INTERMAC MASTER33 workstation revision

DISTINCTIVE CHARACTERISTICS

Numerical Control workstation with three axis and a 3250x1620mm worktable, for milling, drilling and grinding glass sheets.

MECHANICAL STRUCTURE

Composed by gantry axis, it is manufactured with electro-welded steel elements, properly ribbed and normalized, it ensures the stiffness needed for the warranty of performance over time.

The machine’s weight, 8.3ton, is the essential element of solidity.

3250x1620mm WORKTABLE

It allows multiple placements. It is composed of an aluminium table which is rectified by the same operating head for a perfect planarity and it solves the old problem with synthetic tables, which were glued on the iron structure, and therefore, they could come off over the years. The aluminium table has definitively solved this problem.

The machine is provided with a placement system and it holds workpieces through suction cups equipped with a dual vacuum circuit, which allows a simple and quick positioning without the need for mechanical fastening. The vacuum system supplies suction cups, which hold workpieces with a liquid ring vacuum pump of 75 m³/hour and it doesn’t need any maintenance, with a management system divided in two separate areas.

Fittings for suction cups, at the front of the machine, with quick couplings.  Water collection and refrigeration system with 2 full extractable basins of 0.5 m³, placed under the worktable.

N. 2 AUTOMATIC AND ROTATING TOOL CHANGERS WITH 28 POSITIONS

They are positioned on both sides of the machine, allowing the reduction of tool changement times. These new tool changers offer a better shelter for tools because of their position on the side of the structure, in an internal space, sealed with a little door which automatically opens during the tool changing cycle and which also eliminates water jets on unused tools.

Another advantage compared to workstations series before the Master 33, is the possibility to inspect, to extract and so to replace the tools in the magazine during the working schedule, through a door which opens towards the exterior of the machine, which allows the operator to have access to the grinders without interrupting the process. Finally, the verification of the cone’s presence is totally automatic in order to guarantee the anti-collision before the discharge phase, in case of the operator’s mistake in positioning the tools in the forks.

ELECTROSPINDLE

10HP power with vector control of the rotation from 0 to 15000 rpm. Provided with a specific refrigeration system, generated by a conditioner which furnishes the coolant circuit that wraps the same electrospindle. Device with quick fittings for tools like ISO 40 attachment with a mechanical locking system through cup grinding wheels and an unlocking system with a pneumatic cylinder with a 7 bar working pressure. Automatic cleaning of the cones during the tool changing phase with a compressed air injection directly on the cones.

Pressurization pneumatic circuit against polluting substances.

IWNC INTERFACE CONTROL

Master 33 is provided with a IWNC numerical control, integrated on the commercial Personal Computer with a Windows interface.

The advantages of this solution are clear, especially compared with the previous machines that adopted a numerical control management system. The use of a PC with Windows operating system assures an easy and intuitive approach for the operator, a full connectivity with network systems and optical/magnetic systems reachable on the market. The PC is supplied with CD ROM, modem network card, 15” colour monitor and Windows XP operating system. The PC is equipped with teleservice in order to allow remote diagnostics and software updates and modifications through telephone lines/internet.

It is also possible to connect a webcam to the PC, in order to be able to save and transmit, in real time, instant images of some machine’s details to the service.

AXIS DISPLACEMENT

Obtained through digital brushless motors and with a ball screw and balls recirculation. Pretensioned screw, strictly sealed to the structure. Screws and guides are mechanically protected and equipped with an automatic lubrication system.

CHARACTERISTICS OF THE TYPE OF REVISION

The machine, year of construction 2004, is secondhand and it is completely overhauled. A more precise description of future workings will be shown below.

STRUCTURE REVISION

The iron structure will be sandblasted in all the areas that have been possibly damaged by the rusting process or with remaining glass powder. These areas will be plastered and then the structure will be completely repainted with its original colors. All this will be done after the removal of mechanical, electrical and pneumatic installations.

REVISION OF THE MECHANICAL INSTALLATION

Mechanically, every timing belts will be replaced but also support sliding blocks and sliding movements of the carriage (X Axis), the bridge (Y Axis), the head (Z Axis).

The backlashes will be verified and eliminated on the balls recirculation, which are actually in charge of the movements; finally, the fastening bushings of the tool changers will be overhauled too.

REVISION OF THE ELECTRICAL INSTALLATION

Substitution of worn connection cables between the electric panel and various mechanisms (motors, solenoid valves, sensors) with verification of the water pump and the vacuum pump operation.

Electric panel placement, PC-CN substitution with logic update to the most recent one.

REVISION OF THE HYDROPNEUMATIC INSTALLATION

Complete substitution of all the water and pneumatic system pipes with replacement of the taps where suction cups pipes are inserted, but also reference fences and glass holding.

Substitution of water pneumatic globe valves.