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schmug
May 20, 2007



So I decided to continue on with the effort post(s) I started in GBS and move it into it's own thread here. Figured here was as good of a place as any. Original post in the OSHA thread is found below. I will try and update when I can up to and through run off of a part. Hope you all enjoy the ride...



So my work bought a little machine. It's been a long time coming...


That is one of six crates that have been on their way from Italy for about 2-1/2 years now.


Well it now looks like this in our side lot.

According to the driver that one alone weighs 76,000(+).


Purdy Tractor



There are like 5 more like it, although slightly smaller.






Here is where you locate 16 tow motors to lift it off of the bed



So I somehow got talked into working for a bit and missed them moving the largest crate... so so sorry. Rest assured I will not be doing anything except poo poo posting the rest of the day. Please forgive me.
But I did manage to get them squeezing it in the back overhead. Soooo close to not making it.



fwiw, there is a tow motor of equal size on the other side of the crate moving in reverse.


Here is the main machining unit laid out on a nice shiny piece of floor.

10' ladder for reference...It supposedly weighed 76,000 in the crate
Another view

wait, something doesn't look quite right....

OOPS

I'm sure that will buff right out...



And for reference this is what it does.
https://www.youtube.com/watch?v=QjL9ToCpMko
Ours is much larger/newer model(G397 whatever the gently caress that means) of that same machine. It was custom built and took over two years from purchase to delivery to get. Covid may have slowed that down a bit.


Long story short it's a 5-axis rotary transfer machine that will load, fully machine, deburr, wash, unload, and pack Brass CGA valves in ~ 6 seconds. All of that for the low low starting cost of 3.5million dollars.

https://forums.somethingawful.com/showthread.php?noseen=0&threadid=3904642&pagenumber=893&perpage=40#post515379163

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schmug
May 20, 2007



Day two assembly moving right along...

Parts hopper. Thing has to be 20' tall.


Coolant tank


Drivers and power supply's and such cabinet


General footprint:

schmug fucked around with this message at 11:46 on Jun 11, 2021

schmug
May 20, 2007



Some random questions from the previous thread:

LifeSunDeath posted:

Yes
More
Please

Also, why you guys need all these valves?
The world needs all these valves. If a gas goes through something, we probably make a valve for it. Literally.

schmug posted:

LAUGHMYFUCKINGASSOFF I just found out at least three of the spindles on the top of the machine are cocked/crooked/bent/dented/not good from hitting something sometime by someone somewhere
still laughing about this

Arsenic Lupin posted:

Do you guys manufacture only brass valves, or is that used for other stuff, too?
Mainly brass, but a little of most other common "metals" as well. Quite a bit of aluminum, actually. This machine will be used exclusively for brass though.

TjyvTompa posted:

There's not many things in this world that makes me jealous but getting to drive one of those trucks is one of them.
Thanks for the pictures and interesting information.
you and me both. No problem at all. Glad you appreciate it! It's what I do and not too many people I'm friends with understand it, so here we are...




schmug fucked around with this message at 12:03 on Jun 11, 2021

honda whisperer
Mar 29, 2009



Very interesting. I was wondering how the hell you program something like this. Is each station running its own program or are there just a ton of work offsets? Cam or programmed at the machine? I started doing 5 axis stuff recently, but in a normal type of CNC machine and that feels plenty busy so far, I don't know where I'd start for something like that.

schmug
May 20, 2007



honda whisperer posted:

Very interesting. I was wondering how the hell you program something like this. Is each station running its own program or are there just a ton of work offsets? Cam or programmed at the machine? I started doing 5 axis stuff recently, but in a normal type of CNC machine and that feels plenty busy so far, I don't know where I'd start for something like that.

Each station has it its own program. There are 11 machining stations, plus a load and unload station. Each machining station has 3 CNC controlled spindles for it. Each jaw set(station) rotates across an axis'.

Believe it or not we are still working out the programming of it. It's coming turnkey with two jobs programmed for it, but I'm on the hook after that. I'm really hoping it has some kind of software included because I guarantee Mastercam doesn't support something like that. Maybe NX or something, but that poo poo is out of our price range. It does have Siemens controls though, so who knows...

schmug fucked around with this message at 13:55 on Jun 11, 2021

Yooper
Apr 30, 2012



Grimey Drawer

That's a sweet machine. I saw a baby brother to one of these making pump bodies a few years ago. Super cool to watch it work. The enormous explosion of coolant was amazing.

I work at a tier 3 plunge grinding "something" that goes into valves like that, I have no idea who the final customer is though, could be you.

How does the raw brass get into the machine? Bar feeder? Robot? Vibe bowl?

schmug
May 20, 2007



Yooper posted:

That's a sweet machine. I saw a baby brother to one of these making pump bodies a few years ago. Super cool to watch it work. The enormous explosion of coolant was amazing.

I work at a tier 3 plunge grinding "something" that goes into valves like that, I have no idea who the final customer is though, could be you.

How does the raw brass get into the machine? Bar feeder? Robot? Vibe bowl?

Bar is cast-slugged-forged and shipped to us. We used to do all our own casting and forging as well, but monies got involved or something. After we receive the forgings they then get dumped into a giant hopper(pictured above) then on to a conveyor then to a to robot to load/unload.

tangy yet delightful
Sep 13, 2005





I used to broker flatbed shipments and also CNC machines are way cool so now I have a "very large" boner.

Kaiser Schnitzel
Mar 28, 2006

Schnitzel mit uns




Voted one-thread does not feature any big asses, and the machine does not make big asses either!

Very cool machine OP. Italians make very good machines IME. I wonder how many manual humans machinists making valves it is equivalent to.

Selklubber
Jul 11, 2010


Did you build a big castle with the big box afterwards?

schmug
May 20, 2007



tangy yet delightful posted:

I used to broker flatbed shipments and also CNC machines are way cool so now I have a "very large" boner.

I get it. Just watching the riggers do their thing is pretty amazing in itself.


Kaiser Schnitzel posted:

Voted one-thread does not feature any big asses, and the machine does not make big asses either!

Very cool machine OP. Italians make very good machines IME. I wonder how many manual humans machinists making valves it is equivalent to.


Side story on these Italian machines. This type and size of machine has two main competitors that make basically the same machine with different names and they are all located in some "little valley" over there. Apparently the owners are all related to each other. We had quotes from all three. It kind of makes you think....

We have versions from all three in our shop.

schmug fucked around with this message at 12:47 on Jun 12, 2021

Disgruntled Bovine
Jul 5, 2010



That's incredible. We used to make parts similar to (but less complex than) that where I work but we did it on a single spindle machine and it took like 8 setups.

I don't envy you trying to learn how to program that thing. It amuses me that your company would buy a machine like that but balks at the software cost. Typical.

schmug
May 20, 2007



Disgruntled Bovine posted:

That's incredible. We used to make parts similar to (but less complex than) that where I work but we did it on a single spindle machine and it took like 8 setups.

I don't envy you trying to learn how to program that thing. It amuses me that your company would buy a machine like that but balks at the software cost. Typical.

amusing, and very typical, yes. I've been asking about software for this thing for well over a year.

Kaiser Schnitzel
Mar 28, 2006

Schnitzel mit uns




schmug posted:

I get it. Just watching the riggers do their thing is pretty amazing in itself.

Side story on these Italian machines. This type and size of machine has two main competitors that make basically the same machine with different names and they are all located in some "little valley" over there. Apparently the owners are all related to each other. We had quotes from all three. It kind of makes you think....

We have versions from all three in our shop.
Itís kind of the same in the woodworking world. Thereís 2 companies that make really good bandsaws and theyíre 20min away from each other. People think of Germany or Switzerland when they think of high-end niche manufacturing but northern Italy has a much bigger export/machinery manufacturing mittelstand than people realize. SCM is a big woodworking machinery manufacturer there too thatís also apparently one of Europeís largest/best foundries and makes parts for trains and Lamborghinis and tractors and poo poo on the side??

These people make insanely huge bandsaws for cutting slabs of aluminum: https://instagram.com/bandsawfacts?utm_medium=copy_link

kimihia
Feb 1, 2002


Pillbug

Thanks, those are some impressive photographs.

I recently bought some brass valves for water and never really considered how they had been milled. I guess this makes more sense that you'd have a gigantic machine doing it automatically.

Now, talk to me. What are the tolerances here on the machining? (Not that I'd understand but I'll just nod politely.)

schmug
May 20, 2007



kimihia posted:

Thanks, those are some impressive photographs.

I recently bought some brass valves for water and never really considered how they had been milled. I guess this makes more sense that you'd have a gigantic machine doing it automatically.

Now, talk to me. What are the tolerances here on the machining? (Not that I'd understand but I'll just nod politely.)

We mostly specialize in compressed gas valves, but the machining processes are the same for the most part. As far as tolerances go it's a pretty standard +/.005" for most, but we get down to +/-.0005" in some critical applications. RA, or surface finishes, are more of an issue most of time since compressed gasses really need to be sealed at certain areas on the valve(s) or bad stuff can happen.

Will be posting some new stuff soon, but this build is taking quite some time and most of it is pretty mundane,

schmug
May 20, 2007



On a side note I was speaking with one of the builders and he said they just built a machine whose coolant tank/system was bigger than our main machining area. Took them three months to bring the whole thing into operation. So fwiw Big rear end Machine is a very relative term.

Blue Footed Booby
Oct 4, 2006

got those happy feet




Slippery Tilde

schmug posted:

.... So fwiw Big rear end Machine is a very relative term.

Indeed. For a fun time look up the lathes they used to make the guns for battleships.

Disgruntled Bovine
Jul 5, 2010



I live semi-near this monstrosity. If you look close you can see a couple guys standing in front of it.



It's one of two 50,000 ton presses in the US used for forging major aircraft components. Here's an interesting article on them.

https://boingboing.net/2012/02/13/machines.html

Our contracted internal auditor has been there and saw it in person, I'm very jealous of him.

Also the Mesta catalog linked near the end of the article (here: http://archive.org/details/plantproductofme00mest/page/n5/mode/2up?view=theater) is a definite pro-click.

Disgruntled Bovine fucked around with this message at 03:26 on Jun 18, 2021

AstroZamboni
Mar 8, 2007

Smoothing the Ice on Europa since 1997!

How many margaritas per minute (mpm) can this sucker crank out?

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schmug
May 20, 2007



AstroZamboni posted:

How many margaritas per minute (mpm) can this sucker crank out?

lol that thread

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