en

PRoduct PoRtfolioAlPine MetAl tech GRouP

2

3

the Alpine Metal tech Group develops, designs, produces and services special plants and machines for rolling, processing and handling of long products, product identification and product inspection as well as complete packages for continuous casting machines. furthermore, Alpine Metal tech delivers special applications for the testing, production and handling of aluminium wheels. Alpine Metal tech operates globally under seven world leading brands.

Alpine Metal tech is a premium one-source supplier that continually updates and expands its product portfolio with customized one-stop solutions. An excellent example is the Alpine Metal tech ccM package, which responds to customer needs by minimizing interfaces and effectively utilizing synergies.

Alpine Metal tech is a world leader inthe steel and aluminium wheel industrywith comprehensive solutions.

AlPine MetAl tech oPeRAteS GloBAllY undeR the WoRld leAdinG BRAndS:

Alpine Metal tech’s continuous research & development activities focus on customer needs to achieve efficient and reliable production. our R&d concentrates on creating new technological standards.

Alpine Metal tech has a worldwide sales network and is represented both by its own sales subsidiaries and by partners and sales representatives in more than 40 countries. A worldwide concept for customer- focused life cycle services supports the reliability and functionality of all AMt machines in operation. our international service network allows us to compete as a global player supplying standardized products and services to meet the needs of our increasingly multinational customers.

AlPine MetAl techGRouP PRofile

Steel AutoMotive SAfetY life cYcle SeRviceS

&

BuSineSS

&

4

Steel

5

MARKinG MAchineS, cAStinG

hot Spray Marking

Metal Powder Marking Machine

the Metal Powder Marking Machine is designed for marking of slabs and blooms. Marking is performed by blowing metal powder through a gas flame for melting it to the surface of the product. Metal Powder Marking Machines are distinguished especially by marking long-lasting, clear and bright characters, which can vary in size and number of lines depending on individual customer requirements• floor and bridge type • temperature range from 400 to 1100°c• Alphanumeric and special characters, size from 40 to 150 mm• extendable with automatic reading system

the hot Spray Marking Machine is designed for marking of slabs and blooms. Marking is performed by blowing liquid metal which is melted in an electric arc between two wires to the surface of the product. hot Spray Marking Machines are distinguished especially by marking of long-lasting characters, which can vary in size and number of lines depending on individual customer requirements.• floor and bridge type • temperature range from 20 to 900°c• Alphanumeric and special characters, size from 60 to 150 mm• extendable with automatic reading system

dot Paint Marking Machinethe dot Paint Marking Machine is designed for the marking of coils, slabs, blooms and billets. the system is based on paint marking with 7 or 9 nozzle marking sections. the marking equipment can be combined with all nuMtec base machines and is available as stand-alone machine or in combination with MX Punch Marker. • Robot, floor & Bridge version• extremely short marking cycles, as marking is done in one movement • temperature range from -5 to 1,100 °c• Alphanumeric and special characters within 7 x 5 or 9 x 7 dot matrix• character size character size 30 – 150mm• Marking media: Paint, water & solvent based• extendable with automatic reading system

Single nozzle Paint Marking Machine

the Single nozzle Paint Marking Machine is designed for the marking of coils, tubes and sections as well as for slabs, blooms and billets. the system is based on paint marking with single-nozzle marking heads.• Robot, floor & Bridge version• uniform marking image due to the continuous fluent writing

movement • temperature range from -5 to 1,100 °c• Alphanumerical and special characters, size from 30 to 150 mm• Marking media: Paint, water & solvent based• extendable with automatic reading system

6

MARKinG MAchineS, cAStinG

Revolving head Marking Machine

the Revolving head Stamping Machine is designed for the permanent marking of slabs, blooms and billets. Revolving head Stamping Machines are distinguished especially by the stamping of unmistakable and full characters, which can vary in size and number of lines depending on individual customer requirements.• inline, marking during casting, no separate marking position• very low running costs and no consumables costs, except set of

stamps (insignificant)• floor and bridge type possible• temperature range from 600 to 1100°c• up to 24 different alphanumeric characters, size from 10 to 25 mm• extendable with automatic reading system

Mobile Stamping unit

the hand held stamping unit is designed as backup system for the Revolving head Marking Machine. for stamping the unit has to be pressed against the product, the stamping head is pushed in and releases the activation for the punch. the punch has to be activated manually by pressing the trigger on the stamping unit.• light, portable, wireless stamping unit with cartridge loading device• Applicable for hot or cold slabs, blooms and billets• total mobility and complete independence from electrical/media

supplies• connectable extension tool allows the operator to mark hot material

at a distance• identical marking image as from the AMt Rh stamping machine• Automatic readable with AMt ocR Reading system• number of digits: up to 10 characters with one punch• character size 10 - 15mm

ReAdinG And tRAcKinG SYSteMS, cAStinG

vision System

the reading and tracking system is an automatic reading system for many kinds of marked, labelled and printed products. the system allows material tracking from casting to rolling process.• ocR Reading of alphanumeric characters, code Reading• contrast Markings & Stamped Marking• event logging (images of product & marking, machine status)

stored on database server • typical reading performance more than 98%

7

tAGGinG & lABelinG

tag Marking Machine

label Marking Machine

the tag Marking Machine is designed for the marking of slabs, blooms and billets. Marking is performed by nailing the tag direct on the product. Auto tagging System can be designed as robot or bridge type according to local situation and customer requirements.• Process time reduction because of direct application at the high

temperature up to 1200°c• Wide variety of tag sizes• eliminated all kinds of identity losses and avoid the risk of mis-

match during product identification • on-Site Printing thermal transfer Printer; any format and code can

be printed (barcode, QR code, data Matrix…) • Suitable Weather Resistance and for even poor surfaces• extendable with automatic reading system

the label Marking Machine is designed for the marking of coils, slabs, blooms and billets. Marking is performed by pasting the label direct on the product. Auto labelling System can be designed as robot or bridge type according to local situation and customer requirements.• Process time reduction because of direct application at the high

temperature up to 800°c• Wide variety of label sizes• eliminated all kinds of identity losses and avoid the risk of mis-

match during product identification • on-Site Printing thermal transfer Printer; any format and code can

be printed (barcode, QR code, data Matrix, etc.) • Suitable Weather Resistance • extendable with automatic reading system

Mobile label Applicator

the printed label will be taken up with the applicator. hereby the label is sucked by the vacuum plate. for marking the applicator will be pressed against the product and the vacuum button will be released. the press on time is approx. 5 seconds. • light, portable, only air supply necessary• direct Application on hot Products up to 800°c• on-Site Printing thermal transfer Printer• Any format and code can be printed (barcode, QR code, data

Matrix, etc.)• Suitable Weather Resistance• Automatic readable with AMt ocR Reading system, and any other

reader devices• very easy to handle

8

deBuRReR

Slab/Bloom/Billet deburrer

ShRoud MAniPulAtoR

PoWdeR feedeR

Shroud Manipulator

Powder feeder

the Shroud Manipulator enables the user to get a straight connection between the ladle slide gate and tundish. it is designed for moving the ladle shrouds from the storage, cleaning or heating position to the connection point at ladle gate and versa. during casting process the Shroud Manipulator retains the shroud with a constant press-on force at the connection point of the ladle.• Manual, semi-automatic or automatic types available • Press on force (adjustable): up to 10 kn• operation from a safety distance - improve operator safety

the Mould Powder feeder is designed for the automatic distribution of casting powder into the mould. this ensures a constant uniform mould powder distribution during the casting process. the Mould Powder feeder is applicable for all types of powder and granules.• for slab casters only• Powder container with 100l volume• 0.5 to 3 l/min capacity per feeding tube

the in-line rotary hammer type deburring machine is designed for removing burrs from continuous casting products (slabs, blooms & billets) caused by torch cutting. the deburring process is executed during transportation on roller table without stopping the product. the in-line removal of burrs is carried out by a series of hammers which hanging loosely on axles positioned around the deburrer roll. due to the roll speed and the mass of the hammers they hit the burrs several times at high speed before the burr is removed from the product and guided via chutes into a burr removal system.• Product speed up to 40m/min• temperature range up to 1000°c• Significant quality improvement of rolled products (no roll-in of

burrs)

9

MARKinG MAchineS, RollinG

combiJet & hot combiJet Paint Marking Machine high Resolution (16 nozzles)

dot Paint Marking Machine (7 or 9 nozzles)

the dot paint classic marking technology offers a solid marking image which is suited for marking hot and cold steel products. the technology is based on electro-magnetically activated spray guns comprising a nozzles for paint, atomizing air, and cleaning air, which are built around a needle to control the paint flow.• temperature range from -10 to 1,100 °c• Alphanumerical characters, special characters and machine

readable codes, size from 30 to 150 mm in 7x9 or 9x11 dot matrix• Marking media: Paint• Marking speed up to 2.5 m/s • extendable with automatic reading system

the combiJet marking technology fulfils the increasing demand for a high resolution quality marking at high speed. the electro-magnetically activated marking section is fully automatic and requires no manual adjustment. By adding more marking sections together a full flexible matrix is generated allowing demanding marking images to be marked.• temperature range from -10 to 1100 °c• Alphanumerical characters, classification symbols, logos and

machine readable codes, size from 18 to 800 mm• Marking media: Paint• Marking speed max. 2.5 m/s • high resolution quality marking for branding• extendable with automatic reading system

Punch Marking Machine

the punch marking machine is used where a permanent marking is needed. two technologies are offered, i.e. electro-magnetically and pneumatic activated punchers for different applications. Punch marking may be performed on stationary products or during product conveyance.• temperature range from -10 to 1,100 °c• Alphanumerical characters, classification symbols, logos and

machine readable codes, size from 6 to 20 mm• Penetration depth adjustable from 0.2 to 0.4 mm in up to 600 hB• Marking tool: Punch die or needle• Minimum cycle time: marking of 3 lines with 30 character in approx.

5,5 seconds• extendable with automatic reading system

10

MARKinG MAchineS, RollinG

Plate edge Marking Machine

edge marking or fixed labeling as we call it allows steel plates to be stacked without losing the possibility for identifying the individual plates in the stack. the marking is black ink characters and a barcode applied by a continuous ink-jet on a ribbon of white paint. • temperature range from -10 to 300°c• Alphanumerical characters, chinese and machine readable codes,

size from 2 to 10 mm• Marking media: Paint and ink• Marking with standard ink-jet on white paint for background layer• equipment for white background layer integrated into machine• extendable with automatic reading system

high resolution quality marking for branding

combined Automated Marking Machine

By combining our main technologies and building up our machines with standardized modules we are able to deliver high quality and proven customized solutions fitting into any production line.• combination of paint, (cJ-combiJet, classic), punch (Pu-Matrix

needle) and edge (ed- edge) marking technology• customized design for any production line• Bridge or cantilever steel structures• transversal or longitudinal marking also for moveable products• extendable with automatic reading system

With the combiJet technology, Alpine Metal tech responds to the strong branding tendencies in the steel market. the combiJet marking technology is distinguished by ease of use, high speed and high resolution marking. our technology is able to mark any individual marking layout (texts, classification symbols, logos, brand names and machine readable codes). • turns an anonymous product into an advertising media• Gives the product added value• the nameless product becomes a proprietary product• Advertising media for the customers of the steel producers• copy protect your steel product

11

inSPection MAchineS

Brushing Machines

Surface inspection with 3d high Speed Sensors

the automatic vision System allows automatic detection of defects on surfaces by means of image processing, even on surfaces with a big amount of scales. An image processing algorithm distinguishes defects like flakes, cracks, grooves or break-offs from other surface irregularities, such as stamp marks, engravings or scale. every defect or deviation can be reviewed on several screens along the rolling mill.• min. detectable defect size of 1.5mm x 1.5mm x 1.5mm • up to 1.5 m/s line speed• for cold products

A brushing machine is used for the efficient removal of loose scale in order to improve the surface quality as well as for the surface preparation prior to the entry into the non-destructive testing line. the special movement of brushes results in an improved brushing performance and in a reduction in the wear of the used brushes.• up to 2.0 m/s line speed• for cold products• frequency-controlled brush motors• for loose scale and dry contamination

Straightness Measurement System

Straightness Measurement is a contact-less optical measuring method for measuring the straightness of profiles allowing faster and more precise quality checks. horizontal and vertical straightness are being calculated, thus electronically simulating the manual measurement process.• up to 2.0 m/s line speed• straightness measurement is ensued from start to end of profile• for cold products

Stamp Readers

the task is the automatic reading of stamped codes as well as of brandings on the rail. the stampings and brandings are located on the web of the rail. the codes are captured by cameras and evaluated with a well-established algorithm.• up to 2.0 m/s line speed• for cold products• alphanumeric plain text according to rail standards• allows ±30mm horizontal and vertical misalignment

12

Rail Profile Gauge

With the Profile Measurement System utilizing light sectioning techniques, it becomes feasible to measure under all conditions with highest accuracy. the techniques applied allow the complete measurement of nearly every kind of profile in fractions of a second.• Measurement interval approx. 100mm depending on line speed• up to 2.0 m/s line speed• for cold products, but also available for hot products on request

inSPection MAchineS

eddy current testing

the online inspection system based on eddy-current is used for the detection of longitudinal and transversal surface defects on the profile. the equipment includes the adjustment of several segment coils for edge testing (for transverse defects) and rotating probe systems for testing the planar surfaces mainly for longitudinal defects on different kinds of rolled profiles.• up to 1.5 m/s• for cold products• detection of defects according to rail standards• automatic adjustment at product change

ultrasonic testing

ultra-Sonic testing is used for online detection of internal imperfections such as laminar defects, inclusions, tension cracks in rails and other rolled materials. the system is available as water-jet coupling and/or water-gap coupling solution. the machine provides a fully equipped evaluation system operating in multiplex mode for sections to be tested with a pre-adjusted threshold determining the flaw size.• up to 1.5 m/s• for cold products• automatic adjustment at product change on request• closed water cycle• detection of defects according to rail standards

Security Gate

for reasons of safety, the installation of a height and width measurement station is recommended. this station consists of a basis frame on which two infra-red light grids, one horizontal and one vertical, are installed-on. By means of this arrangement, which works with an accuracy of +/- 5 mm, a roller table stop can be generated, in case a rail profile enters the system which exceeds in dimension the profile which is intended to be the next to enter.• accuracy ±5mm• for cold products

13

inSPection MAchineS

Barcode Applicators

the Bar code Applicator is directly installed in the testing line. the rail id as well as other data are transmitted to the system whether from the central computer system or directly from the mill computer system. this information is transformed to a bar code, printed and applied to the rail which passes the system with a speed of up to 2 m/sec.• up to 2.0 m/s• for cold products

Multi colour Marking System

the multi-channel marking unit is installed at the end of the testing line. With the installed length measurement devices a location of the detected defects is possible. each kind of straightness, profile, surface and internal defects is being marked using different colours.• up to 2.0 m/s• up to 5 different colors plus solvent• for cold products

transport and Guidance units

for the transport and guidance of the rails within the area of the testing line, 8 transport and guidance units are foreseen, which are installed between the different testing devices. these devices also serve for fixing the position of the rails, passing through in order to avoid undesired transverse movements of the rails.• up to 2.0 m/s• for cold products

demagnetisation unitto ensure a good result at the eddy-current testing Machine, the use of a demagnetization unit is recommended, in case that the tested rails are handled by a magnetic crane before they enter the testing line area. frame mounted demagnetising tunnels are principally used for continu-ous processing to enable the continual automatic throughput of long products. demagnetising tunnels are available in a range of capacities, depending on the dimensions and shape of the product to be demag-netised. the tunnels are designed according to customer‘s specific needs and requirements.• residual magnetism < 10 Gauss, depending on line speed• for cold products

14

toRch cuttinG MAchineS - flAt PRoductS

SSc -Slab Swivel type counterweight Machine

• the machine is lowered by a pneumatic cylinder providing a single and simple movement by pushing down the synchronization skid against the slab. the skid returns back in top position thanks to the rear protection plate used as counterweight

• in case of a power failure or emergency, the skid is lifted in a safe position by manual or automatic purging of the cylinder and the machine is released from the strand

Sve - Slab vertical lowering electric type

the machine is combining two mechanical movements driven by a strong electromechanical drive which supports the torch beam and thebelow water plate with the synchronization skid. By lowering, the skid is going down until the slab surface stops the movement. At the same time the torch beam is going down uprightly by means of a vertical raceway keeping the torches vertical regardless of the thickness of the slab. With this mechanical system, there is no need for a torch height equipment system with all components like motors, end switches etc.

vertical torch cutting Machine for continuous slab casting plants• casters utilizing a vertical design allows for continuous casting of

high-alloy grades; this casting technology requests high performing torch cutting Machines able to accomplish their task in an unusually rough environment with perfect accuracy and reliability.

• Gega vertical tcM (machine type: SvM – Slab vertical Machine) are composed of a horizontal machine carriage moving vertically between two columns and synchronizing the movement with the strand by pneumatically actuated clamping arms. two independent torch carriages travel on rails which are mounted on the machine carriage.

• the machine is protected against the radiant heat of the hot strand by generously dimensioned water plates at the bottom and front side of the machine.

15

toRch cuttinG MAchineS - flAt PRoductS

toRch cuttinG MAchineS - lonG PRoductS

Secondary torch cutting Machines for slab subdividing

for subdividing mother slabs in shorter daughter slabs of preselected length Gega developed the Secondary tcM facility including two movable portals (machine type: PMB – Portal Movable Beam) - built-up transversal to the roller table. for the cutting operation the portals are equipped with two torch carriages for transversal cutting. Both machines are designed for cross cuts with only 1 torch or with 2 torches simultaneously. With input information provided by a measuring roll the slabs, transported by a roller table, are stopped in a certain window and the two portal cutters are positioned along the transport direction in order to achieve the preselected length of the daughter slabs.

BPl - Billet Pendulum-cutting Machine-light

• An electro cylinder moves the pendulum cutting torches• for an adjustment of the nozzle distance to the material (depending

on the sizes), the torches has to be adjusted manually in the torch holder

• the torch will be taken to the strand edge during clamping via a mechanical device which is mounted to one of the clamping arms

BlM - Billet / Bloom linear-cutting Machine

• A gear with a frequency controlled synchronous -motor drives the linear cutting torch

• the torch can be equipped with motorized height- adjustment or manually adjusted at the torch holder

• the exact position of the strand edge is determined by Plc via the travelled distance during clamping

16

ScARfinG

Scarfing Manipulator

Scarfing Manipulator has the flexibility to scarf whole slab surfaces, strip scarf, spot scarf, and/or edge scarf (dependent on ancillary equipment installed.)• Most flexible and efficient• from an air-conditioned and dust protected cabin the scarfing

nozzle is controlled via joy-stick by the operator enabling a precise scarfing work.

• lower costs for auxiliary equipment as fume extraction systems, water treatment plants or scrap management systems

hand Scarfing

2-Sided and strip (Band) Scarfing Machine

tWo (2) Sided ScARfinG MAchine are the best option for customers requiring a semi-automatic equipment that has an exceptional balance between high capacity and low maintenance• equipped with Gega Scarfing Burners producing a finish required by

stringent rolling mills.• Significant production flexibility and media savings resulting from

the ability to control individually each burner segment and having separate top and side scarfing carriages.

• Gega offers Strip (band) and special scarfing machines such as fixed strip, selective strip, corner, billet or bloom scarfing machines.

Gega´s Safety hand Scarfing torch type Shf including scarfing nozzle is used for a complete or partial scarfing or removing surface layers of crack effected zones of raw ingots, blooms, slabs and mouldings consisting of unalloyed or low- alloyed steels.• Gases are mixed in the scarfing nozzle, a safety design feature

minimizes the risk of flashback to further protect the operator

17

PReheAtinG

cutting tractor - coRti

PoRtABle cuttinG eQuiPMent

offline toRch cuttinG MAchineS

Slitting and Subdividing machines

Preheating Station

Automatic preheating equipment designed for drying and heating ladle and tundish• uniform flame distribution allows more effective drying and heating• Automatic temperature regulation• increase of economic efficiency by use of recuperative technologies

• Manually controlled cutting torch• designed for emergency cuts in continuous casting plants and

cutting up scrap material• equipment meets high safety standards implemented in a modern

and simple design• Simple handling, robust and resistant design and accurate cutting

results• customized solutions are always possible• Available with remote control

• Related to off-line operation many applications request a high level of accuracy and flexibility for material sizing and subdividing.

• Gega slitting machines are able to perform high quality length cuts depending on different requests related to the final product; sizing of tapered slabs and length subdividing but also cross cuts are typical tasks for this machine category; high quality of laser and sensor equipment are enabling excellent cutting results

• further applications with similar design and equipment are subdividing all kind of scrap material with different forms and thicknesses.

18

MAchineS foR lonG cARBon Steel

cooling Beds

Rolling Stands

&

Reversing or continuous mode - Koch h&K shapes steel with roll-ing forces of up to 25.000kn in single stands or complete rolling mills: Blooming stands, edging stands, universal stands, finishing stands and open rolling mill or tandem mill.• hydraulic roll adjustment systems with automatic gauge control

(AGc)• Axially shiftable rolls• hydraulic overload control• Quick, semi-automatic roll change• fully automatic feeding, intelligent turnover and shifting devices for

short pass schedules and efficient rolling

on Koch h&K cooling beds, long products cool down homogeneously and are transported with great care. this minimizes residual stress and distortions in the material on its way from the rolling mill to the finishing line.• electric or hydraulic drives• forced cooling through cooling fans• Pawl-type, chain-type, rake-type cooling beds available• calculation of air flow in the hall (aerodynamic proof)

Abrasive cutting Machines

Abrasive cutting machines are used for cutting hot and cold steel prod-ucts when specific high demands are placed on the quality of the cut, for example, when cutting to selling lengths or the microstructure of the material must not be affected.• Suitable for cutting high-alloyed steels, non-ferrous metal alloys or

other high-grade materials• Wide range of travelling and pendulum cutting machines for differ-

ent cross-sections, square and round such as special sections• optimized cutting operation in terms of time and quality

Straighteners

Koch h&K Straightening Machines allow steel producers to deliver straight products with minimal residual stresses.• horizontal or vertical variante for all types of rolled sections available,

cantilever or doubled sided housing• individually configuration according to customer requirements with

hydraulic locks and computer-controlled adjustable speed drives for the straightening shafts

• Ancillary equipment necessary for the straightening operation available

• Automatic changing of all rolls by a special manipulator

19

MAchineS foR lonG cARBon Steel

flying Shears / Stationary Shears

&

flying shears of different designs are used to cut the rolling stock in wire rod, bar and section mills, in continuous blooming mills as well as in steel plants behind the casting bow. Stationary shears are used for large cross-sections, the material is stopped for the cut.• electrically and hydraulically driven shears rated for shearing pres-

sures from 250 to 1,000 tonnes• Stationary shears for non-moving materials (billets, round and

square blooms)• All ancillary equipment such as feeding and discharge systems,

scrap handling, positioning and sample taking equipment available

Saws

Koch h&K designs and supplies a wide range of sliding frame and chop saws with blade diameters up to 2,400mm for rails, beams and sections, hot or cold cut.• Perfect saw for cold or hot cuts, single sections or layers• design of complete process including saw table, clamping devices,

length stop, sample taking equipment, scrap handling and other ancillary equipment

• comparatively low costs for the saw blades and short time for their replacing

20

AutoMotive

21

PRoduction MAchineS

nuMtec Barcode System

MARK 100 - Marking System

Md 825 - camera System

the Mark100 system is a fully integrated machine for automatic pin stamping of alloy wheels. the system can apply any kind of alphanumeric characters as replacement of manual marking in the production process.• can be used for monoblock and flow-forming wheels• inline machine, loading with standard roller tables• free scalable marking characters• options available (i.e. sprue control, …)

the Md 825 is a fully automatic design recognition system for cast alloy wheels. the wheels can be recognized with the as-cast surface at the beginning of the production cycle or after machining with or without paint.• 3d-geometric measurement for save separation of wheel types• Additional separation criteria like wheel diameter, height and offset • Machine recognition capacity of maximal 600 wheels / hour• integrated system, all necessary components ready and assembled

MARK 400 - data Matrix - unique Serial number System

nuMtec has developed a serial number system with MARK 400 for full traceability of aluminium wheels through the entire production process.• Production faults and problems can be tracked to single machines

and production steps• Wheels will be read during normal movement on the conveyor• Marking machine and reading system are a combined package

• Automation control of production, from the casting process to the mechanical machining

• highest reliability of the system with the use of laser scanner, reaching reading rates of more than 99.9 %

• More than 20 wheel producers in europe, uSA and Asia producing more than 70 million wheels/year based on nuMtec barcode system

• far higher reliability compared to conventional camera systems.• Automatic production control of conveyor systems, X-ray systems,

sprue punching and drilling systems, marking systems, deformation measurement systems and mechanical machining cells.

22

PRoduction MAchineS

Md 30 - Manual distortion Measurement

Md 140 - inline distortion Measurement

the Md140 measurement machine will be used for 100% distortion monitoring of cast alloy wheels directly after the casting process or after the heat treatment process• Automatic measurement of up to 200 wheels/hour with a single unit• flatness measurement of outboard flange and hub float• integrated type recognition (with nuMtec barcode scanner or

optionally with design recognition camera system)

the flexible Md30 laser measurement machine is used for distortion measurement at manually operated machining lines.• Measurement at casting area: flatness of outboard flange and hub

float measurement• Measurement of painted wheels: correction and optimization of

diamond cut process• including interface Profibus/Profinet

Robot cells

flexible robot cells for fully automatic mixed wheel production in best wheel quality• integration of all available cnc machines possible• flexible production, simultaneous machining of different wheel

types and sizes without set up times• Production capacity of up to 960 wheels/day, depending on the

machining times• control of the cell with a Plc system including visualisation, full data

storage of wheel information for flexible production, with interface to a plant control system

Ref - deflashing Machine inline-version

the Ref was developed to remove the flashes for reliable X-ray and roller table transport • Single or double unit machines available• deflashing capacity up to 240 wheels/hour• deflashing of outboard flange, inboard flange, side/split flash• With optional laser contour measurement system

23

PRoduction MAchineS

Positioning unit for Md 300

Md 300 - Measurement and Positioning at cell

the Md300/320 machine is used for 100% process control measurement of alloy wheels before entering the cnc machining cell.• for integration into a production cell• high reliable nuMtec-Barcode or camera system• Reduction of runout and imbalance issues through overall wheel

quality improvement• fully automatic laser measurement in the area of outboard flange

and hub• Generation of correcting data for cnc machines

the prepositioning unit with camera system is used in robot cells to orient the wheel to the proper positioning of the valve hole.• Rotation positioning for cnc drilling process• Automatic correction of angle at drilling machine loading• operation and control fully integrated into Md300 system• different wheel types on one production cell through camera system

cAM 100 - valve hole Positioning

Md 400 - test System for Pilot Bore

the Md 400 is a system for fully automatic measurement of the pilot bore directly after cnc machining• Range of centre bore diameter from 48 to 85 mm• closed control loop with oP1 cnc machine for centre bore

machining• non-contact laser measurement• different wheel types on one production cell through laser system

the cAM 100 is used for precise wheel orientation on the pre-cast of the valve hole.• different options for several environment conditions available• interface to all standard cnc machines• different light options available• Special protection housing for integration at the drilling machine

available

24

PRoduction MAchineS

Md 200 - Measurement for diamond cut

the Md 200 measuring machine for diamond cut is used to precisely measure the design side of wheels for / prior to diamond cut process.• calculation of correction values for cnc machining • for chucking at inboard flange or attachment face• Massive reduction of scrap and rework rate at diamond cut process• different versions for manual lines available

Md 860 - Modular inline testing Machine

the inline inspection system (Md860) for aluminum wheels offers safety at production because of a 100% inspection of all critical wheel parameters at each individual wheel.• capacity of around 5500 wheels per day• Modular machine frame and transport system• easy integration of new customer requirements• central operator interface and data storage

25

teStinG MAchineS

RRh - Radial fatigue test

ZWARP - Biaxial Wheel test

the biaxial wheel test machine, is used for fatigue tests or life tests of disc wheels. the wheel is running inside a drum and is applied to with radial and lateral forces as well as tilt angle force.• test of fatigue and endurance simulation for passenger cars and

light truck alloy wheels with defined load profiles• load and camber angle will be applied with electrical servo drives• Side forces will be applied by rolling against a spacer disk• test according wheel specification § 30 Stvo, SAe J2562, AK-

lh08

the RRh machine is used for fatigue and endurance testing of wheels by rolling the wheel on a drum under specific radial load conditions.• Available with 1 to 4 load stations, individually for passenger cars

or truck wheels.• easy and user friendly wheel change position due to vertical drum

arrangement.• for execution of all law regulations according § 30 Stvo, AK-lh08

specification, SAe J2562, nBR 6752

BuP – cornering fatigue test

the cornering fatigue test is defined as a type of audit for the certification approval and ongoing monitoring of vehicle wheels. the test parameters will be defined from the actual statutory provision and from the wheel load of the test wheel. • Simulation of the rotary bending moment which will be applied

during normal road cornering• depending on machine version, the bending moment can be

individually selected from 0.5 to 80 Kn. • test according wheel specification § 30 Stvo, SAe J2562, AK-

lh08, nBR 6752

AZn - ZWARP Multiaxial Wheel testing

the multi-axial test machine is used for fatigue and endurance tests on aluminium wheels for cars and light trucks, by rim-rolling them on a coated load drum• corresponding forces for load, camber and skew will be applied by

electrical servo motors and motion control systems• Measurement of the forces in all directions will be done with load

cells• Available with 1 or 2 individual load stations, as standard or as

dynamic test machine• testing according regulations § 30 Stvo, AK-load cycle AK-lh08,

SAe J328, and SiS d4103 (nürburgring)

26

eXA – Manual Radial and Axial Runout

teStinG MAchineS

impact / Radial impact test

the results of accident and collision research demand wheels which preserve and maintain their functions even under the heaviest of loads. the impact test simulates the fracture behaviour of the wheels on the front side flange travelling over a defined obstacle. the radial-impact test simulates the fracture and deformation behaviour of the wheels on the back side flange travelling over a defined obstacle.• test according specification iSo 7141, BSAu, tRiAS 43, SAe

J175, JASco c608-750, foRd S74 eB 100 /cd, JASco c608-75 iJ, AK-lh08, § 30 Stvo and nBR 6752

eXA – Radial and Axial Runout

MAKRA measuring machines were developed to make the simultaneous measurement of concentricity and run-out on the outer and inner tyre seat possible.• calculation of 1st to 10th harmonic and physical identification for

positioning and marking• Measurement of the following parameters:

radial runout front and back side, axial runout front and back side, tyre seat circumference inside and outside, wheel width, wheel offset, centre bore diameter

MAKRA mobile and compact measuring instruments were developed for testing the concentricity and run-out of tyre seats near the production line.• for testing close to production site• for optimization of lathe process, for special adjustments of the

chucking system based on measurement results• clamping on the centre bore with the special MAKRA chucking

system

27

PRoduction MAchineS

ABv - Sprue Point drilling Machine inline version

the ABv machine is developed for the automatic sprue point drilling of alloy wheels after the casting process. it’s a strong and reliable machine, setting the standard for flexibility and efficiency.• inline loading with included conveyor system• drilling of sprue from design side of wheel• Special cleaning system after drilling process• connection to standard chip conveyor

Ref - deflashing Machine for Robot loading

ABv - Sprue Point drilling Machine for Robot loading

the ABv machine is developed for the automatic sprue point drilling of alloy wheels after the casting process. it’s a strong and reliable machine, setting the standard for flexibility and efficiency.• Machine for sprue drilling with robot loading • drilling speed up to 13 mm/sec without deformation to wheel hub• flood or mist cooling through drilling tool• connection to standard chip conveyor

dhS – valve Stem handling System

the valve stem handling system is used for fully automatic sealing of the valve hole prior to helium leak test.• Gas-tight closing of valve hole with standard stems for helium leak

test machines• no individual programming of different wheel types necessary• Specially designed for helium leak test machines built by vdh

the Ref was developed to remove the flashes for reliable X-ray and roller table transport • Robot loading with mixed wheel types• deflashing of outboard, inboard and side/split flash• With optional laser contour measurement system

28

chucKinG technoloGY

chucking at 1st operation 3 inch Size

• chucking of up to 3 different inch sizes without changing procedure• Size detection system integrated into chucking system• chucking of all sizes at the same vertical height• high turning speed up to 2500 rpm for fast machining

chucking at 2nd operation

chucking at 1st operation

• chucking solutions with finger chucks for highest quality of wheels in respect of runout and imbalance

• different options for centring from inside our outside of the outboard flange

• construction and positioning of resting pad and chucking fingers create the ideal chucking situation for best wheel quality

• chucking sensors for detection of clamping errors

Workholding for drilling

• for the workholding at cnc bolt hole and valve hole drilling, a wide range of different types of workholding is available

• the tilting of the workholding for valve hole drilling can be done with cnc axis or with pneumatic control

• customized version available for machining of front- And backside of the wheel without unclamping

• Reduction of setup time with the use of step-jaws for 3-inch sizes

• chucking at the machined inboard flange with 3-jaw chuck with centrifugal force balancing for constant chucking force over the total rpm range

• for big size wheels and/or fragile wheel designs, 4 or 6 jaw chucks with up to 8-times higher stiffness with less chucking force available

• different jaw designs to avoid any deformation at the chucking process

29

SAfetY SeRviceS

30

civil AiRPoRtS

civil Aircraft Rescue & fire fighting training Simulator

the range of a single or hybrid design aircraft Simulators to meet the training needs of cAt 1-10 / index A-e Airports. live fire training for real world scenarios - fully customised designed simulators, from light aircraft to a wide-bodied, dual fuel, triple-decked aircraft simulator• icAo cAt 1 to 10 Aircraft Simulators• fAA index A-e Aircraft Simulators• customer focused design• Multi-fuel / electronic ignition / Plc control

locAl AuthoRitY / civil defence

lPG and carbonaceous fire training Simulator

Simulators designed to local authority’s/ civil defense specifications for a variety of applications, from sophisticated live fire simulators for fire and rescue training centers for fire departments to mobile/transportable fire training simulators. our range covers traditional block/brick/concrete or steel fire houses with internal lPG, carbonaceous and Kerosene fire Scenarios. demonstration, Attack and Window carbonaceous compartment fire training units and drill towers are also available.• domestic dwellings• Retail Premises• industrial Buildings• high-rise

induStRiAlMultilevel industrial fire training facilitiesMulti- level industrial / Petrochemical training complexes incorporating vessel, split flange, pipeline, fuel spill, and gas bottle fire scenarios. training rigs can be configured to any size or type of unit according to customer specification, from single level to multiple level complexes and large scale facilities with state-of-the-art fire simulation and control technologies.• vessel and tank fire Simulator• industrial Pipe and Split flange fire Simulator• fuel Spill fire Simulator

31

MARitiMeMaritime fire training unit and damage repair Simulators

Multi deck and multi-functional. they can accommodate areas for both basic and advance fire fighter training. A damage repair unit is also available. live fire training for real world maritime scenarios. configured to any size or type of unit according to customer specification, from small scale rigs to complex, large scale ship facilities with state-of-the-art fire simulation and control technologies.• engine rooms• Galleys• Bridge / deck• Ship doors / ladders / Access

oil & GAS

oil and Gas training Simulators

training rigs can be configured to any size or type of unit according to customer specification, from small scale rigs to complex, large scale facilities with state-of-the-art fire simulation and control technologies. Platforms, accommodation areas, helidecks, helicopters, pressure vessels, fuel spills, booster pumping stations, gathering centers, storage tanks, pump houses, pipelines and well heads • oil Storage tanks• industrial vessels

tRAininG SchoolS

international and domestic training Schools

MilitARYMilitary hybrid and Single Aircrafts

Simulators range is giving emergency and fire training crews the chance to practice tackling realistic fire scenarios in settings which are relevant to their needs. full range of fire training facilities: planning, general arrangements, detailed design: aircraft, fire house, industrial complex, ship simulators, fire screen/vessels, compartment fire training units, drill towers, high rise buildings, cars, road tankers etc.• Government / Private• Multiple fire Scenarios• centralised control and observation

State of the art technology for hot fire training simulators specifically designed for military applications. fully configurable to defense customer specification, variants can include multipurpose aircraft with large scale simulation features - such as jet fighter, helicopter and transport aircraft• transport Aircrafts• Jet fighters• helicopter

AlPine MetAl tech holdinG GMBhBuchBeRGStRASSe 11, 4844 ReGAu / AuStRiAtel.: +43 / 7672 / 78134-0, fAX: +43 / 7672 / 25429e-MAil: office@alpinemetaltech.com

www.alpinemetaltech.com