Gantry Machining Center : This machine tool is a high-rigidity, high-precision gantry machining center, specifically designed for processing various steel and aluminum parts. It operates smoothly and with precise positioning. In line with the characteristics of machining and the demands of modern high-precision and high-efficiency processes, this machine tool is designed and manufactured using integrated mechanical, electrical, and hydraulic technologies, along with new technologies in modern machine tool development. It can perform both rough and precision machining, demonstrating strong, efficient, and continuous machining capabilities during roughing. During precision machining, it ensures superior surface quality and accuracy. The machine tool's overall structure is designed using the internationally advanced finite element method in collaboration with Southeast University, offering excellent load-bearing capacity, scientifically distributed stress, and high stability. The design ensures ample overload margin and a high safety factor, making it highly resistant to impact and capable of operating continuously for three shifts without stopping. The machine tool boasts a high-rigidity structural design, reliable stability and retention, and comprehensive accessories. Its parts are modularly designed with a high standardization level, offering excellent interchangeability and consistent quality. The machine tool is advanced in design, reliable in performance, easy to operate, and convenient for maintenance. Additionally, the machine tool incorporates advanced European equipment and processes, featuring a high-rigidity frame structure that not only facilitates robust cutting but also meets the machining needs of precision components.

1. High rigidity structure
(1) The bed is made of precision HT300 high-quality resin sand cast iron. After secondary aging treatment with thermal aging and vibration aging. The overall structure of the machine tool consists of a closed rigid frame structure consisting of a bed, double columns, and fixed crossbeams. The workbench moves longitudinally along the bed guide rails (X-axis), and is equipped with a vertical high-power multifunctional sliding pillow milling (boring) head on the fixed crossbeam. The milling and boring head slide moves horizontally along the crossbeam guide rails (Y-axis) and the sliding pillow boring and milling head moves up and down (Z-axis)
(2) The main basic components of the machine tool, such as the bed, workbench, column crossbeam, lateral sliding plate, milling head slider, etc., are all made of high-strength cast iron and resin sand molding, which has good shock absorption, thermal stability, and high structural strength and rigidity of the entire machine. The Y-axis two guide rails are designed and optimized using finite element analysis to achieve maximum rigidity and stability.
(3) The door frame of the machine tool is an integrated casting structure, with excellent rigidity.
(3) The design of a wide base and two X-axis guide rails makes the machine tool stable like a rock, with excellent rigidity.
(4) The standard nitrogen balance greatly reduces the thermal extension of the Z-axis screw, thereby improving the processing quality.

2. High precision and high specification screw
(1) The three-axis machine tool is equipped with Japanese THK screws as standard, and hollow screws can also be selected for maximum protection
Verified the accuracy of the machine tool.
(2) The diameter of the three-axis screw of the machine tool is 80/63/63mm, and the lead is 20/12mm.
(3) The three-axis servo is connected directly to the screw, greatly controlling the conduction gap.

3. High precision heavy-duty guide rail
(1) The X-axis adopts two 55mm heavy-duty roller guides to ensure heavy load.
(2) The Y-axis adopts three 55mm heavy-duty roller guides, ensuring the stability of Z-axis movement.
(3) The Z-axis adopts two 55mm and two 45mm strips, ensuring the smoothness and high rigidity of heavy load re cutting.

4. Comprehensive testing
(1) The machine tool adopts RENISHAW's laser interferometer and ball and rod tester from the UK to ensure linear motion of the machine tool
Accuracy and dynamic response performance. The spindle and spindle motor are dynamically balanced by a spindle vibration meter to ensure the smoothness of high-speed motion.
5. Beautiful, high-end, and safe electrical design
(1) The electrical design fully complies with CE standards. The use of imported cables effectively reduces the impact of electrical interference, while also adopting
Using European circuit design and manufacturing standards, the electrical appliances are stable and easy to maintain.
6. Tool cooling system
(1) The tool cooling system adopts an external circulation method, and the coolant flows into the chain plate elevator at one end of the bed through the spiral chip removal groove on both sides of the bed. After filtration and separation, the coolant flows into the coolant box on the elevator, and then is transported to the cooling nozzle at the spindle position by the coolant electric pump.
7. Smooth chip removal system
(1) The machine tool bed is equipped with spiral chip conveyors on both sides, which can transport the processed iron chips to the chain plate lifting device at the front end of the machine tool bed. The lifting device is equipped with a cutting fluid water tank, which is equipped with a high head coolant pump. The high head water pump transports the purified cutting fluid to the end of the spindle, which has multiple cooling nozzles. The cooling nozzles spray the cutting fluid onto the tool to cool it. The debris is collected by the elevator and transported to the recycling truck.
8. Lubrication of machine tool guide rails
(1) The lubrication of each axis guide rail adopts a central integrated self timed quantitative lubrication system, which is automatic lubrication and may experience pressure loss
And oil shortage safety protection.
9. Protection form
(1) The X-axis guide rail of the machine tool is protected by a stainless steel telescopic protective cover.
(2) The Y-axis guide rail of the machine tool is protected by a telescopic organ protective cover.
(3) Install maintenance ladders and protective railings on the gantry frame.
(4) The X, Y, and Z axes are equipped with drag chain protection devices.
10. CNC system
(1) The CNC system adopts the Japanese HEIDENHAIN TNC640 model or Siemens D828 D842, Fanuc i30, i0, with a standard tool tip following, which is particularly suitable for the processing of molds and aviation structural components.
11. Electric control auxiliary device
(1) Fully enclosed constant temperature electrical cabinet, standard protection, sealed and dustproof, equipped with lighting inside the electrical box.
(2) The main operation station can conveniently perform various operations and controls, and is equipped with an electronic handwheel. The machine tool is equipped with servo system overload automatic protection and alarm devices, as well as mechanical power outage protection devices.
(3) Set software limits for each motion axis of the machine tool.
Notes:
(1) Machine tool power demand: 80KVA, the machine tool has leakage protection and power outage protection.
(2) Three color indicator lights for the working status of the machine tool.
(3) The machine tool noise meets national standards.
(4) Three phase AC power supply: 380V ± 10%, -15%; 50Hz ± 1Hz.
(5) Environmental temperature: 10-30C º.
(6) Relative humidity: ≤ 80%.
Air source pressure: 0.6~0.8 MPA

TNC 640 CNC System
Intelligent solutions meet demanding application requirements
24 control loops (22 with safety features), including up to 4 spindles
Multi touch display screen version
Milling, turning, and grinding processes
User friendly HEIDENHAIN Klartext conversational programming or G-code programming
Rich processing and detection cycles
High speed program segment processing speed (0.5 ms)
High performance, high surface quality, and high precision
Dynamic collision monitoring function, higher safety and reliability
Detailed parameters
 CNC System HEIDENHAIN TNC640
(2) Display:  English 19″
(3) CFCF card interface, portable operating system 
2.  Work trip  
(1) x (x-axis)   3100 mm
(2) y (y-axis)  2200 mm
(3) z (z-axis) 800 mm
(4)  (Spindle nose to table)  150~800 mm
3.   
(1) (Table size) 3000X1500 mm
(2) (Max. loading capacity)  8 t
(3) T (Size of T-slot) 28x200x7 mm
(4)（Width between two columns） 1700 mm
4. (SPINDLE)  T70 HEIDENHAIN  MEPRO 
(1) (Spindle speed) 10000 rpm
(2) (Spindle taper) HSK-A100 
(3) (Spindle motor)  54 kw
(4) S1（Spindle torque） 200 n.m
(5)4（Spindle center water cooling） 3 mpa
(6) A（A Axis Rotation Range） -110-+110 
(7) C（C Axis Rotation Range） -360-+360 
5. (SLIDE WAY)   
(1) x (x-axis)  （2guide rail） 55X2 P
THK ( THK Japan) mm
(2) y (y-axis)  （3guide rail） 55x3P
THK   ( THK Japan) mm
(3) z (z-axis)   （4guide rail） 55x2+45*2P
THK   ( THK Japan) mm
6. （Driving screw）  
(1) (Ball screw accuracy) C3 
(2) (Ball screw diameter x.y.z)  80/63/63（THK） mm
(3)（Three-axis lead） 20/12 mm
(4)（Motor connection）  (Connected through a coupling) 
(5)（Number of bearings at both ends） 8/7/6 pcs
7. （Three-axis motor）  
(1) x (x zaxis motor) 11KW       62  n.m
(2) y (y zaxis motor) 9KW        47 n.m
(3) z (z zaxis motor) 9KW        47(brake) n.m
8. (FEED RATE)   
(1) X (x  axis rapid feed rate) 12000 mm/min
(2) Y (Y  axis rapid feed rate) 12000 mm/min
(3) Z (Z  axis rapid feed rate) 12000 mm/min
(4) (Three-axis cutting feed rate) 0-10000 mm/min
9. ( tool )  
(1) (Max. tool length) 300 mm
(2) (Max. tool dia) Ø120 mm
(3) (Max. tool weight) 8 kg
(4) (Tool specification) HSK 
(5) （Maximum number of tools） 24 pcs
(6) （Tool change time） 6 s
10. （VDI/DGQ3441）  
(1) (Positioning)  0.010／1000 mm
(2) (Repeat positioning)  0.006／1000 mm
(3) (Least input increment)  0.001 mm
10.   
(1) (Power Capacity) 100 kva
(2) (t weight)  30 t
(3)(Packing  8000x3400x4500 mm

Our equipment is distributed across Turkiye, Europe, and the USA. We work exclusively with renowned machine manufacturers who utilize only top-tier components. This commitment to quality guarantees the longevity and reliability of our welding machines.

 

When you choose a machine from our catalog, you not only receive a premium product but also enjoy a comprehensive warranty, expert consulting, in-depth training, and ongoing maintenance. If you'd like more information about our laser beam welding machines, please reach out to our knowledgeable managers.

 

**Understanding the Laser Beam Welding Process**

 

Laser beam welding relies on specialized equipment that enables the creation of high-quality joints at remarkable speeds. The welding occurs through the heating and melting of the metal being processed, facilitated by a laser beam that penetrates the material. The equipment generates a consistent light flux, and the desired focus is achieved using guide mirrors and focus lenses.

 

Here’s a brief overview of how the laser welding process unfolds:

 

- **Connection of Parts:** The parts to be welded are pressed tightly together and securely fixed at multiple points on the machine's worktable.

- **Laser Setup:** The machine’s head is positioned precisely over the area designated for the welding seam.

- **Activation of the Generator:** The operator activates the machine, triggering the heating, melting, and vaporizing of the particles.

 

The laser beam’s small cross-section allows it to reach and fill even the tiniest cavities and irregularities in the material, resulting in a smooth and uniform joint seam. This feature is distinctive to laser beam welding. Furthermore, the swift movement of the laser beam minimizes the time available for oxidation to occur in the metal.

 

With laser beam welding, you can achieve two primary types of connecting seams:

 

- **Full Penetration Weld:** Ideal for welding stainless steel pipes.

- **Intermittent Weld:** Suitable for welding smaller parts with surface imperfections.

 

**Welding Different Materials**

 

Each metal possesses unique characteristics that must be considered during the laser beam welding process. It's advisable to pre-clean any materials prior to welding, particularly those that are susceptible to corrosion. This can be easily accomplished using a standard stainless steel brush.

 

- **Titanium:** When welding titanium parts, pre-cleaning is essential. This can be achieved through sandblasting, followed by etching, washing, and treating the metal with helium.

 

- **Aluminum:** Given its tendency to oxidize and release volatile elements, it is recommended to etch aluminum and treat it using a hand scraper.

For more personalized advice or specific queries, feel free to contact us at (info @ mecanicacnc.com )

 

**Galvanized Steel Welding Guidelines**

 

When it comes to welding galvanized steel, as well as brass and other zinc-containing alloys, a handheld laser machine is not suitable. This is primarily due to the potential release of harmful volatiles. While it is possible to weld these materials using a laser, it necessitates a robust exhaust system to ensure safety.

 

**Choosing the Right Laser Beam Welding Machine**

 

At Virmer, we prioritize our customers' needs and aim to assist you in selecting the laser welding equipment that aligns perfectly with your production requirements. To facilitate your decision-making process, we have outlined key factors to consider when purchasing laser beam welding machines.

 

**Laser Emitter Considerations**

 

The choice of laser emitter hinges on two critical parameters: power and brand.

 

- **Power**: Select the power level based on the thickness and type of metal being processed. For welding materials up to 3 mm thick, a 1000 W emitter will suffice. If you’re dealing with thicker materials, higher power equipment is essential.

 

- **Brands**: The following laser emitter brands are highly recommended:

 

  - **Leader Brand**: Known for high precision and double beam protection, this brand delivers top-notch quality.

 

  - **Affordable IPG Alternative**: While slightly less effective, this brand offers high-quality laser emitters at a lower price point. It works particularly well for aluminum welding.

 

  - **Versatile Manufacturer**: This brand specializes in welding various metal types, excluding non-ferrous metals.

 

  - **Budget-Friendly Option**: Ideal for production that focuses on aluminum and stainless steel, this brand delivers solid performance without breaking the bank.

 

All these laser emitters are capable of high-quality welding, making them excellent choices to consider as you select your welding equipment.

 

**Types of Equipment Heads**

 

Laser welding heads come in two configurations:

 

1. **Single Engine Block with Focal Lenses**: This setup generates a laser beam with a spot diameter of up to 5 mm, making it ideal for welding thicker metals. It’s advisable to pair this equipment with a wire feeding system for optimal results. The weight of this head is around 0.8 kg.

 

2. **Dual Engine Blocks with Focal Lenses**: This version is designed for welding elements up to 1 mm thick, ensuring high-quality results through oscillation. This head weighs up to 2 kg.

 

By understanding these specifications and brands, you'll be better equipped to choose the right laser welding machine for your needs.

For the first version, the weight of the head is up to 0.8 kg, for the second – up to 2 kg.

Certainly! Here’s a rewritten version of the text with a professional and informative tone:

**Cooling System** 

High-quality laser beam welding machines are equipped with double-circuit chillers that effectively cool both the laser emitter and the welding head. Investing in a laser machine with this advanced cooling system guarantees an extended service life.

 

**Overview of Mecaica Laser Weld Machine** 

The Mecaica laser weld machine is specifically designed for manual laser welding. It is capable of processing various metals, including:

- Aluminium

- Titanium

- Stainless steel, galvanized steel, and carbon steel

 

This machine is available in four configurations, featuring laser sources with power options of 1500W, 2000W, and 3000W. Customers can choose between two emitter brands: Max, which comes standard in the basic model, and Raycus.

 

With dimensions of 1120x550x1120 mm, the machine is outfitted with a dual-motor welding head and a programmable control system that allows for precise adjustments of weld seam type and thickness.

 

The Mecaica laser weld machine ensures high-quality and durable welding by eliminating material deformation during the process, thus negating the need for mechanical post-treatment. This efficiency translates into time savings for users.

 

Designed for ease of use, the machine is accessible to operators without extensive training. To initiate the welding process, simply secure two metal objects in multiple locations and begin.

 

Our clients rely on the Wattsan laser weld machine for the production of:

- Electronics

- Doors

- Elevators

- Spare car parts

 

Additionally, it finds applications in both the automotive and aerospace industries.

If you need further customization or additional details, feel free to let me know!

24- axis CNC machining centre, designed to perform milling, drilling and cutting operations for aluminium profiles. It is made up of an automatic magazine and a thrust feed system for profiles sized up to 6500 mm complete with profile clamping gripper drive and servo motors.

 

-      In the central machining part, there is 4 spindle motor that one is at upside, one is at downside, one is at left side and one is at right side. Machine also has laser machining head and left and right side of the machinery.  The CNC milling module is equipped with 4pc electrospindles and 2pc Laser head, which are enables at the left and right side of the workpiece to be machined,from top, down, back and front faces of profiles. The CNC 3-axis cutting module is made up of 3 pcs of Ø550 mm saw blades, with fixed angle of +/-45°and 90°. You can also select one 550mm blade which can turn all angless from 45 to 135 degree as well.

-      MLM 6500 HAWK also comprises an automatic outfeed conveyor unit leading from the cutting unit to the unloading magazine. The unit is made up of a magazine with transverse belts for unloading machined work pieces.

 

-      The Cutting unit with numerically controlled horizontal feed, with dia.550 mm blade and a wide cutting range: -45° , +45° and 90° and all angles automaticly. . The cutting angle setting is fully automatic; the unit movement is controlled by a 3-axis CNC.

 

-      Automatic bar feed and workpiece unloading Numerically controlled, high precision and high speed bar positioning system. The system is complete with a gripper to block the profile with automatic feed into the center station. The loading and unloading belt magazines are used to load profiles with length of up to 6.0 m and offload lengths of up to 4.0 m.

 

-      Milling unit is fitted with an exclusive left-right-up-down-left angular and right angular on which the spindle motor head and laser head work units interpolated on 12 axes can operate at the same time: X, Y, Z, A

 

-      The high-speed electrospindle is air-cooled, and Laser heads with air compressor connections. Air compresor is included inside the scope of supply of the complete line.

-      Barcode printer is industrial type and it allows each cut profile to be identified with identifying features from the cutting list. In addition, barcode printing enables easy identification of the profile itself, which is particularly useful for subsequent machining steps on Machining Centres or assisted assembly lines.

Aluminium Profile Shot Blasting Machine by PromaX Makine

Aluminium 4 head crimping machine for fast aluminium profile windows production. 2200 x 2700 mm wider corner crimping machine. 23 axis servo motors, as automatic system.

f

Manufacturing Process of Aluminum Frames for Solar Panels

Solar energy has emerged as a vital solution in the global quest for sustainable energy sources. Among its key components, solar panels stand out as crucial instruments harnessing sunlight and converting it into electricity. Within the intricate anatomy of solar panels, the aluminum frame serves as a foundational element, providing structural integrity and support. Understanding the comprehensive process involved in the production of aluminum frames for solar panels offers insights into the meticulous craftsmanship and technological advancements driving renewable energy solutions.

1. Aluminum Extrusion: The journey begins with the aluminum extrusion process, where aluminum alloys are meticulously formed through a die to create the desired cross-sectional shape of the frame. This initial step sets the stage for achieving precise dimensions and profiles tailored to the specifications of the solar panel design.

2. Precision Cutting and Machining: Following extrusion, the aluminum profiles undergo precision cutting and machining procedures to refine their lengths and contours. Advanced machining techniques, including milling and drilling, are employed to ensure the creation of intricate features such as mounting holes and assembly interfaces.

3. Surface Treatment and Coating: To enhance durability and resistance to environmental elements, the aluminum frames undergo surface treatment processes. Anodizing, powder coating, or chemical treatments are applied to the surfaces, providing corrosion protection and augmenting aesthetic appeal.

4. Integration of Auxiliary Components: Integral to the assembly process is the integration of auxiliary components such as corner brackets, sealing gaskets, and fastening hardware. These components are meticulously positioned and affixed to the aluminum frame, ensuring structural robustness and compatibility with solar panel assembly.

5. Rigorous Quality Assurance Protocols: At each stage of production, stringent quality assurance protocols are implemented to uphold industry standards and product excellence. Dimensional accuracy, material integrity, and surface finish are meticulously evaluated through comprehensive testing methodologies to ensure compliance with stringent performance requirements.

6. Advanced Finishing Techniques: In the pursuit of exceptional quality and aesthetics, advanced finishing techniques are employed to elevate the visual appeal of the aluminum frames. Customized finishes, including textured coatings and decorative treatments, are applied to impart a distinctive appearance while preserving functional integrity.

7. Packaging and Logistics: The final phase encompasses meticulous packaging and logistics operations to safeguard the integrity of the aluminum frames during transit. Careful attention is devoted to packaging materials and handling procedures to mitigate the risk of damage and ensure the safe delivery of the products to their destinations.

Conclusion: The intricate process of manufacturing aluminum frames for solar panels exemplifies a fusion of precision engineering, innovative technology, and sustainable practices. Through meticulous craftsmanship and unwavering commitment to quality, these aluminum frames serve as indispensable components in the global transition towards renewable energy solutions, empowering communities with clean, sustainable power for generations to come.

• The solid cast construction with integrated turn table ensures optimal profile support for cutting to length with angular accuracy
• Continuous pivoting range adjustment of the saw heads from 0° to 45° to the left and right. This makes external and internal dimension cuts possible
• Vertical and horizontal pneumatic material clamping units ensures optimal profile fixation
• Equipped with saw blades as standard
• Equipped with digital display E 111 as standard
• Pulsed coolant system

 

Cutting length variants

• 3,000 mm
• 4,500 mm
• 6,000 mm

 

Options

• Workpiece supports
• Transom stop
• Extraction system
• Material clamping units
• Roller conveyors
• Saw blades
• High performance cutting fluid

 

Controller variants

• Manual cutting length adjustment with digital display E 111