet and one on the outlet)
and a fixed roll on the outlet.
2. SHEAR UNIT
This structure is made entirely of welded steel. The guide rolls are made of
tempered and cemented steel. The whole unit runs on ball bearing guides arranged
longitudinally compared to the line. The unit is positioned longitudinally by means
of a pair of hydraulic cylinders. The shear fits a blade for cutting the leading and tail
end of the coil and is operated by a pair of appropriately sized hydraulic cylinders.
The blade also has an electrically controlled device that controls the clearance
between the blades based on the thickness of the strip to be cut. The shear
unit also fits the strip width measuring device, which consists of two pneumatic
sensors, which, by means of a linear transducer, define the exact position of the
strip. On the inlet, there is a roll that feeds the strip once the front end has been
cut. On the outlet, there is another roll that works on three positions: high, to
support the strip during the accumulation phase in the accumulator, intermediate,
for shearing and welding and low, for rejecting trims left after cutting the front end.
3. WELDING TORCH POSITIONER
The welding torches mounting is made entirely of welded steel. The torches can
be adjusted in all directions and are driven by an electric motors with inverter
control to be able to adjust their feed speed. The edges to be welded are born by
a copper plate with forced water cooling system.
5. WELDING GENERATOR
A generator is included for welding the tail-front end of the strip; the choice
depends on the material to be processed. The strip joining unit is in any event
designed for MIG/TIG welders with PULSED ARC and programmer.
CUTOFF toac 254
This cutoff model has been designed to cover a large range of stainless steel tubes
welded with Laser High Frequency technology.
The structure of the machine is composed of a fabricated base in normalised steel
supporting the carriage, which runs on linear recirculating ball guides.
The carriage is equipped with two saws that make the cut by rotating around the
profile.
The low speed cold saw technology guarantees a virtually free of burr cut quality
which is now strongly demanded in the international tube market.
Movement of the carriage is controlled by a rack and pinion on accelerator that
provides the necessary thrust force to perform the cutting cycle in accordance with
the established performance parameters.
All functions of the unit are managed by a microprocessor,
which makes it possible to control the machine with a very high
level of reliability, ensuring very precise cutting lengths without
influencing the effective production speed on the basis of which
the cutoff performance parameters are optimised.
The GUARANTEED bar length tolerance is ± 1.5 mm at the
maximum operating speed, although significantly higher
precision is also possible.
These cutoffs are fully automatic: once programmed they can operate
without requiring the constant presence of the operator at the control desk.
9
TUBE LINE
OTO 40616 ETC
(Easy Tool Change)
The machine is designed with a Flexible Forming system (FFX NAKATA), by means of
which the actual forming rolls need not be changed but simply adjusted according to
special programs based on the type of tube being produced. The fin-pass and sizing
sections are equipped with interchangeable 4-roll stands.
Tool changing is designed to minimize change-over times and operator involvement
throughout all the phases of the tube mill. Still bearing in mind existent tube forming
concepts, we have automated the tool pick-up and adjustment operations for the
new size. With operational simplicity in mind, the pre-arrangement and setting
processes in the work position of the new tools are automatic.
The quick tool change system is based on the possibility to remove and replace not
the complete stands, as is typical for smaller machines – but just the roll unit on the
shafts with relevant supports complete with side assemblies. The whole operation
involves just one single extraction movement from the top.
All the driven units are mounted on bases with cardan joints, which by means of
a runner coupling system (similar to roll mill), engage and disengage automatically
thanks to hydraulic grippers that keep the joint in the vertical position and slide
the shafts out with hydraulic horizontal movement. When the cardan joints are
disengaged, the shafts are completely freed and can thus be removed with their
supports, rolls and side assemblies when these are supplied. This possibility of easy
removal is thanks to the fact that the stands are opened from the top so that the
components, appropriately slung and handled by a crane with driver, can be pulled
out. The two shoulders are indeed designed to take a structure at the top that runs
transversally compared to the tube axis, bearing the adjustment jacks of the top rolls
with relevant electric drive and absolute encoder.
This structure is driven by an electric geared motor and a hydraulic blocking system
with play pick-up in the working position. The 4-roll stands are adjusted at the bottom
and sides by electric geared motors and absolute encoders. During handling, the
ends of the jack screws fit into dedicated T slots on the bearing supports of the
upper shaft; a pair of hydraulic cylinders per screw pick-up any vertical play. The
upper shaft; a pair of hydraulic cylinders per screw pick-up any vertical play. The
adjustment screws are just resting for the other movements.
As already mentioned, the whole roll positioning cycle for extraction is performed
automatically so that all the operator has to do is hook the top supports and take the
set of components out with one single movement. The top supports with rods that
run in dedicated seats also pull the side assemblies and the bottom supports in the
extraction movement from the stand to be then placed on a dedicated support offline. The operator may therefore hook the new set of rolls and place it in the stand,
again with just one single movement.
The machine is supplied at least with two sets of horizontally driven shafts and two
sets of side idle roll assemblies so that one set works and one is off-line for roll
change-over. The customer can in any event order extra sets of shafts and supports
that can be left permanently assembled with the same set of rolls to reduce off-line
re-tooling times.
Furthermore, a special tool is supplied to make it easier to disassemble and reassemble the rolls on the driven spindles off-line. As for servo-adjustments, each 4roll stand is backed by 4 motors and relevant absolute encoders, for the adjustment
of the top rolls, bottom rolls and two independent side rolls respectively. Each stand
has an independent drive of the single horizontal shaft, made up of an electric
AC motor coupled with a 2-speed gear and helical reduction unit on the output
connected to the cardan transmission. The two driven units are built into one single
structure.
INTERNATIONAL SERVICE NETWORK
SALES DEPARTMENT SELLS THE FIRST MACHINE,
CUSTOMER SERVICE SELLS THE SECOND
The design and manufacture of increasingly cutting edge machines is just a part
of the company’s mission, which aims at the total satisfaction of its customers
spread around the world; even if OTO MILLS has reached an incomparable level
of reliability in terms of the operational efficiency of its machines in over 30 years
of activity, feasible faults can still not be ruled out 100%: it is with this in mind
that OTO MILLS is rapidly working towards creating a wide-spread International
Service Network in order to assist its customers promptly and effectively on site;
customers who place their trust in OTO MILLS and invest in its products cannot
allow for costly and unproductive down-times in the case of feasible operational
problems; the policy of OTO MILLS in relation to “customer service” is not limited
just to repairing a fault, but it extends to a Service concept that includes advice,
instructions and the transfer of know-how so that the machines of OTO MILLS
working at the customers’ premises are always increasingly efficient in terms of
productivity, both qualitatively and quantitatively speaking.
The project that was experimented initially in America, is expanding also to
Mexico and Brazil, to subsequently expand gradually also to all countries in which
OTO MILLS machines are at work: this de-localisation program of Service Points
is a “must” in an ever-globalized world and our personnel who provide this kind
of service will be specialised and proficient technicians and engineers with years
of experience in mechanical and electronic tube mills.
This is just one of the many actions that we are implementing, because we
consider our customers not just as mere “buyers of OTO MILLS products”
but as equal and essential partners at our side in this continuous and endless
challenge towards excellence.
11
FIANARANTSOA ALL-PURPOSE CENTRE
HAUTE MATSIATRA REGION
MADAGASCAR
Oto Mills has decided to sustain the Mangwana social promotion Association in a project that supports the
communities of Madagascar.
The target for 2010 of the Mangwana social promotion Association, with head office in Lucca and the Vanona
Malagasy Association, with head office in Fianarantsoa, is that of creating an all-purpose centre in one of the
poorest areas of the city of Fianarantsoa situated 400 km south of the capital Antananarivo.
Madagascar is suffering a troublesome time from a political and social point of view; following the overthrow
of the state in March 2009 and its current instability, there is an atmosphere of fear, uncertainty, poverty and
misinformation, which has made the population’s previous difficult situation even worse.
The all-purpose centre aims at creating a point of reference for all the families of the city, where they may
find a welcome and the possibility to discuss their problems in a meeting place where they can access
information, learn to read and write, receive education and professional training.
The activities planned for this centre based on a yearly calendar will cover all the topics in which Mangwana
has been involved for four years in Madagascar, namely hygiene, health, nutrition, education, social,
communication and information.
In December 2009 and January 2010, we searched for the most suitable place in the various areas of
Fianarantsoa; the land will be subsequently purchased and the bureaucratic and administrative aspects will
be formalised; during the last week of March, the first stone will be laid during a traditional ceremony and the
building work of the centre will commence in the months that follow, ending with the centre’s inauguration at
the end of October 2010.
The main results expected following activities that can
be carried as of November 2010 are:
— Greater possibility of medical care, reduction in
illnesses bound to the improper use of water and to
precarious hygienic conditions and reduction in the
child death toll.
— Reduction in the cases of malnutrition and
guarantees of sustainable management of nutritional
resources.
— Increase in literacy and the knowledge of youngsters,
valorising art and children’s creativity as a means of
communication and individual promotion.
— Acquisition of an endogenous culture on human
rights, civil rights of children and women and
environmental safeguard. Creation of a spirit of
alliance between different social levels.
— Freedom of expression and access to information,
acquisition of proficiency and skills, increase in
juvenile occupation, promotion of human rights and
valorization of the woman’s role within the society
13
Collaboration project with the
University of Parma
For some years now, Oto Mills has been working
on a project in collaboration with the University of
Parma to develop a design method of forming lines
for producing electrically welded tubes, starting from
the simulation of the process. Those in charge of
this important project are the Engineering Director,
Andrea Anesi and the Research and Development
department, with Luciano Micali and Fabio Barbolini.
A particularly important aspect in the roll forming
process is the type of material processed, the
thickness of the metal sheet and the quality of the
material itself. One must also bear in mind that the
material must not be work-hardened during the
forming process and deformations must be limited to
less than 10%.
The target of Oto Mills is that of obtaining results to be
able to discuss the requirements of the product to be
produced with the customer to then be able to offer
the most suitable machine, aiming at simulating the
process. It is indeed of crucial importance to know the
strains and the deformations developed throughout
the various transformation phases of the metal sheet
into tubes to optimize all the components making up
the line, especially the rolls and to identify the number
of steps needed to obtain the finished product.
For this purpose, modern equipment and software
programs are exploited which simulate a “virtual
forming line” to establish the deformations and strains
involved throughout the process.
Oto Mils’ mission is therefore that of developing a
scientific design method to be able to define the
machine as a whole. In the current range of lines, it
is possible to produce tubes up to 16 inch, but the
future target is that of extending the production range
to tubes of 20/22/24/26 inch.
In these pictures: images concerning some projects.
ELLE TRE ACHIEVES
ISO 9001:2008 CERTIFICATION
ELLE TRE Srl, a worldwide leading supplier of electronic systems for industrial
automation, logistics and industrial information technology, is proud to announce the
achievement of ISO9001:2008 certification for its management system governing
the design, development and provision of the products included in the company’s
five production lines.
Following an intense process of preparation, training and involvement of all the staff
lasting not more than 10 months, the first audit, which has taken place in February
2010, verified the company’s complete conformance with every single ISO9000
requirements.
This accomplishment is the result of effort, perseverance, and time dedicated
to sharing and connecting principles and concepts to the company’s everyday
operational and organizational methods.
With this great achievement and the commitment dedicated to obtain it, ELLE TRE
intends to assert, as its main strategic value, a high organizational capability aiming
at customers’ plain satisfaction.
ELLE TRE considers this certification not simply as the finish line but a milestone in
its way toward the excellence which requires continuous improvement.
The firm commitment and coherence demonstrated by ELLE TRE prove how the
company considers its own staff as the starting point to meet the customers’
expectations.
15
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OTOOTO
MILLS
S.p.A.
ViaVia
D. Marchesi,
4 ·4z.i.
Rondello
(RE)Italy
Italy Tel.
Tel.
+39
0522
481211 Fax
Fax+39
+390522
0522964188
964188 E-mail
[email protected]
[email protected]
MILLS
S.p.A
D. Marchesi,
· z.i.
Rondello 42022
42022Boretto
Boretto (RE)
+39
0522
481211
Cap.Soc 826336,00 € i.v.
| VAT id nr. IT 00908590359 | M.RE 009659 – Nr.Reg.Impr. 9563 | Società soggetta ad attività di direzione e coordinamento della società MARFIN S.r.l.