Schneyer WPK Waldrich Coburg [Kompatibilitätsmodus]

Transcription

WPK
Wiener Produktionstechnik Kongress 2014
2. Wiener Produktionstechnik Kongress 2014
High precision machining with simultaneous axis by
Large Universal Machining Centers
7./8. May 2014, Wien - Austria
Peter Schneyer
Werkzeugmaschinenfabrik WALDRICH COBURG GmbH, Coburg
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by P. Schneyer - Waldrich Coburg, 08. May 2014
WPK
Agenda
1. Waldrich Coburg
2. History of Machine Tools
3. Applications for the Machine Tool Industry
4. Applications for the Diesel and Gas Engine Industry
5. Applications Super Large Gear Drives
6. Application for Super Large Ship Propellers
7. High precision Parabolic Antennas for Satellite Applications
8. Technological Trends
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1. Waldrich Coburg
and Veste Coburg
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1. Waldrich Coburg
Products
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WPK
History of machine tool
Situation in the year 1850
1. Turning Machine since 1830
2. Drilling Machine since 1850
3. Milling Machine since 1850
4. Round Grinding Machine since 1850
Source, „Museum Industrielle Arbeitswelt“, Steyr, Österreich
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WPK
History of machine tools
Summery:
-
From the year 1830 the maching technology of turning was
relatively completed. The production of flate surfaces was
mainly done by hand.
-
In England all main types of machine tools for turning,
drilling, milling and round grinding were known from the
year 1850.
Source, „Museum Industrielle Arbeitswelt“, Steyr, Österreich
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WPK
Waldrich Coburg designed
Multi--TechnologyMulti
Technology-Concepts since 1980
The call for reduction of costs and machining time requires a most flexible machine
concept.
Complete workpiece machining on only one machine helps to minimize the
expenditure for non-productive work (workpiece setup, -transport, ...) as well as it
leads to higher Quality.
With a Waldrich Coburg Machine customer gets an
ALL on ONE solution.
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WPK
Agenda
1. Waldrich Coburg
4. Applications for the Diesel and Gas Engine Industry
5. Applications super large gear drives
6. Application for super large Ship Propellers
7. High precision Parabolic Antennas for Satellite applications
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MasterTec 4000 ATAT-M3
High--Precision – Application for the Machine Tool Industry
High
Machine Concept, Layout, double Table
M3-RAM, Z-axis
hydrostatic guide way
MasterTec
Attachment magazin
6 spindle units
M3-Ram-Stock
Y-axis, on crossrail
MasterTec-cossrail, W-axis, on
column
MasterTec-double table,
X-axis
linear guide way
MasterTec
tool changer and tool
magazin
with robot
Machine Tool Double Table with moving Cross Rail
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MasterTec 4000 ATAT-M3
High
Machine Concept, Layout, double Table
Availability > 97%
accuracy in µmAct. value
Tolerance
Flatness of guide ways
3,9 [µm]
10,0 [µm]
Straightness of left guide way
2,6 [µm]
5,0 [µm]
Straightness of both guide ways
3,7 [µm]
5,0 [µm]
Twist between both guide ways
2,9 [µm/m]
10,0 [µm/m]
Attachments
Technical Data
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9000 rpm
max. rpm
3300 Nm
max. torque
63 kW
max. Power
Face contact spindle-tool
MMS
MultiTec 3500 ATAT-M4
High
Machine concept and Layout
• Drilling
• Milling
• Turning
• Turn-Mill
• Grinding
Machine Tool Double table with one integrated rotary table
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High
Machine concept Grinding
Cylindrical Grinding
with vertical grinding unit
Tolerance
Axial run out
5,0 [µ
[µm]/1100 mm
Cylindrical form
5,0 [µ
[µm]/1100 mm
Machine Tool rotary table Accuracy of the workpiece
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High--Precision - for the Machine Tool Industry
High
Machine concept Flat Grinding
Flat Grinding
with horizontal grinding unit
Tolerance
Flatness
5,0 [µ
[µm]/2000 mm
Parallelism
5,0 [[µ
µm]/2000 mm
Machine Tool rotary table Accuracy of the workpiece
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Agenda
1. Waldrich Coburg
4. Applications for the Diesel Engine Industry
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World Market Leader in Machining of
4-Stroke Diesel Engine Components
Main key elements of the engine block
Mounting Holes for
Cylinder Head
4-Stroke
Stroke--Engine Machining Cylinder Liner by two simultaneous axis
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Form and position Tolerances of the Diesel Engine Casing
Tolerance
Roughness of Camshaft Bearing
Roughness of Crankshaft Bearing
Ra 1.6
Ra 1.6
Cylindrical form of Camshaft Bearing
Cylindrical form of Crankshaft Bearing
0,01 mm/100 mm
0,01 mm/100 mm
Coaxiality of Camshaft Bearing
Coaxiality complete Camshaft Bearings
Coaxiality of Crankshaft Bearing
Coaxiality complete Crankshaft Bearings
0,02 mm BearingBearing-Bearing
0,08 mm/6000mm over all Bearings
0,02 mm BearingBearing-Bearing
0,08 mm/6000mm over all Bearings
Diameter of Crankshaft Bearing
250 H6 +0.025/0
Diesel Engine Casing Accuracy of the workpiece
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Machining by Universal Head and Boring Bar
4-Stroke
Stroke--Engine Machining Cylinder Liner by two simultaneous axis
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Machining the 3 main parts
2-Stroke
Stroke--Engine High Precision Machining
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Four Waldrich Coburg PowerTec Gantrys in a „Super Factory“
2-StrokeStroke-Engine PowerTec‘s in a „New Diesel Engine Plant”
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2-Stroke
Stroke--Engine Machining Crankshaft Main Bearing of Bedplate
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2-Stroke
Stroke--Engine Machining Coupling Flange of Crankshaft
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MOST
POWERFUL
2-STROKESTROKEDIESELDIESELEngine
14 Cylinder Engine
Max. Power:
108,920 hp at 100rpm
Each Cylinder
7780 hp
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WPK
Agenda
1. Waldrich Coburg
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PowerTec 13000 AGAG-S2
High--Precision – Large Gear Driving Industry
High
Machine Concept, Gantry with Rotary Table
Super Large Gear Drives High Precision Machining outer Gear Ring
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High
Machine Concept, Gantry with Rotary Table
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High
Spindle Unit HSPO 900, S2, P=75 kW
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Agenda
1. Waldrich Coburg
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PowerTurn 10000 M3/NC
High--Precision – Ship building Industry
High
Machine Concept, Vertical lathe for 5axis
Ship driving industry High Precision Machining of Ship Propeller
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WPK Wiener Produktionstechnik Kongress 2014
Agenda
1. Waldrich Coburg
7. Parabolic Antennas for Satellite applications
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Machining of Parabolic Antennas
5-AxisAxis-“High“High-PerformancePerformance-Cutting“
Assembled
Parabolic
Antenna
Waldrich Coburg Assembly Shop Technology Forum 2011
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Tolerances
Surface form
Roughness Ra
30,0 [[µ
µm]/6000 mm
1,6 [µ
[µm]
Waldrich Coburg Machining Shop 3 Segments on a Gantry Machine
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Waldrich Coburg Assembly Shop LaserTracker is checking the part
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WPK
Agenda
1. Waldrich Coburg
7. Parabolic Antennas for Satellite applications
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ALL on ONE – concept
Multi--Technology
Multi
Technology--Machine Tools
• Larger sizes and weights of workpieces (up to 500 t.)
• New materials for Turbines, Inconell, IN 617, IN 718
• More powerful tooling concepts
• Complete machining, less Set Up’s
• Powerful and larger Machine Tools
• Higher Automation (AAC, ATC, APC)
• Laser integrated measuring system
for controlling workpiece and machine tool
“Super Machines”
• PowerTec 10000 AG, S20 RAM, 4000 mm
• PowerTec 13000 AG, S2 RAM, 3000 mm, Gearmilling D18000 mm
• PowerTurn 10000, S2S2-RAM, 4000 mm, +ST3
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Schneyer WPK Waldrich Coburg [Kompatibilitätsmodus]

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