machine-tools allied with the wind - danobatgroup · shaft gear housing turning · grinding ... ·...

C M Y CM MY CY CMY K

machine-toolsallied with the wind


DANOBAT GROUP 3 - 5

Applications 6 - 7

· Tower 8

· Wind Turbine Blade 9

· Hub 10 - 11

· Nacelle 12 - 13

· Gearbox 14 - 15

· Generator 16 - 17

· Pitch & Yaw Gear Motors 18

· Bearings & Flanges 19 - 20

Machines 21

· Fully Automated Composite Parts Manufacturing Process 22

· Sawing & Drilling, and 3D Plasma Cutting Machines 23

· Turning Machines 24

· Boring Mill Centers 25

· Grinding Machines 26 - 27

Index

2


Your Global Business PartnerDANOBATGROUP, with more than fifty five years of experience, offers a range of advantages whichhelp your company to satisfy your manufacturing needs.

DANOBATGROUP is the largest machine toolmanufacturer in Spain. Over the last 55 years,DANOBATGROUP has supplied machines to highlyreputed customers, consolidating a worldwide presence.

DANOBATGROUP is the machine tool division of oneof the most important Spanish industrial holdings,MONDRAGON corporation.

DANOBATGROUP is specialized in different manufacturingtechnologies (boring & milling, grinding, turning,bandsawing, fully automated composite partsmanufacturing process, drilling and punching).

This wide range of products are marketed under twoworld renowned brands: SORALUCE (boring & milling)

and DANOBAT (lathes, grinders, punch presses,bandsaws and composite processing machines).

With top class manufacturing plants in Spain, Germanyand UK and sales and service offices all over the world,DANOBATGROUP is a reliable global supplier of provensolutions for different manufacturing and machiningprocesses. A determined commitment to become YOURGLOBAL BUSINESS PARTNER.

3

TOTAL: 15,526 TOTAL: 91,511

* 2008 data

One Leading Machine Tool Group, two distinguished brands

13,989

6,282 9,162

13,989 6,282 9,162

38,868

48,687

1,045

2,911

38,8682,911 48,687 1,045


DANOBATGROUP offers a wealth of accumulated knowledge ofdifferent machining technologies to the market. Completemanufacturing processes or specific machining operations can beprovided. Wind Power Generation, Aerospace, Automotive, Railwaysand Capital Goods are focused sectors of DANOBATGROUP’sindustrial strategy.

DANOBATGROUP offers the wind energy sector customized solutionsfor the manufacturing of blades, hubs, nacelles, gearboxes, rings,towers and other components of an aerogenerator.

The combination of different machining technologies such as sawing,turning, boring & milling, grinding and composite process automationallows to DANOBATGROUP to provide complete turn-key projectsto our customers.

The Group is highly focused on the Wind Energy Sector, as beingmember of “Spanish Wind Energy Association” (AEE),“AmericanWind Energy Association” (AWEA) and founding member of “SpanishEnergy Supply Chain” (ESC).

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around the World

turnover250

200

150

100

50

02004 2005 2006 2007

(M €)

2008

137 140

187208

232

personnel1400

1200

1000

800

600

400

200

02004 2005 2006 2007 2008

1007 1033 1036

13001330

international sales

02004 2005 2006 2007 2008

109 104119

139

176

(M €)

250

200

150

100

50

OEM

ALSTOMENERCONGAMESAGENERAL ELECTRICSIEMENSSUZLONVESTAS

OEM SUPPLIERS

ALFONS DIECKMANNA+SATA GEARSBECKMANN VOLMERB+SECHESAEIKHOFFEMUSIENDAKIEOZENEUSKALFORGINGEUSKOFEST SPAN

ReferencesMOVENTASPERKEORENKREXROTHSE FORGESEWSTORK GEARSWÜSTHOFFWUXI SANWEIWUXI WANLIZ+F

FLENDERGET GAMESAHCHELDECOINGETEAM INDARJIANGSU WENHUIJ. M. MENDIOLAKERSTENKINKELEKLINGELNBERGLAKBERMAN DIESELMOL-MATRIC


5

The Ultra-precision shop of Ideko ik4 (see above), temperature and humidity controlled, is dedicated to carry out research projectsand development of machines, components, measuring systems and contains testing equipment for ultra-precision applications.

The prototype shop of Ideko ik4 (800 m2), is dedicated to researchprojects on machining processes; its major activity is with partnershipprojects with machine end users. The shop, temperature controlled at±0.5º, serves as a showroom of the technological capacity ofDANOBATGROUP; carrying out trial tests, developing research projectsfor the members of the Group, optimizing traditional processes anddeveloping new ones.

Within the DANOBAT GROUP, IDEKO ik4 develops the R+D+I activities.


Applications

sawingturningdrillinggrinding

BEARINGS &FLANGES

page 19 - 20

grinding

PITCH & YAWGEAR MOTOR

page 18

HUBboring & milling

page 10 - 11

page 9

WIND TURBINE BLADEfully automatedmanufacturing process

WIND TURBINE BLADE

HUB

NACELLE

GEARBOX

GENERATOR

PITCH & YAW GEAR MOTOR

BEARINGS & FLANGES

TOWER

AutomatedComposite Parts Sawing Drilling Turning Boring & Milling Grinding

ProductionTechnologies

6


GENERATORturninggrindingboring & milling

page 16 - 17

millingsawingdrillingplasma cutting

TOWER

page 8

boring & milling

NACELLE

page 12 - 13

turninggrinding

boring & milling

GEARBOX

page 14 - 15

E

7


By two opposed moving column milling machines, the completemachining of the tower edges metal-sheet is carried out in one set-up.

The combination of SORALUCE’s Digitmill software and special tooling allows bothhigh accuracy and productivity, achieving high quality chamfers for subsequentautomatic welding, avoiding manual adjustment and reducing manpower costs.

. DIGITMILL enables the correction of the machining program of big size componentsaccording to the deformation error on them, providing high quality chamfering.

Advantages:

· Assistance to the operator

· Improvement of the performance of the machine

8

TOWER sawing · drilling · milling

Sawing & drilling, and plasma cutting lines for the internalmetal structures of towers.

The extensive know-how acquired over many years of product developmenthas enabled DANOBAT to expertly design, manufacture and comission fullyautomatic sawing and drilling lines for metal structure applications such asinternal structures of towers.


WIND TURBINEBLADE fully automated

manufacturing process

DANOBAT offer new technologically advanced solutions forautomating and controlling of the wind blade manufacturing process.

9

Automated stages

· Glass lay-up· Glue & Gel-coat application· Edge trimming & Surface grinding· Measuring & inspection

Working in consonance with its customers/partners toboost their competitiveness, will increase output andcost efficiency:

Danobat introduces autocontrol procedures in each stepin order to achieve a high fabrication process reliability.

• lead-time reduction > 45%• human labour reduction > 60%• material consumption reduction > 10%• blade repeatability & quality improvement > 60%


10

HUB boring & milling

SORALUCE provides high performance, reliable and accuratemachining of hubs, one of the most complex and critical part of awind turbine, providing:

SORALUCE multi purpose boring mill centers offer a full machining and verificationprocess of hubs, including simulation, milling, boring, drilling, tapping and measuringoperations.

· Machining of the blade support face· Machining of the generator support face· Machining of the nose support face


11

- Top quality machining heads, which are robust, flexible and reliable

- Development of new heads to suit special manufacturing requirements

- Automatic head changing systems for unattended machining processes

- Rigid high powered machines for heavy stock removal

- Thermal stability and dynamic adjustment of the machine

- A wide range of accessories to ensure the machine is exactly matched to thecustomer’s requirements

- The complete machining of a hub in only 2 set-ups

- Turn-key projects: clamping fixtures, cutting tools, CAD-CAM processing, simulation,training, production launch support is always at your disposal.

SORALUCE provides complete machining solutions with thefollowing available at your disposal:


12

boring & millingSORALUCE introduces the verification procedure in order to detectand avoid beforehand possible errors, potential collisions, or areasof inefficiency by machining process simulation. This processenables errors to be detected and corrected even before the programis loaded into the machine control, thereby removing the need ofmanual prove out.

Furthermore, the verification allows for the optimization of program cutting speedsto ensure a more efficient machining process.

The SORALUCE machining process provides both the reliability and the level ofperformance required in the manufacture of high-value components in the wind powersector.

NACELLE


13

Main operations carried out in the nacelle:

· Machining of the tower point face.· Machining of the jaws bore face.· Machining of the generator fitting face.


GEARBOXShaftGearHousing

turning · grindingboring & milling

High precision OD grinding machinesHG-62/72/92 are flexible solutions for universal or production grinding. They can be used forcomponents from 600 to 6,000 mm length. The HG-62/72/92 grinding machines offer reliableand accurate customer-specific solutions providing:· Different grinding operations in one clamping· DANOBAT made electro spindles on “B” type swivelling wheelheads· Wide range of compact swivelling wheelheads· MDM absolute measuring system is available

14

Turning CentersDANOBAT has within the TCN family a wide range of turning centers for the turning of gearboxshafts. Configuration of lathes may be adjusted according to each particular requirementsdue to the modular design concept, which provides the most cost effective machine solution.Keyways may be also finished accurately on the same clamping using the Y axis.

Shaft


GearVertical Turning CentersThe DANOBAT VTC range of machines providessolutions for high precision applications.The VTC features ensure optimum performanceaccuracy and repeteability.· Ram size:

250 mm x 250 mm – 300 mm x 300 mm· Table drive motor:

60 kW – 80 kW – 100 kW

HousingThe SORALUCE multi-purpose boring mill centers offer exceptional versatility and enhancedproductivity benefits for gearbox components. The automatic head changing systems together withaccurate rotary and travelling tables allow high precision machining of components in a single set-up, enabling to achieve high concentricity requirements demanded on those parts.

15

Vertical Grinding MachinesDANOBAT offers high capacity vertical grindingmachines for the machining of wind turbinegears. The DAN-VTG series provides:· Internal, external and surface grinding· “B” axis and automatic tool change· Probing software· Hard turning option

· Size and taper gauging· Pre-grinding measuring cycles· Interrupted process measuring cycles· Post process measuring andcomparison with grinding tolerances

High precisionAccurate profiled tapersPost process grinding report


16

GENERATORStator & RotorShaftSupport

Stator & RotorVertical Turning Centers

The VTC range of machines combines high turning performance andhigh accuracy over the machine lifetime.

The modular design enables a wide range of specifications to beconfigured in a short time and to be produced quickly, efficiently andcost effectively.

· Maximum turning diameter: 6,000 mm

· Table drive motor: 60 kW – 80 kW – 100 kW

turning · boring & milling · grinding


High precision grinding machines

· Longitudinal travel: 600 – 6,000 mm

· Swing 900 mm

· Twin wheel on “B” axis

· MDM absolute measuring system

SupportSORALUCE boring & milling machines are prepared toreach the most difficult-accessible areas of a generatorframe. The wide range of milling heads and the automatichead changing system turns the boring & milling machineinto a flexible machining center ready to machine differentmaterials, shapes, requiring various stock removals.

B2B1 B6

B8 B9 B10 B11

17

Turning CentersDANOBAT lathes allow the possibility to remove high chip volume with the special configuration for generatorshafts, featuring a double turret lathe. Driven tools may be also incorporated, enabling to combine differentoperations in a single machine.

High precision “B” axis

The European patented Danobat’s exclusive high precisionintegrated swivelling “B” axis, provides accurate wheelheadpositioning:

· Driven by a torque motor

· Direct read out of axis position

· High rigidity

· Maintenance free

Shaft

S


For the grinding of pitch & yaw systems, DANOBAT proposes external andinternal/external high precision grinding machines equipped with natural granite bedand linear motors technology.

. Internal/External grinding machines:

· Turret with up to four spindles

· Radii grinding

· Post process gauging

grinding

. High precision grinding machines:

· Longitudinal travel: 400 – 600 mm

· Swing 300 mm

· Wheelhead on “B” axis

· MDM absolute measuring system

· One finished part in one clamping

18

PITCH & YAWGEAR MOTORS


sawing · turning · milling

Accurate milling and drilling operations, working in pendulum loading,resulting in massive cost savings.

19

BEARINGS &FLANGES

High production horizontal cutting machines to start the process ofmanufacturing of rings.

There are two different solutions: a wagon system to support veryheavy components or gantry type sawing machine with portablesawhead.

· Maximum sawing diameter: up to 2,500 mm

· Length: 2-3…12 meters. According to customer's requirements.

Milling & Drilling

Sawing


Vertical Turning Centers

Proven performance in combining turning and drilling operations withhigh precision and productivity.

Possibility of adding a second Ram for simultaneous machining andmaximum metal removal.

· Maximum turning diameter: 6,000 mm

· Table drive motor: 60 kW – 80 kW – 100 kW

BEARINGS& FLANGES

20


Machines

Grinding Machines

ProductionGrindingMachines

InternalGrindingMachines

VerticalGrindingMachines

page 27page 26 page 27

Boring Mill Centers

page 25

Turning Machines

HorizontalLathesTurningCenters

VerticalTurningCenters

page 24

Sawing & Drilling, and 3D Plasma Cutting Machines

page 23

21

Fully Automated Composite Parts Manufacturing Process

page 22

Sawingmachines

Sawing &Drillinglines

3D Plasmacuttingmachines

page 23 page 23

page 24


22

Highlights:

· Own new developed technology

. Fabric Automatic Deposition (D.A.F.), either dryor impregnated, onto the mould under set-uppressure

. Ultrasonic based cutting system

. Auto-controlled roll storage

· Automatic reel feeder

· In-line impregnation possibility

· Auto-control systems

· In-machine curing

· Mould extraction

Fully Automated Composite PartsManufacturing Process

Longitudinal travel

Vertical travel

Cross travel

Resine type

Fibre type

Fabric type

Fabric reel diameter

Fabric reel length

units DAF

m 8 - 200

m 2 - 7

m 2 - 20

- Poliester / Vinil-ester / Epoxy

- Glass / Carbon / Basalt

- Unidirectional / Multiaxial / 3D / Mat

mm 10 - 1000

mm 10 - 2000

Fully automated manufacturing process of large structural composite parts.

Close to our customers, Danobat offer especially customised machines, critical in production lines,covering the complete machine life cycle, which results in a REPEATABILTY & QUALITY improvementas well as a LEAD TIME reduction.

. Auto positioning with respect to the mould

· Flexible to customer requirements

. Modularity concept

· Teleservice. Quick diagnosis and remote problemsolutions

· Offline simulation and programming

· Advance data managing and control solution

· Traceability of manufactured parts

· Safe-working conditions assured by theimplantation of protections according to CEStandards


Sawing & Drilling, andPlasma Cutting Machines

23

Highlights:· Machine prepared to work with bimetal & carbide blades· Automatic cutting parameters software “'PASO A PASO”· Intelligent cutting deflection control· Automatic running in process

Max. cutting capacity

Band sizes

Main motor power

units GH/CP-TV

mm 2,500

mm 54 / 67 / 80x1,6

kW up to 25

Sawing Machines

Highlights:· CNC mitre cutting machines -45º/+60º· Machine prepared to work with HSS and carbide· Loading / unloading customised solutions


Max. drilling diameter

units CPI/T3CH

mm 1,500

mm 50

Sawing & Drilling lines

3D Plasma cuttingmachinesHighlights:· Possibility to cut round pipes· DSTV importer· Marking system


Max. cutting diameter

Plasma source

units RPD-T

mm 1200 x 600

mm 500

up to 600 Amp


24

Horizontal Turning Centers

Swing over bed

Swing over saddle

Max. turning length

Max. main motor power

Max. chuck diameter

units TH/TCN

mm 600-1,100

mm 430-900

mm 7,000

kW 125

mm 250-1,000

Turning Machines

Vertical Turning Centers

Highlights:· Fixed or elevating crossrail· Live spindle or static tooling models· Two ram models for maximum metal removal· Automatic tool setting units· In process work gauging· Tool force monitoring and tool breakage detectionsystems

· Coolant through spindle· Direct linear measuring scales· Hydraulic counterweight for the vertical axis· Electric cabinet cooling systems

Max. turning diameter

Table diameter

Table drive motor

Ram dimensions

Live spindle power

ATC

units VTC

mm 1,600-6,000

mm 1,400-5,000

kW 60-80-100

mm 250x250-300x300

kW 17-22-37

no. 18-24-40-60-80

Highlights:· Slant bed· Ground & hardened steel guide ways· Ultraprecision headstock bearings· Automatic centralised lubrication· Optional “C” axis· Coolant through the tools


Boring Mill Centers

25

Multi-purpose Floor type Boring Mill Center offer exceptional versatility and enhanced productivitybenefits. The SORALUCE “F series” meets the continuing demand of wind power market for higherreliability, greater efficiency and increased manufacturing output.

Highlights:· Design and manufacturing of Top Qualitymachining heads, being robust, flexible andreliable, focused on the Wind Power market

· Automatic head changing system forunattended machining process

· Robust machines with cast iron structuresto provide maximized rigidity

· Complete accessories to match the machineto the customer’s requirements:

- Adaptative control to improve the cuttingconditions

- Anti-collision system to protect themachine and the component

- A wide range of integrated rotary-travelling tables (loads / dimensions)

- Operators’ platforms with vertical andcross movement to allow the operatorto gain greater access to the workpiece

Longitudinal Travel

Vertical Travel

Cross Travel

Head Power

Automatic head changing

ATC

units Boring Mill Centers “F” series

mm 4,000 - 30,000

mm 2,100 - 6,500

mm 1,300 - 1,900

kW 30 - 46

Automatic / Orthogonal / Horizontal

no. 40 / 60 / 80 / 100 / 120Orthogonal head1ºx1º (1ºx0,001º) / 37 kW4,000 (6,000) rpm

Fixed horizontal head37 – 46 kW3,000 (4,000, 5,000, 6,000) rpm

Special head designed asper customer´s requirements

Automatic head changing system

- Pendulum working system for loading/unloading without interrupting the cycletime

- Splash guarding designed to thecustomer’s requirements

- High-pressure coolant through thespindle

· Other standard features to suit currentrequirements:

- Safety guarding in accordance with CEstandards

- Automatic centralized lubrication

- Direct linear measuring scales

- Rapid traverses up to 25 m/min

· Turn-key projects: clamping fixtures, cuttingtools, CAD-CAM processing, simulation,training, production launch support, etc.


Grinding Machines

26

Highlights:

· Wheel head on a “B” axis

· Different wheel head configurations

· Absolute MDM measuring unit

· Various In-Process gaugingpossibilities

· Post process dimensional andgeometric report

· Very high flexibility

· One finished part in one clamping

Distance between centers

Swing over the table

Max. weight

Max. wheel size

Peripheral speed

mm 600 500-1,500 1,000-2,000 1,500-4,000 2,000-6,000

mm 350 450 450 650 1,050

kg 100 150 500 1,500 7,000

mm 600x150 760x250 508/610x150 915x300 1,060x150

m/s up to 100 50-60 45-60

units FG PG HG-62 HG-72 HG-92

Production GrindingMachines


Vertical Grinding MachinesHighlights:

· Internal and external grinding with high frequency spindles

· "B" Axis:

- Automatic Tool changing

- Optional tangetial head

· Probing software

· Hard turning option

Max. diameter

Max. height

Swing

“B” axis

units VG

mm 1500

mm 500-1000

mm up to 1600

option

Internal Grinding MachinesHighlights:

· Radius grinding on “B” axis

· Turret with four spindles on “B” axis

· In process measuring and post process grinding &geometric report

Max. diameter

Max. height

Swing

“B” axis

units ID

mm 460

mm 300

mm up to 600

option

27


DANOBATTel. +34 943 748044E-mail: [email protected]

DANOBAT-OVERBECKTel. +49 2772 801-0E-mail: [email protected]

SORALUCETel. +34 943 769076E-mail: [email protected]

BIMATEC SORALUCETel. +49 6431 97820E-mail: [email protected]

Arriaga Kalea, 2E-20870 Elgoibar (Spain)Tel. +34 943 748300Fax. +34 943 743674E-mail: [email protected]

Tel. +55 11 3082 9080E-mail: [email protected]

Tel. +86 10 64673639E-mail: [email protected]

Tel. +91 20 6609 4531E-mail: [email protected]

machine-tools allied with the wind - danobatgroup · shaft gear housing turning · grinding ... ·...

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