Machine tools for modern industries - Camozzi USA · companies in taking the most out of digital...
Transcript of Machine tools for modern industries - Camozzi USA · companies in taking the most out of digital...
Machine toolsfor modern industries
Company profile
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WE KNOWWHAT YOU DO,WE HAVE ALLTHAT YOU NEED
Innse-Berardi represents a land markfor the main sectors of “heavy mechanical engineering”: energy, earth moving,naval, mining, defense, aviation, aerospaceand railway; by making machines where performance and constant innovationare their strengths.The range of the Innse-Berardi solutionsincludes: big vertical milling machines,horizontal boring and milling machines;both in a hydrostatic and mechanicalversion, special machines that allowthe company to qualify as a strategicand technological partner that can offerits customers a complete turnkey service.
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INNSE FOUNDATION
1887
INGERSOLL FOUNDATION
1892
BERARDI FOUNDATION
1926
INNSE & BERARDI MERGE WITH THE CAMOZZI GROUP
1997
INNSE-BERARDI FOUNDATION
1999
FOUNDATION OF CAMOZZI MACHINE TOOLS
2004
INGERSOLL MERGES WITH THE CAMOZZI GROUP
2003
We make much morethan big machines.We provide great solutions
INNSE-BERARDI
OVER 130 YEARS OF EXPERIENCE IN THE MACHINE TOOL INDUSTRY
PRODUCTION AREA OF 47.000 SQUARE METERS
AN INTERNATIONAL NETWORKIN ORDER TO ENSUREASSISTANCE ALWAYSAND EVERYWHERE IN THE WORLD
A TECHNOLOGICAL PARTNER TO PRODUCE CUSTOMIZED SOLUTIONS
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Company profile
The synergy with the Camozzi Group,which the company is part of since 1999,has allowed Innse-Berardi to makeavailable all its richness in technical skills,methodology and R&D, coming fromthe different integrated production actualities.The skills range from the engineering fieldof production technologies – from metallurgyto industrial electronics, to the mechanical precision machining up to the process arrangement and management.The cooperation between the companiesof the Group makes it possible to manage different stages of the production chainwhich is completely Made in Italy.Whether it be an FMS or a “standard”machine, or a revamping or a single project,the result assured by Innse-Berardiis that the solutions provided perfectlymeet the customer’s requests and guarantees the maximum quality standards.
› AUTOMATION
› MACHINE TOOLS
› TEXTILE MACHINERY
› CAMOZZI SOLUTIONS PROVIDER
› INNOVATION
Camozzi Group divisions
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FACTORIES
COMMERCIALAFTER-SALES
A winning team, made upof men, productiontechnology and advancedmanagement processes
CAMOZZI GROUP
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Innse-Berardi
Within the Camozzi Group, Innse-Berardi, together with the American Ingersoll Inc. Company, is part of the CamozziMachine Tools division, specialized inthe production of medium large machinetools for machining aluminum, cast iron, titanium and steel. Besides the differentmodel types of medium and large sizedboring and milling machines and the large range of attachments and special heads, the Machine Tools division offers specific technological solutions for special machining such as railway switches, rotor turbinesor for laying carbon fiber composites inthe aviation industry. The Innse-Berardi machines are also equipped with IoTsoftware and solutions developed thanksto the expertise of the Innovation division, where the Camozzi Research Centerworks alongside with the Camozzi Digital, created to support manufacturingcompanies in taking the most out of digital innovation and to operate accordingto the technical-organizational standardsof the industry 4.0.
Industry 4.0
A mission: to createadded value by meansof skills and technology
MACHINE TOOLS DIVISION
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Company profile
Being a Solution Provider means that youhave to provide added value solutionsin terms of machinery, software and services.Innse-Berardi puts besides the mechanicaland hydrostatic machines the developmentof dedicated softaware and IoT solutionsmade in partnership with Camozzi Digitaland Microsoft, which allow to implementadded services, from the managementand analysis of the data related to the machine, up to the preventive maintenance.Furthermore, through the overhauling service, retrofitting and revamping, it is possibleto constantly optimize the performanceof the machines by adapting them, in time,to the market requirements.
IoT Technologies at the service of modern industry
COMPLETE SOLUTIONS
› ›IoT
SOLUTIONS FOR THE INDUSTRY 4.0
A SINGLE PARTNER WITH INDUSTRIAL AND DIGITAL EXPERTISE
VALUE PROPOSAL IN VIEW OF THE TOTAL COST OF OWNERSHIP
TECHNOLOGIES FOR SYSTEM PRODUCTIVITY INCREASE
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Innse-Berardi
INNSE-BERARDI REMOTE MAINTENANCE
INNSE-BERARDI. YOUR INDUSTRIAL PRODUCTIVITY BOOSTER
OVERHAULING RETROFITTING REVAMPING
SERVICE AND SPARE PARTS
Resetting of original machineperformances
Maintenance and modernizationto improve the machine performances
DEDICATEDMACHINES
RS
FCT
FMM
MECHANICALTECHNOLOGY
ZENITH VISION
ATLAS VISION
CERUTI VISION
HYDROSTATICTECHNOLOGY
ARIES 2 / 3 / 4 / 5 (FAF)
ATLAS 2 / 3 / 4
GENERAL MECHANICS, ENERGY, CHEMICAL / NUCLEAR, AVIATION / SPACE,
MARINE, EARTH MOVING, RAILWAY, IRON AND STEEL
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INNSE-BERARDI PRODUCTION MANAGEMENT
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Company profile
Organized to offer maximum efficiency in all working phases
PROCESS
To offer value to one’s own customers, meansto offer them something unique, expressly studied for the one specific application. This goal is well clear from the beginning. That’s why there are “Application Specialists” in Innse-Berardi,real application experts, that by working in partnership with the customer, they supporthim in studying the process, and transformingthe requirements into detailed technical specifications to be passed on to the Technical Department. That’s how every project startsand that’s how every solution starts to grow.
SalesEngineering
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ApplicationDepartment
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Preliminary Project Design
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ProjectDesign
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Job Order Begins
4 › ››››Specialized technicians,with many years ofworkpiece experience,will carry out a detailedstudy of the machining method so to finishdefining all the details.
After obtaining the order,the Commercial Department and the Sales Engineeringdept. will transfer allthe technical/commercial information over to the ProjectManager to begin the Job Order.
The machining processes,usually accompanied bythe physical availability ofthe workpiece or of the semi finished pieces, are analyzed by the Sales Engineering Service(SIV) and the customer.
Based on the results ofthe analysis, accordingto the previous point,the commercial department will complete the procedure by issuing a detailed offer including a preliminary project design.
The designers will define the technical details by using modern engineering devices and integrated PLM and a broad ERP system. Such technical details arethen taken over by the Production and Quality Departments.
FLEXIBILITY, EXPERTISEAND TECHNOLOGYAT CUSTOMER’S SERVICE
FROM THE APPLICATION ANALYSIS TO THE COMMISSIONING
TOTAL QUALITY GUARANTEEDFOR EACH PRODUCTION STAGE
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Pre-assembly6
Finalassembly
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Pre-testingand pre-acceptance
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FinalAcceptance
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Delivery and installation
9› › › ›The main machinesub-assemblies aremounted and, in manycases, pre-tested onthe bench before beingpassed over to the finalassembly phase.
The pre-acceptance functional testof the machine is carried out together with the customer, by checkingaccurately and by machining a workpiece according to NAS standards.During this step an intense trainingphase takes place in order toinstruct the customer on the useand maintenance of the machine.
Once the machine has been installed and tested, it is again subject to strict testing, which consists in repeating specific functional tests with the customer as well as the machiningof the final workpiece.
During this step the machinestarts to actually take shape.A team of specialized assembly technicians will carry outa complete assembly of the whole system in a dedicated areainside the Innse-Berardi plant.
The shipping documentsare prepared so to deliverthe machine tool atcustomer’s site.A team of technicians will then erect and start-upthe machine there.
MAXIMUM PRECISIONWITH NO DIMENSION LIMITS
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Company profile
CIS
LPSTQM
SCM
LEAN PHILOSOPHY
TOTALQUALITYMANAGEMENT
S U P P L Y C H A I NM A N A G E M E N T
Our productionis leanand intelligent
LEAN PHILOSOPHY
To operate with a full quality systemmeans to manage the production cycleand its related procedures on the basisof a “lean” approach , such application reflects on the company activitiesquite fully: from the designing ofthe equipment to the dimensional testing,from the tool presetting operationsto the inspection during machiningphases, from the maintenance operationsto the process stability analysis.The company flexibility reflects onthe ability to offer a modular approachto the designing and to produce allthe supplementary phases withinthe company, from the mechanical machining to the electronic equipment.
METROLOGYROOM
MACHINING IN TEMPERATURE CONTROLLED ENVIRONMENT
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Innse-Berardi
TOTALQUALITYMANAGEMENT
“Quality” for usmeans to go beyondall expectations
TOTAL QUALITY
where the temperature and the humidity are monitored. It’s equipped with a new generation CMM machine (Coordinate Measuring Machine) with which to check working volumes that are up to 8 x 3 x 2 meters. The job orders are managedby using specific software supportedby the SAP management.
Like all the other companies ofthe Camozzi Group, besides havinga certification according to the ISO 9001 standards, Innse-Berardi operates with a TQM system (Total Quality Management), according to which all the production phases, from the designing to the job order beginning phase, to the assembly production, are followed by strict quality and functional inspections.The same goes for the machine installation and start-up and it also includes specific training sessions for the operators. Dimensional quality inspections arecarried out thanks to a metrology room,
CMM(COORDINATE MEASURING MACHINE)
CRM
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Company profile
Intelligent systemsfor an intelligent company
MANUFACTURING 4.0
Recent developments in the field of digital technologies have led to the developmentof new models of companies that make of distributed intelligence and communication skills two essential elements. Accordingto the Industry 4.0 paradigms there areno machine tools, there are no warehouses, there are no systems that provide specific separated functions.Rather, there are Cyber Physical Systems (CPS) able to interact in an intelligentway, among themselves to exchange information, monitor each other and coordinate themselves autonomously.It is precisely in this view that theInnse-Berardi machines are designed and produced, like real Cyber Physical Systems capable of collecting process data by means of suitable sensing and telemetry on the main electromechanical parts and actuators (temperature, vibration, speed, acceleration,
cycle time etc.), and to communicate with the other components of the “factory system” through integrated communication solutions IoT (Internet of Things). Thus it is possible to monitor and analyze the main process KPI (Key Performance Indicators), as well as energy consumption, machine status and the efficiency of each individual element, detecting abnormal patterns or the appearance of statistical or recursive phenomena. Thanks to partnership with Microsoft, these applications can be usedin the cloud by using the Azure IoTplatform that, in addition to securityand consistency also makes available a setof standard services for the integration in the management circles of the company.
ANALYSIS OFPERFORMANCE OF
THE MAIN PROCESS KPI
ANALYSIS OF ENERGY CONSUMPTION, MACHINE STATUS AND EFFICIENCY
AZURE IOT
DETECTION OF ABNORMAL PATTERNS, DRIFTS OR
STATISTICAL / RECURSIVE PHENOMENA
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Innse-Berardi
Everything under control24 hours a day,always and everywhere
REMOTE MAINTENANCE
To prevent malfunction is far betterthan to repair and proper maintenance, especially in predictive procedure, allowsto always keep efficient the production assets. Thanks to a data capture system integrated in the machine control,the “remote maintenance” system developed by Innse-Berardi detectsthe operating parameters of the mostcritical parts and transmit it to a remote monitoring station thus anticipating the possible occurrence of operational anomalies. The users of the Innse-Berardi machines can therefore count on a H24 ongoing assistance that our technicians, although thousands of kilometers away,can guarantee in order to monitor the efficiency of the machine, reducing thusthe down times in favor of greater productivity and a longer life for the system.
CLOUD
ADVANCED ANALYTICS
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“Made in Italy” of 130 yearsOur productionis entirely Zero-Km
PRODUCTION
Anything that takes shape, from the idea to the project, from the single parts to the final assembly, is the total result of intellectual property and skilled labor of the “Made in Italy”, or better yet, of the “Made in Camozzi Group”. None of what is produced, even the smallest component, is made abroad. Even the cast ironcomponents are made in Italy by a company belonging to the Camozzi Group: Fonderie Mora Gavardo, and processed by Innse-Berardi making use of the same machine tools that areinstalled in the workshops of many prestigious customers worldwide. The same applies tothe manufacture of electric switchboardsand the hydraulic and pneumatic systems.Real zero-km production done with skillsand technologies.
MACHINE INSTALLEDIN INNSE-BERARDI
INSPECTION GUARANTEED OVER THE ENTIRE PRODUCTION CHAIN
OWN PRODUCTIONOF ALL COMPONENTSAND SUBSIDIARY CIRCUITS
PRODUCTION PROCESSES CARRIED OUT ACCORDING TO THE CAMOZZI GROUP QUALITY STANDARDS
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Innse-Berardi
MACHINING WITHINTHE COMPANY
BEDLINE
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Company profile
Our machines are strategic,just like the target sectors
MAIN MARKETS
Has always been present in thisfield, Innse-Berardi produces horizontal and vertical milling-boring machines, either with hydrostatic support, or which slide on linear guides and rollers, for machiningturbine cases and not only.In addition there are milling machines for generator rotor slotsor turbine rotor, also there arethe multi-spindle drilling machines for terminal and intermediate tube plates for heat exchangers.
From the machining requirements related to large diesel engines,to the gigantic transmission boxes. The “Marine” sectoris always a highlight for Innse- Berardi, which for decades supplies large machine toolsto all the major manufacturersof equipment, componentsand semi-finished pieces fitted on board of merchant ships as well as civil and military ships.
Innse-Berardi is able to offer different technological solutions for the aviation / aerospace industry, which include the machining of a number of aircraft components: fromthe landing gear in steeland aluminum, to the largesize components of the fuselageand ending with the main structures in aluminum, titanium or composite materials.
ENERGY MARINE AVIATIONAEROSPACE
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Innse-Berardi
One of the “hardest” and complex sectors, where reliability is one of the most important features because a plant shutdown may cause a loss of millions of dollars. In this sector Innse-Berardi has an extensive expertise ranging from the machining of structural components, frames, gearboxes, including engines.
EARTH MOVINGAND MINING INDUSTRY
In order to satisfy the needs of the railway sector, Innse-Berardi is able to offer machines either with a horizontal spindle or with a vertical spindle for machining locomotive engine blocks, bogies, the structures of the coaches, as well as the machining of rails and switches (frogs, tongue rail etc.)
RAILWAY
Perhaps it representsthe historical field in whichthe Innse-Berardi machinetools are always used:for machining cylinders, rollers, transmission elements, large mechanical parts and special equipment made of steeland cast iron.
IRON AND STEEL INDUSTRY, GENERAL MECHANICS
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Company profile
High speedmachines
MECHANICAL
PRODUCTS
• The structures are designed with an FEM analysis to ensure high rigidity, during high speed machining, and high accuracy
• Modular extension of the length of the axes
• Extremely rigid kinematic chains with backlash recovering system
• “C” axis built-in the RAM or in the attachment heads
• High speed travel of the axes and high spindle rpm
• Possibility of integration with complex production systems
• High flow and high pressure of coolant
• Rotary or turning tables
• Standard and custom attachment heads with 1 or 2 axes controlled by CNC
• Attachment magazine for automatic attachment changing
• Possibility of different configurations for the tool magazine from 30 to 500 seats
• Machine safety guards
• CNC: Siemens, Heidenhain, Fanuc, Fidia
• Measuring and inspection devices for the workpiece and for the tools
• Optical systems for the inspection and the measurement of the workpiece
• Geometrical compensation system
• Compensation, in real-time, of RAM elongation errors
• Monitoring of tools and process
• IBNET Innse-Berardi Production Management
• IBRM Innse-Berardi Remote Maintenance
ATLAS VISIONZENITH VISION M-T-PCERUTI VISIONHighlights
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Heavy-duty machineswith hydrostatic guideways
HYDROSTATIC
PRODUCTS
ARIESATLASHighlights
• The structures are designed with an FEM analysis
• Preloaded hydrostatic bearing system on all axes with prismatic guides
• High torque and power on the main spindle and on the attachment heads for heavy machining
• Extreme positioning accuracy for very good quality finishing
• Extremely rigid kinematic chains with backlash recovering system
• High RAM exit
• Electromechanical compensation, in real-time, of RAM flexion during the exit (ARIES)
• Balancing of RAM with and without attachment heads
• Adaptive control of technological parameters
• Geometric Adaptive Control
• Standard and custom attachment heads with 1 or 2 axes controlled by CNC
• “C” axis built-in the RAM or in the attachment heads
• Attachment magazine for automatic attachment changing
• Possibility of different configurations for the tool magazine from 30 to 500 seats
• CNC: Siemens, Heidenhain, Fanuc, Fidia
• Measuring and inspection devices for the workpiece and for the tools
• Optical systems for the inspection and the measurement of the workpiece
• Geometrical compensation system.
• Compensation, in real-time, of RAM elongation errors
• Machine safety guards
• Monitoring of tools and process
• IBNET Innse-Berardi Production Management
• IBRM Innse-Berardi Remote Maintenance
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High productionspecial machines
SPECIAL
PRODUCTS
• Thanks to different kinds of attachment heads and to machine versatility it is possible to carry out all the milling and drilling operations on generator shaft in one set-up
• Preloaded hydrostatic bearing on prismatic guideways
• High material removal rate by main slotting head, which is able to supply extreme torque value necessary to use large diameter disk cutters
• Automatic attachment changer
• Automatic tool clamping with coolant flow around and through the spindle
• High productivity rate thanks to the simultaneous machining with two opposite synchronized units
• Automatic tool clamping with coolant flow around and through the spindle
• Digital servo-motors and drives
• Complete monitoring of the machine
• High reliability with the possibility of tele-service/diagnosis
• High dimensional hole accuracy
• Fully automatic drilling operations
• Adjustable spindle pitch
• Complete monitoring of all drilling parameters: oil delivery, axial drilling thrust, drilling power
• Dedicated drilling cycles
• Operator graphic support
• Customized fixture design
• Independent operator platform
• Deep and accurate holes
RS Highlights
FCT Highlights
FMM Highlights
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Innse-Berardi
Tables andattachment heads
ACCESSORIES
ACCESSORIES
• Rotary tables
• Roto-traversing tables
• Turning tables
• Tilting tables
• Annular tables
TABLES
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1 / TUM Universal head with 2 continuous working axes
2 / TSAR Indexed right angle head
3 / SLIM Right angle narrow head
4 / TU Head with 2 continuous positioning axes
5 / UT Facing head
6 / TS Stationary right angle head
7 / TWI Universal Indexed head with two axes
8 / F Spindle extension
9 / TSAR Indexed right angle head
10 / TS-SL Right angle narrow head
11 / TOM Universal head with 2 axes
12 / TT Turning head
ATTACHMENT HEADS
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Company profile
An investmentthat lasts in time, very long-lasting
RETROFITTING REVAMPING AND OVERHAULING
All our machine tools are born to lastas long as possible over time and to assure customers that their investment will not onlyre-pay them under the terms established,but that will last so long as to becomean asset of fundamental importance duringthe company’s life. In order to guaranteea maximum duration of the investmentand fully meet also future customer needs, Innse-Berardi offers a series of technical assistance services that include, in additionto the maintenance, also overhauling or mechanical and / or electrical “regeneration”, revamping / retrofitting to modernizeand modify the performance of the machine adding new efficiency.
REVAMPINGPerformance improvement
ASSEMBLY OFELECTRIC PANEL
INNOCENTI CWB MACHINEBEFORE
INNOCENTI CWB MACHINEAFTER
INDUSTRIALPRODUCTIVITY BOOSTER
APPLICATION ANALYSISAND SYSTEM RECONFIGURATION
CONSTANT TECHNICALASSISTANCE FOR SYSTEM PERFORMANCE OPTIMIZATION
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Innse-Berardi
RAM HEADASSEMBLY
REVAMPING ALSORENEWS THE DESIGN
INNSE-BERARDI.PRODUCTIVITY BOOSTER
Camozzi Machine Tools worldwide
Innse-Berardi spaSocietà UnipersonaleVia Attilio Franchi, 20 25127 Brescia ItalyPh. +39 030 3706011Fax +39 030 [email protected]
Innse-Berardi GmbHPorschestrasse, 173095 AlbershausenGermanyPh. +49 7161 9101080Fax +49 7161 [email protected]
Innse-Berardi RuTverskaja ul., 20/1125009 Moscow Russian FederationPh./Fax +7 495 741 [email protected]
Innse-Berardi ShanghaiMachine Tools Trading Co. Ltd.Room 308, Italian center, 999 Ning qiao Rd.Jinqiao Export Processing ZonePudong, Shanghai 201206P.R. ChinaPh. +86 21 50315034Fax +86 21 50550076 [email protected]
Ingersoll Machine Tools, Inc.707, Fulton Avenue Rockford, 61103 Illinois USA Ph. +1 815 9876000Fax +1 815 [email protected]
www.innse-berardi.com
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