LPZ G-MODUL

Line for fully automatic processing of "AL shaped hollow and solid profile bars" up to 7,450 mm in length. The line is composed of interconnected segments - modules, whose work coordination, as well as the simultaneously running production processes in them, is controlled by a custom-written CNC line control program KOMANDOR.

LINE MODULES AND SEGMENTS:

- "Dynamic" CNC single-axis motorized belt conveyor with intelligent gap-free documenting function, including loading bridge, and pneumatic sliding and straightening mechanism. Designed for profiles included in the specification. 

- "Huricane" CNC single-axis motorized positioning feeder with a specially designed vice for clamping trough profiles of non-standard shapes. (automatic positioning of the profile in two axes)

- "Mercury" CNC "ARC" dual-axis interpolated cross-cut milling unit at the input 

- "G Modul dual" CNC "HELICAL" three-axis interpolated main machining unit equipped with 12 work spindles. Machining by milling, drilling, countersinking and thread cutting; from above, below and from behind. 

- "Golem" CNC motorized positioning vice with multitasking and two-axis material positioning function

- "Trajektoria" CNC two-axis motor system for positioning the sawing unit during the work cycle. 1x flat saw motor. Controlled trajectory of the cutting unit allows copying of various surfaces, ensuring controlled removal of sawdust, optimization of cutting time, progressive extension of tool life as well as minimizing energy consumption per cut. Return of the saw to the basic position under the work table shortens the time for feeding the material to a new position and at the same time ensures a cut without back abrasion. (Due to productivity, clean cut and controlled direction of sawdust, our new approach to cutting thus relegates to the past, previously common and progressive cutting methods, which were considered, for example, controlled opening of the cutting gap when the cutting blade returns.)

- "Ejektor" pneumatic ejector of finished pieces

- "Retro" output table with pneumatic heating and filling sensor.

BASIC CHARACTERISTICS OF THE LINE:

- HMI touch panel as a dialogue window for the machine operator. It has a complete menu for:

- selection of machining programs

- collection of statistical data

- three-level service menu

- factory settings

- G-MODULE is equipped with CHECK TOOL sensors for automatic calculation of corrections in programs for newly installed tools

- CNC motor positioning of the processing units is via ball-nut screws SFU4040; SFU2510 and SFU1610, along linear guides fitted with HGR30 and HGR25 carriages

- Equipped with DELTA electronics / HMI, PLC, SERVODRIVERS, SERVOMOTORS, INVERTERS /

- HERTZ frequency-controlled electro-spindles

- Positioning accuracy from independent measurements 4P/0.01mm

- Machining accuracy ±0.1mm

- Fully automatic operation after loading the magazine.

- Beacon signaling of device status

- The line is ready to be equipped with EWON equipment for remote management

Technological process of the work cycle:

- By turning on the machine with the main switch, the input conditions are automatically checked.

- By meeting the input conditions, the machine is put into standby mode.

- The standby state is signaled by a beacon optical signaling and a touch panel.

Basic entry requirements:

- The status of the safety circuits is checked.

- Operating air pressure is checked

- The pneumatic branch is automatically activated to bring the pneumatic drives to their starting positions

- The servo axes are initialized and set to their starting positions, according to the order defined in the program.

By selecting a machining program, the loading bridge of the motorized magazine is automatically moved to the position for inserting the profile bar. At the same time, the touch screen displays graphics and data about the loaded bar.

- The rod is inserted by pulling it onto the bridge

- The correctness of the loading is confirmed by pressing the button (the position, type and gross dimensions are checked)

- The conveyor automatically takes the bar onto the conveyor belts.

- The bridge will rise and ask for a new pole.

- The conveyor delivers the first bar to the Huricane feeder and continues its bar loading operation until it is full.

- The software ensures intelligent filling of the conveyor so that there are no empty spaces in the conveyor and at the same time the Huricane profile bar positioning feeder is preferentially supplied with semi-finished products.

The machining program starts fully automatically when the bar is transferred to the Huricane CNC positioning feeder .

- The bar profile number and machining program are assigned

- The Huricane feeder positions the bar for shortening.

- The output saw unit Trajectory will perform a flush cut

- The Huricane feeder moves the bar through the machine

- The working position of the aggregates and guide jaws is then activated to create transverse grooves.

- After bending, the Huricane feeder transfers the bar to the servo-motorized vice jaws

- Motorized vice jaws, by sensing the bar, perform its most suitable positioning for the G-Module processing units, taking into account the use of the multitasking function.

- The individual detailed machining macros are gradually executed in the machining program.

- The machining process has a precisely defined order of individual steps.

- Finished pieces are gradually cut from the bar by the Trajektoria CNC output saw unit.

- The positioning accuracy of sawing and milling units is +/- 0.05mm, and the machining accuracy is +/-0.1mm.

- The working zone of the machine is in a covered, illuminated cabin with noise insulation. - In the X movement axis, the cabin openings are fitted with bristles to minimize the scattering of chips.

- In the event of an unplanned interruption of the machine's work cycle - and by resuming the cycle, the machine continues from the last executed machining macro.

- The sawing unit has a socket for connecting an extraction hose