The Pemamo MVRL160 – vertical technology
For companies active in high precision honing, the technology offered by Pemamo is recognised worldwide. The concept of continuous expansion of the tools, the possibilities for adjustment to the tenth of a micron and very high repeatability of the well known beige and brown machines were however not available for some types of parts non-feasible in horizontal position. Since this year’s EMO, Pemamo offers with the MVRL 160 a new solution of vertical honing that completes its product range. Simultaneously the company changes the colours of its machines, its logo, its building and even its name (see box below). Mr. Alain Grimm, CEO and Reto Decker, Sales manager give us more details on this year’s important changes for the company.
At the last EMO, Phosa SA, the company designing Pemamo products presented a machine with linear motors and the success has been there. During the period of crisis the company could have continued to improve its products or try to propose something radically new. A broad marketing study was organised with the help of the agents of the manufacturer and the idea of a vertical machine using Pemamo’s know-how and technology has been discovered, raised, debated, studied… After more than one year of work, the machine has been put under tests and the results exceeded expectations. Six months later the machine is presented at the EMO, don’t miss it.
Let’s see the main features of this new product:
The tool can be horizontal or vertical, it doesn’t change fundamentally the honing operation itself. Tools used are also the same (and for customers working with both types of machines, compatibility is guaranteed). Mr. Grimm says: “We have developed this machine starting from a clean sheet to combine our expertise and needs detected in the market. With our offer in horizontal machines we couldn’t achieve the honing of some kinds of parts”. Mr. Decker adds: “For heavy parts, the realisation of the floating holder can quickly become tricky and costly working in horizontal. With the new MVRL 160, we can not only machine heavier parts, but the holders are much simpler for all kinds of part”. Therefore, even if the investment for the machine is more important, savings done on clamping systems allows customers to have a better ROI, even if the part could be honed in vertical and horizontal.
Compact and modular
The new MVRL 160 is fully integrated, the cooling system and filters are included in a floor space that is much smaller than for an equivalent machine working in horizontal. The specification was very clear, the machine had to be completely modular and embeddable in a high production system. It is therefore designed to be configured with flexibility. For example, it can be equipped with one, two or three totally independent spindles (in the horizontal machine the two spindles are mounted on the same slide) Mr. Decker says: “We can therefore adapt each spindle speed and feed rate to the process to realise”. The table also displays extended clamping possibilities, from a simple plates with T grooves to a rotary table equipped with two, four or even six positions to hold parts or even to a conveyor belt system when several machines are associated. Mr. Grimm says: “The machine is really the heart of a modular system and it can be continually adapted to the needs of our customers“.
Main features of the MVRL 160
Presentation: EMO 2011
Delivery time: 3, 4 months, first machines early 2012
Working diameter: from 1.5 to 20 mm (for bigger Ø, please consult the manufacturer)
Spindles: Synchronous motor, speed from 50 to 8’000 t/min
Torque: 11 Nm up to 4’000 t/min
Part weight max: 100 kg
Stroke max: 350 mm
Honing depth max.: 200 mm
Slides max acceleration: 26 m/s2 frequency: 1-500 moves per minute
Weight: 1500 kg
Floor space: 1.7 m2 (40% less than an equivalent machine in horizontal)
Clean and efficient design
The new colours are certainly acting on the perception, nevertheless when you see the machine, it impresses by its small size and its “simple and first-class” aspect. Marc Vallon, the engineer in charge of the project particularly refined working ergonomics. The touch screen panel is ideally placed just above the machining area, but it is also removable and allows users to keep it on hand, for example during adjustment from the side of the machine. All machine organs are accessible from front and rear, sides are left completely free, it is therefore possible to set-up series of machines side by side without lost space. Clamping systems are universal and present on each machine. Thus, if the customer wants to add brushing or measurement operation, implementation is quick and easy.
Pemamo technology for everyone
The air-jet measurement system allows users to validate honing operations, both in terms of dimensions and geometry. In the case of a part with an altered geometry, for example a hole barrel-shaped or conical, the interface of the control is very simple. Using drawings the operator can quickly identify the case, indicate the dimensions and the machine handles corrections. All programming is thus assisted by a “house” interface that ensures that repeatability in the scale of one micron does not depend on one “fairy fingers” operator but on Pemamo’s technology.
Pemamo is not only provider of machines but it also provides tools. Therefore the company masters the whole production and can finely adjust the machine to the tool and vice versa. Mr. Decker says: “We offer a full advising service, we help our customer choose the machine best suited to his needs and then we validate the process and produce test parts. Thus when the machine is ready to be delivered, he can be sure that everything is in order and corresponds to the specifications”. To determine the level of precision in usual machining, a small statistical analysis of delivered machines is highly instructive. Only a few of the realised parts are within a range of 5µ. The vast majority of applications lies in the realisation of parts within tolerances of 1 or 2 µ of cylindricity.
More choice for customers
The new MVRL 160 not only offers new possibilities to the markets (parts that were previously not benefiting from the Pemamo technology), but it also expands choice for customers. According to the sizes of batches, the levels of desired automation, the complexity of the holders and of course the preferences of the clients, they now have a choice between horizontal or vertical machining. Mr. Grimm says: “We offer the Pemamo quality in both cases. Our goal is to help our customers doing the best investments according to their needs“.