production of new machines overhauls modernizations accessories service horizontal boring mills

Transcription

1 production of new machines overhauls modernizations accessories service horizontal boring mills

2 ABOUT US HISTORY The company RETOS VARNSDORF s.r.o. has its registered office at the premises of the former manufacturer of Varnsdorf machine tools, company PLAUERT, which was founded by manufacturer Arno Plauert at the beginning of the 20th century. The manufacture of horizontal boring mills began in After World War II, one of the machine tools factory association satellites was formed from this firm, company TOS Varnsdorf. In time, the main manufacturing plant resettled to new premises, and the original premises were among others utilized for overhauls. This plant has been preserved until today, after a series of transformations. The company RETOS VARNSDORF s.r.o. was set up in March 1992, based on the aforementioned operation of overhauls of the horizontal boring mills manufacturer, a that-time state enterprise TOS Varnsdorf. It took over the programme of the centre and, at the same time, began with their own design and expansion of the portfolio of machines on which it does not perform overhauls only but also large reconstructions leading to significant upgrades. In the 20 years of its existence, the company introduced a number of successful upgraded models, some of which permanently form the bearing programme of the company for more than 10 years. TODAY The premises of the company, administration and manufacturing area is situated in the North of Bohemia at the border of Germany, at the edge of the Šluknov projection and Lužické mountains in the Varnsdorf municipality. 80 employees work in the company, and their professional structure corresponds with the strategic goals of the company, mainly the ability of our workers to satisfy individual needs of our customers, and present ideal technical solutions to them. For new designs we utilize computer technology to 100% with advanced CAD systems (Autodesk Inventor, AutoCAD, E-plan). The technological maturity diffuses from designing process into the manufacturing process and purchase process through direct link between the CAD systems and the information system Helios Orange. This solution enables flexible reaction to special requirements of our customers, significantly shortens the time and eliminates the error rate of job order implementation. In our work we fully continue in the traditions and experiences of the 105-year existence of the mother manufacturer, and we still closely cooperate mainly in the area of manufacture. WHP10CNC WHP10CNC is a contouring floor type of horizontal boring machine of original design of the company RETOS VARNSDORF s.r.o. It fully respects the requirements on high production productivity, with maximum consideration of safety and operation convenience, as well as thoughtfulness towards the environment. Spindle speed range 3000 rpm Headstock travel (Y) 2000 mm Column transversal travel (X) max mm Spindle travel (W) 710 mm modern design complete coverage of the group column / headstock maximal safeness of the operation optional travel of X axis rapid traverse - X=28 m/min; Y=24 m/min optionally RAM W100B-CNC W100B-CNC is a contouring table type of horizontal boring machine of original design. It is an option to the manually operated machine W100A, which has been produced for several decades. The machine has been designed according to the frequent customer s requests for redesign of the mentioned machine W100A to CNC model. Spindle speed range 3000 rpm Headstock travel (Y) 1220 mm Table longitudinal travel (Z) 900 / 1710 mm Spindle travel (W) 710 mm Table clamping surface max x 1500 mm x mm Table loading capacity max kg robust design travel in the X axis mm optionally fi tted by automatic toolchanger W100A Historically very successful type of conventional boring mill W100A was successively transferred from the mother manufacturer TOS Varnsdorf a.s. In the fi rst phase, from 2005, only in terms of manufacture, and since January 1, 2009, also including the distribution under the RETOS brand. Design of new machines and machines after overhaul was unifi ed to the most extent possible, in order to unify the operation, maintenance, servicing and use of spare parts. Spindle speed range 1120 rpm Headstock travel (Y) 1120 mm Table longitudinal travel (Z) 810 / 1250 / 1750 mm Spindle travel (W) 900 mm Table clamping surface max x 1500 mm x mm Table loading capacity max kg the last one standardly produced conventional machine of TOS Varnsdorf a.s. manufacture robust design travel in the X axis mm The company has more than 10-year experience with the application of quality control systems according to ISO 9001 / The management system is regularly audited and processes improved on continuous basis. FUTURE The strategic goal of the company is stable creation of profit in a long-term horizon. Long lasting satisfaction of our customers, tact and open mind are the prerequisites to this challenge. The company RETOS VARNSDORF s.r.o. intends to continue being a modern, stable and trustworthy company for its employees, suppliers and customers.

3 OVERHAULS NUMERICAL MACHINES In general, overhaul includes total disassembly of machine, exchange of bearings, seals, worn gear wheels, spindles, reinforcing of guideways with hardened steel plates (or their regrinding, if these are already on the machine), and their grouting with plastic material, complete machine geometry, replacement of covers, new electric installation and surface treatment. A necessary prerequisite is meeting the requirements of current legal regulations and technical standards, mainly in relation to the operational safety of the machine. All the machines mentioned herein are upgraded substantially, in order to enhance their technical level and technological capacities to the current requirements of machining process. Modern digital control systems are applied HEIDENHAIN (the itnc 530 series) and SIEMENS (SIN 840D), with rich capacities of technological programming. They further facilitate e.g. interconnection of the machine with the company internal network for easy maintenance and distribution of technological programmes, or for servicing and diagnostics of the control system. The driving units and motors used are SIEMENS and HEIDENHAIN, depending on the control system used. New electric installation of the machines consists mainly of TELEMECANIQUE components. The drives of individual axes are executed through clearance-free transmissions of the timing belts and ball screws. Drive of table rotation is secured by planet gears resp. harmonic gears ALPHA resp. HARMONIC DRIVE. Table rotation is considered an accurate positioning axis (in optional angle), with the exception of machine WFQ80NCA-CNC, where this axis is fully interpolation (allows machining on cylindrical surface). Individual moving groups are usually hydraulically clamped. Regardless the aforementioned parameters, all machines are available in a design with non-sliding spindle to 5000 rpm, or with motor spindle with parameters specified by customer. Upon customer request, the machines can be equipped with automatic toolchanger (ATC), tool cooling kit (HCZ), oil-mist cooling, cooling through spindle axis (CHOV), workpiece cover, swarf conveyor or additional accessories, such as touch probes, milling heads, extra rotary tables, clamping angle plates, etc. The scope and design vary according to the type of the machine. WFQ80NCA-CNC Workspindle diameter - mm Spindle speed range 5000 rpm Headstock travel (Y) 1020 mm Column longitudinal travel (Z) 950 mm Table clamping surface 850 x 850 mm x mm Table clamping surface + additional supports 850 x 1600 mm x mm Table loading capacity + additional supports 5000 kg the only one machine of our production considered to be a machining centre cross-shaped beds non-sliding spindle up to 5000 rpm fully powered B axis - table rotation (allows vertical lathe-turning) rapid traverse of 17 m/min headstock balancing hydraulic fi tted by automatic toolchanger with tool changing time of 10 s (from cut to cut) by default WHN9-CNC, WH10NC-CNC Spindle speed range max rpm Headstock travel (Y) 900 / 1150 mm Table longitudinal travel (Z) 1200 mm Table transversal travel (X) 950 mm Spindle travel (W) 710 mm Table clamping surface 1000 x 1120 mm x mm no matter what the original type is (from WHN9A to WH10CNC) the machine after upgrade reaches parameters comparable to the new one new or upgraded headstock up to 2500 rpm is used optionally non-sliding spindle up to 5000 rpm WHO11NC-CNC Workspindle diameter 112 mm Spindle speed range 3500 rpm Headstock travel (Y) 1470 mm Table longitudinal travel (Z) 1500 mm Spindle travel (W) 450 mm Table clamping surface 1250 x 1400 mm x mm Table loading capacity 4500 kg size between WH10NC-CNC and WHN13-CNC sliding spindle up to 3500 rpm for continuous run and up to 4000 rpm for short-time operation optionally non-sliding spindle up to 5000 rpm optionally fi tted by automatic toolchanger with tool changing time of 10 s (from cut to cut) WHN11-CNC Workspindle diameter 110 mm Spindle speed range 900 rpm Headstock travel (Y) 1250 mm Column longitudinal travel (Z) 1000 mm Spindle travel (W) 630 mm Table clamping surface 1250 x 1250 mm x mm Table loading capacity 8000 kg cross-shaped beds

4 OVERHAULS NUMERICAL MACHINES WHN13-CNC Workspindle diameter 130 mm Spindle speed range max rpm Headstock travel (Y) 2000 / 2500 / 3000 mm Column longitudinal travel (Z) 1250 mm Table transversal travel (X) 2000 / 3500 mm Spindle travel (W) 800 mm Table clamping surface max x 2200 mm x mm Table loading capacity kg cross-shaped beds no matter what the original type is (from WH13 to WHN13CNC) the machine after upgrade reaches parameters comparable to the new one new headstock up to 3300 rpm is used optionally non-sliding spindle up to 5000 rpm optionally fi tted by automatic toolchanger with tool changing time of 10 s (from cut to cut) OVERHAULS CONVENTIONAL MACHINES In general, overhaul includes total disassembly of machine, exchange of bearings, seals, worn gear wheels, spindles, reinforcing of guideways with hardened steel plates (or their regrinding, if these are already on the machine), and their grouting with plastic material, complete machine geometry, replacement of covers, new electric installation and surface treatment. A necessary prerequisite is meeting the requirements of current legal regulations and technical standards, mainly in relation to the operational safety of the machine. Besides standard works, associated with overhauls, the engine lubrication systems of most machines is reconstructed, and modern metering systems are applied. The scope of works is individual on every machine, depending on the specific type, model or customer requirement. In no case these machines are upgraded in the sense of reconstruction to CNC controlled machines. HP100 Spindle speed range 1120 rpm Headstock travel (Y) 1600 / 2000 mm Column transversal travel (X) up to the beds mm Spindle travel (W) 900 mm fl oor type option to the W100A it is possible to manufacture a new machine (parts of W100A are used) WH63, WH80 Workspindle diameter mm Clamping taper 4 5 Morse Spindle speed range rpm Headstock travel (Y) mm Table longitudinal travel (Z) mm Table transversal travel (X) mm Spindle travel (W) mm Table clamping surface 800 x x 1090 mm x mm Table loading capacity kg own crane equipment mounted on the column W75 Workspindle diameter 75 mm Clamping taper 40 ISO Spindle speed range 1800 rpm Headstock travel (Y) 900 mm Table longitudinal travel (Z) 1000 mm Table transversal travel (X) 1250 mm Spindle travel (W) 560 mm Table clamping surface 950 x 950 mm x mm separate motors for driving of spindle speed and of feeds / of rapid traverses ISO 40 clamping taper W9, W9A Workspindle diameter 90 mm Clamping taper 40 ISO Spindle speed range 1400 rpm Headstock travel (Y) 1120 mm Table longitudinal travel (Z) 1400 mm Table transversal travel (X) 1250 mm Spindle travel (W) 710 mm Table clamping surface 1000 x 1120 mm x mm smaller option to the W100A ISO 40 clamping taper optional design with removable facing head

5 W100A, W100, H100A Clamping taper Morse 6 / ISO 50 Spindle speed range 1120 rpm Headstock travel (Y) 1120 mm Table longitudinal travel (Z) 1250 / 1750 mm Spindle travel (W) 900 mm Table clamping surface max x 1500 mm x mm Table loading capacity max kg robust design travel in the X axis mm almost indistinguishable from he new machine the same parameters as the new machine has the same range of accessories as the new machine has ACCESSORIES RT05 CNC rotary table of the original construction is designed as an accessories for the WHP10CNC machine or other machine tools. It is planned to integrate the controlling of the table into the controlling system of the machine. Table loading capacity - rotation 5000 kg Table loading capacity - static 8000 kg Table clamping surface 1250 x 1250 mm x mm Z longitudinal travel of table 1000 mm Table weight 4000 kg Basic dimensions - lenght 2600 mm Basic dimensions - width 1250 mm Basic dimensions - high 850 mm MT03 Manually operated rotary table of the original construction is designed as an accessories for machine tools. It is planned to clamp the table to an clamping plate. The control of the table is independent on the controlling system of the machine. Table clamping surface 1250 x 1250 mm x mm Table weight 1800 kg Basic dimensions - lenght 1800 mm Basic dimensions - width 1400 mm Basic dimensions - high 400 mm AVN R01-60, R02-60 Automatic toolchanger of the original construction is designed for machines WFQ80NCA-CNC, WHN13-CNC and WHO11NC-CNC. Installation is planned during overhaul or upgrade of the machine in RETOS. Additional installation of equipment to an older machine or machine after overhaul is not possible, without the electric installation reconstruction and adaptation of the mechanical parts. For WFQ80NCA-CNC and WHO11NC-CNC, the device is not compatible with the original design of the workspindle. Tool changing time 10 s Number of tools 60 pcs Pitch of beds 130 mm Maximal tool diameter 200 mm Maximal tool lenght 500 mm Maximal tool weight 25 kg Maximal weight of tools in magazin 1120 kg Operating air pressure 5 bar Weight 1500 kg Equipment advantages: tool changing time of 10 s (from cut to cut)

6 SERVICE MEASURING AND OPTIMISATION OF GEOMETRIC ACCURACY OF THE MACHINE We measure geometric accuracy of horizontal boring mills manufactured by TOS Varnsdorf a.s. and RETOS VARNSDORF s.r.o. using a modern laser interferometer RENISHAW XL-80, in combination with measuring system for NC and CNC machines RENISHAW BALLBAR QC10. Why? accurate and reliable machine is one of the basic building stones of fi rst-rate manufacture poor-quality machine does not necessarily cause production of rejects however has essential infl uence on labour productivity there are various causes of occurrence of poor-quality products, apart from machine error tool error, mistake on the drawing, inconvenient technology, operator s fault, error in NC programme, etc. - the wider the portfolio of potential causes is, the more diffi cult and longer is their analysis - it certainly is good to know that the machine is not the cause of it. Area of application Laser XL-80 - CNC and also conventional machines Ballbar QC10 - CNC machines with possibility of circular interpolation Measuring options straightness of movable groups guidance evaluation of mutual perpendicularities of movable groups evaluation of metering system errors and inaccuracies diagnostics of clearances in movable groups drives diagnostics of movable groups drives adjustment Results of measuring expert opinion of technical condition of machine summary of results in clear charts and tables evaluation of results according to the ISO 230-2, VDI / DGQ 3441 and ČSN standards Final status - target optimisation of geometric accuracy of basic machine hardware balance, perpendicularity, limitation of clearances optimisation of metering accuracy linear and non-linear correction of metering systems machine dynamics optimisation accuracy of machining, starting up to position elimination of machine hardware imperfection impact on accuracy of machining The condition of measuring execution is functionality of the machine, machine readiness and measuring environment (cleanliness, stable temperature). SPARES We provide manufacture, sales and distribution of spare parts and technical documentation for machines of TOS Varnsdorf a.s. and RETOS VARNSDORF s.r.o. manufacture for the territory of the Czech Republic and abroad. Machines of TOS Varnsdorf a.s.: all NC and CNC machines, older than 10 years all conventional machines, regardless the year of manufacture for H100, H63(A) and H80(A) machines, spare parts are not supplied as standard (solved individually) Machines of RETOS VARNSDORF s.r.o.: all machines, regardless the year of overhaul / upgrade for H100, H63(A) and H80(A) machines, spare parts are not supplied as standard (solved individually) CUSTOMER SERVICE We provide customer service of machines manufactured by TOS Varnsdorf a.s. for the territory of the Czech Republic and abroad. Machines of RETOS VARNSDORF s.r.o.: warranty and post-warranty service customer service, incl. supplies of spare parts all machines, regardless the year of overhaul / upgrade

7 Machines of TOS Varnsdorf a.s.: post-warranty service exclusively, upon the customer s request service, incl. supplies of spare pars all conventional machines selected CNC machines excl. currently manufactured types of SPEEDTEC, TOSTEC, WRD130/150, WH105CNC and WHN110/130 series QUALITY MANAGEMENT Certifi cate TÜV ISO 9001 ISO ISO Why we have ISO... The company management system certifi cation enhances competitiveness of the company, both inland and also abroad. In many cases, it is the prerequisite of participation in tenders, especially at companies with foreign capital. The certifi cation facilitates issue of Declaration of Conformity, without the attendance of the authorized person. In the area of ecology, we consider elimination of negative impacts on environment our moral duty, as well as minimisation of direct stress on employees within the manufacturing process. Certifi cate TÜV ISO History In 1999 the company RETOS VARNSDORF s.r.o. was granted Quality Certifi cate by TÜV Anlagentechnik GmBH, according to ČSN EN ISO 9001:1994. In 2001, the company extends Quality Management by the area of ecology and obtains Certifi cate according to ČSN EN ISO 14001:1997. In 2002, the company passes successful audit according to revised standard ČSN EN ISO 9001:2001. In 2006, the company passes successful audit according to revised standard ČSN EN ISO 14001:2005. In 2006, RETOS passes over to certifi cation company TÜV International s.r.o. - COTI to be certifi ed according to ČSN EN ISO 9001:2001. In 2007, RETOS passes over to certifi cation company TÜV International s.r.o. - COTI to be certifi ed according to ČSN EN ISO 14001:2005. In 2009, audits are associated for the purposes of QMS & EMS management. In 2010, the company changed over to the ČSN EN ISO 9001:2009 standard. In 2012, the company passes succesful recertifi cation audit valid to 2015.

8 COMPANY DIRECTOR Ing. Jan Müller tel./fax: PRODUCTION DIRECTOR Petr Ramisch tel.: ext ramisch.petr@retos.cz COMMERCIAL DIRECTOR Ing. Irena Rumlenová tel.: fax: rumlenova.irena@retos.cz FINANCIAL DIRECTOR Ing. Jaroslav Charvát tel.: ext charvat.jaroslav@retos.cz TECHNICAL DIRECTOR Petr Litava tel.: ext litava.petr@retos.cz HEAD OF PURCHASING Václav Stehlíček tel./fax: stehlicekml.vaclav@retos.cz ReTOS Varnsdorf s.r.o. Žitavská Varnsdorf ID No.: TAX ID No.: CZ What is our activity Our company covers complete portfolio of services associated with operation of horizontal boring mills of TOS Varnsdorf a.s / RETOS VARNS- DORF s.r.o. in machinery production. From the delivery of new or recycled machine, overhauls, partial or medium repairs, consultancy and customer service, up to delivery of spare parts, accessories and accompanying documentation. It focuses mainly on domestic and Western Europe markets, but delivers also to Canada, US, Russia, China and Australia. Manufacture of new machines: conventional machines long-term success of type W100A, taken over by mother manufacturer TOS Varnsdorf a.s. CNC machines - novelty of the company s own design, WHP10CNC fl oor type boring mill of medium size and W100B-CNC table type boring mill. Overhauls: portfolio of machines covers the manufacturing programme of TOS Varns dorf a.s. and, approximately since 1995 includes conventional and also NC or resp. CNC machines the parameters and technological capacities of CNC machines after upgrade are comparable to those of new machines in their category complete overhauls and upgrade are executed exclusively in the manufactu ring premises of RETOS in Varnsdorf Partial repairs: overhauls of selected machine nodes in the manufacturing premises of RETOS overhauls of mechanical part of machine in the manufacturing premises of RETOS upgrade of electric equipment at customer Servicing: warranty and post-warranty service of machines delivered by us customer service of older machines manufactured by TOS Varnsdorf a.s. check and optimization of machine geometry using the classic method (conventional gauges), or using laser interferometer Spare parts & documentation: spare parts supplies for machines of TOS Varnsdorf a.s and also of RETOS VARNSDORF s.r.o. sale of technical documentation for all RETOS and TOS machines of more than 10 years of age M STUDIO 08/2012 errors and omissions excepted