A New Concept for Multitasing Milling Centers

As we all know, the wind power industry is in a period of rapid development, the main direction of technological progress is to increase power generation. Mainstream generator manufacturers are developing models that expand to meet the demand for offshore wind power to increase production.

As we all know, the wind power industry is in a period of rapid development, the main direction of technological progress is to increase power generation. Mainstream generator manufacturers are developing models that expand to meet the demand for offshore wind power to increase production. The continuous development of the industry and the continuous progress of technology have put forward new requirements for the manufacture of parts - in the production of components need to be combined with different processing processes.

In view of this trend, Mekatech, a leading OEM equipment manufacturer in the wind energy sector in Requembere, Spain, has decided to work with SORALUCE to develop a new concept of multi-task boring milling centers that can turn, mill and pupil on a machine and add new parts to its portfolio.

This newly developed facility is the Solalus FXR 16000 Multi-Task Milling Center. It has a vertical movement of 6500 mm, a lateral movement of 1900 mm, a milling power of 70 kW, and two working areas. In the first area, the machine has a rotating × of 3000 mm and 2500 mm with a load capacity of 60 Tn. The second workstable has a multi-tasking station of 3500 mm, a linear motion of 2500 mm and a load capacity of 50 Tn, providing 106 kW of power to perform the required turning operation at a speed of 120 r/min. Work items above 7000 mm can be flipped in the second work area.

This is a highly advanced machine tool that represents a new category of removable column milling segments. Combining milling and turning operations on a single machine provides flexibility that milling machines do not have. As a result, structural parts such as hubs and frames can be machined by combining turning and milling in a single machine, and large rotating parts can be machined. High customization is not only about integrating turning functions into the machine, but also about the functional components required in the machine, such as turning head tailored for new work parts. In this regard, few manufacturers with proven experience in the design and manufacture of milling machines and crimss can provide solutions. SORALUCE is one of a small number of machine tool manufacturers.

Built on the SORALUCE FXR Milling Center platform, the solution adopts a new design concept that provides a higher level of ergonomics and safety, while optimizing the high-tech potential of the machine to ensure maximum productivity.

The machine also integrates SORALUCE's innovative technologies, including:

1. Innovative DAS system. Actively improve machine rigidity, resulting in cutting performance improvements of up to 300%. The system has shock-absorbing effects that reduce the risk of tremors. The system integrates a range of sensors that control tremors in real time and monitor the processing process. The process control algorithm automatically optimizes the cutting conditions using the obtained signals and modifies the tool's working parameters to improve stability and maximize productivity.

2. Sliding pillow balance, a sliding pillow drop dynamic compensation system, to ensure the entire sliding pillow work area of geometric accuracy. The system improves position by reducing the geometric errors caused by the slide pillow drop. This drop is affected by the weight of the milling head, in which case the milling head can be adapted to the machining head with different functions. Therefore, the system is of the importance.

3. Adaptive control, can monitor the power consumed during the process to automatically adjust the forward speed, thereby improving processing efficiency and reducing processing time. The system does not require a learning process, which helps it to be used and improves its suitability in processing individual pieces.

4.DHC is a self-calibration system that increases the positioning accuracy of the tool when using a directional head, thus offsetting the error of the head itself.

5. Eco-efficient function. For example, a sleep mode system can save energy due to a disconnected peripheral during a waiting time (for example, during loading and unloading work or maintenance). This is a feature that can be set up by the user, so it can adapt to the different ways each customer works.

The SORALUCE FXR-16000 Multi-Task Milling Center is also an Industry 4.0 machine tool with a comprehensive cloud-based monitoring package that allows Mekatech to control machine and machining status from anywhere. This function controls the status of machine indicators in real time, such as the program being executed, the tools in use, the speed of axes and milling heads, and so on.

Mekatech chose SORALUCE because of its high reliability, wide power range, rigidity and flexibility, as well as its extensive industry experience in wind power. The widely used SORALUCE milling boring provides a customized solution for each operating application and automatic tool and tool replacement, minimizing head/tool downtime.