Soraluce’s opening of a new factory dedicated to the assembly of portal-type machining centres, coupled with the launch of a new range of “redesigned and revitalised” machines, has not only reinforced the company’s world lead in portal-type machining technology but the accompanying innovative technology developments for continually-improved machining routines – including single set-up milling, boring, turning and grinding – also highlighted the company’s constant progress and expertise in providing customers with complete manufacturing solutions.
Indeed, the three-day Portal Summit event also enabled the company to showcase a new compact range (the TA Series) of bed-type milling machines where grinding has now been added to the capabilities of milling, boring and turning in the same set-up.
In addition to the new machines, Soraluce also demonstrated a range of technology innovations, including the new:
[] DWS (Dynamic Workpiece Stabiliser) smart machine damping solution – to eliminate chatter on the workpiece, and
[] VSET – which simplifies component set-up by minimising workpiece alignment and, as a result, generates set-up time savings of up to 70 per cent.
These complement the company’s existing innovative manufacturing tools of:
[] Smart HMI machine interface – which has now been enhanced to allow, for instance, operators to view two ‘screens’ showing workpiece and machine data simultaneously on the same CNC panel, such as 3D plans and machine condition monitoring;
[] Vertical ram balance – effectively an additional axis, closed-loop controlled with its own direct positioning system to compensate for cross beam deformation on larger portal machines;
[] DAS+ chatter elimination technology; and
[] TBS table balancing system for asymmetric loads.
The summit at the new factory (a short walk from Soraluce’s existing plants in Spain’s Basque Country’s Bergara region) that has cost Euro 9 million, accommodates an assembly shopfloor of 4,900 m2 served by overhead cranes with capacities rated at up to 80 tonnes. These are fed by the constituent machine parts produced by a range of suppliers (of proprietary parts) and, crucially, by Soraluce factories that produce all critical machine parts – including beds and bedways and especially the wide range of machining heads that Soraluce can provide.
An expansive and climate-controlled manufacturing and test area (in an existing Soraluce factory) is dedicated to head production and quality control, where the head casings are machined in-house to ensure accuracy levels then each head is hand assembled. One measure of the thoroughness of the process is an exhaustive test procedure that sees every head undergo 72 hours of in-factory testing on test ‘rigs’ plus 125 hours of machine testing before being released.
Several machines on show at the summit emphasised the scope of the operation; representative models from the new-look, hi-tech range that, says managing director Rafael Idigoras, “is now available with customised milling and turning heads, for example, and features enhanced precision machining as well as working areas perfectly adapted to users’ requirements – for example, one or two operator platforms to ensure optimal views of the process as well as full visibility of tool magazine and easy access for maintenance”.
The introduction of a machining head that combines milling, boring, turning and grinding was demonstrated on the TA-M 25, one of a new range of compact machines for multi-tasks on components up to 8,000 mm diameter in a single set-up. With a chuck featuring an innovative rotational locking system, the bed-type machine included a grinding head that, in trials, had achieved surface finishes of Ra 0.4/0.5 when infeed and traverse OPD, ID and surface grinding. Future developments will embrace angular and face grinding with ‘straight’ wheels.
The grinding head being demonstrated on the TA-M 25 bed-type machine
The new Multi-tasking Compact range covers longitudinal, vertical and cross travels of 2,500 mm to 4,000 mm, 1,250 mm to 1,800 mm and 1,200 mm to 1,500 mm, respectively, and having table capacities of up to 10,500 kgs (milling) and 3,000 kgs (turning).
Like all Soraluce machines, they are based on the company’s renowned build characteristics of accuracy and rigidity gained from a full cast iron construction underpinned by finite element analyses, to generate high levels of constant productivity via a high torque direct drive spindle motor inside the ram, with built-in cooling system, as well as Soraluce’s pioneering linear guiding technology that is based on in-house developed damping pads complemented by INA guiding systems on each axis.
They join an extensive (and now expanded) range portal machines in moving table, gantry and moving cross beam styles – all available from Soraluce’s exclusive UK and Ireland distributor, T W Ward CNC Machinery (Ward CNC). The machines types cover an extensive range of machining capacities:
[] PM moving table models X, Y, Z and W (cross beam) axes from 5,600 mm to 7,600mm, 4,500 mm to 5,000 mm, 1,500 to 2,000 mm and 1,000 mm to 2,000 mm, respectively; and
[] PMG, PRG and PXG gantry models – X, Y, Z W axes: 6,000 mm to 10,000 mm; 4,000 mm to 10,500 mm; 1,500 mm to 3,000 mm; and 1,000 mm to 4,000 mm.
PMG 6000 – one of the new-look portal machines
Commenting on the new range, Ward CNC’s Head of Strategic Accounts & Projects, Stuart Lawson, says: “Soraluce’s ongoing commitment to machining excellence, combined with industry leading innovative solutions provides Ward CNC customers with immediate access to unrivalled production technologies in terms of milling, boring, turning – and now also grinding – in a single set-up. This partnered with our own ultra-high levels of engineering applications expertise and service back-up, means UK customers can continue to rely on Ward CNC to provide cost-effective answers to their production problems, for workpieces of every size and in all materials.”
Importantly, it was also the display of DWS and VSET – developments driven by Soraluce’s IK4-Ideko technology centre – that drew an equal level of attention from visitors to the summit.
DWS is an active damping device to eliminate chatter. Comprising a controller and one or more inertial actuators placed on the part to be machined, the result is better surface finishes, especially in areas of the workpiece that may be ‘more flexible’. DWS complements Soraluce’s DAS+ smart system for eliminating chatter, and both systems integrate with the machines’ CNC system (Siemens or Heidenhain).
DWS in action – workpiece shows the differences between chatter and DWS control
VSET is a measurement system to simplify component set-up. Using 3D vision, two of its three modules (VSET Measuring – the capture of optical reference points, and VSET Fitting – compares measured data with a 3D model of the part) are run with the part off-machine, without interruption to machine operation and the third module, VSET Alignment, integrates the results of measurement with the machine’s CNC and the component positioning on the machine table. Set-up times can be slashed by up to 70 per cent.
Indeed, Soraluce says VSET will repay itself in less than a year, depending on throughput.
VSET calibration points (above) are recorded then compared when workpiece is set-up on the machine table (below)
With 110 full-time technology professionals, the IK4-Ideko technology centre is dedicated to “paving the way” in manufacturing advances, and another revelation nearing completion is the ability to use wireless inspection routines to ascertain any volumetric errors in a machine. The technique – which is claimed to be more cost-effective than traditional alternatives – promises to offer full calibration of small- and medium-capacity machines within just four hours. Laser interferometry will continue as the chosen calibration method for large-/ultra large-capacity machines.
While Mr Idigoras is undoubtedly very proud of the new factory – and was very pleased with the attendance of 500 or so visitors at the Portal Summit – he also stressed how Soraluce today is very much a system solutions provider, with an expanded machine range (including portal milling machines, borers and VTLs) and the use of tools such as Industry 4.0, as well as automation systems and advanced applications engineering services.
“We know our past, we are managing our present and we are planning our future,” he adds, “so that we continue to set new standards in milling, boring, turning – and grinding.”
[] Useful viewing: the Portal Summit event video can be viewed at: https://youtu.be/SLszM_rQsr4
