Automation: wide range of solutions for Breton machines

No one seems to remember that the machine tool itself it’s an automation! 

Not too many years ago, the NC was the operator brain and robots were still to be invented.
Now the situation is completely changed and in the industrialized area, in order to be competitive, we need to remove the constraint of a ration 1:1 between operator and machine.
The automotive industry started with the massive production of few products, the high technology companies need to do the same with many small batches of complex and different products.

Breton production is dedicated to these customers, providing them solutions capable to run alone 24 hours/day with remote monitoring and control. The electronic and software improvements are a big help to reach this challenging target but they cannot work without a strong and reliable machine automation.
The best way to describe automation solutions that Breton can provide is to show some real applications developed to answer real customer claims:

PALLET CHANGER WITH 5 STATIONS

Customer claim: remove any time spent for machine setup, avoid mistakes due to wrong fixture setuo, disconnect operator setup time from machine operating time.

Solution: Breton designed and supplied to Piaggio Aerospace 6 tailor made Ultrix 800 machining centres featuring special ergonomic solutions for the best workpiece accessibility, each one is equipped with a total of 5 pallets (4 loading stations and 1 high precision setup station) and a manipulator. The result is a multi-pallet solution characterised by a very compact layout. The extreme accuracy of Breton Machine Tools is possible also thanks to the special pallet changer solution, based on a hirth serration that provides higher performances respect to the standard competitors system. Pneumatic, hydraulic and electronic connections can be supplied to the tooling.

HEADS CHANGER

Customer claim: strong reduction of cycle time while performing roughing and finishing operations on large size aerospace components.

Solution: Breton supplied to an important Aerospace company a Maxima 1600, fitted with a heads changer system. The head storage hosts a high torque milling spindle (up to 480 Nm and 14,000 rpm) suitable for roughing, and a finishing spindle (up to 94 Nm and 28,000 rpm). The machine is equipped with two bridges and is 16 meters in length, so can be configured to run two pieces together (for example one roughing operation and one finishing operation) or a single long piece removing material with the two heads. Breton Flymill 1600 HD K160 fully achieved the customer requirements providing a strong cycle time reduction together with a perfect flexibility.

PENDULUM MODE WORKTABLE CHANGER

Customer claim: avoid long machine stop during the setup operation of a typical aircraft structure big component.   

Solution: this problem can be solved providing a long machine with two separated areas (one for machining and one for piece setup) or by using a table change system. For TAI (Turkish Aerospace Industries) Breton chose the second solution, providing a total of 3  Breton Flymill 1300 2T K30 equipped with a table change system that allow the operator to spend all the time he needs to perform a perfect piece setup while the machine is milling another component on the second table.

MULTI POSITION TOOL STORAGE

Customer claim: the use of multitasking machines has increased the number of requested tools (milling, turning, grinding) but not the available space. Customers want smart solutions.

Solution: one Breton well know key feature is the development of tailor made solutions. We are capable to take the best-in-class tool storage solutions from the market and adapt to the different customer requirements.
One example is the 200 positions tower type tool storage integrated on our Breton Maxima 1600 (mixing HSK-A100 for milling and Capto C8 for turning) with up to 3500 mm turning capability.
Another solution is the 200 positions tool storage fitted on our Breton Maxima 2000 K80.
Breton designer used the 8 meter machine length to hide the system in the machine footprint. A robot picks up the tool and transfers it to a tool changer avoiding any waiting time.

MEASURING FEATURES

Customer claim: reduce the features cost and complexity, be sure to remove from the machine a conforming piece.

Solution: the machine probing systems are provided as standard solution by many different competitors. The difference of Breton solution is the strong integration with the machining process and the measuring performances thanks to high machine accuracy. Breton can provide a turn-key solution to check the machine condition before starting operation, perform a perfect piece setup, even on deformed components, machine, measure and automatically correct the part saving all the measurements for statistical analysis. The only thing that the operator has to do is press the start green button. The final result for an important Aerospace customer is a measuring difference between Breton Ultrix and CMM of less than 0,01 mm.

HUMANOID ROBOT

Customer claim: create an automatic machining line to produce tire moulds with a minimum operator surveillance. 

Solution: Breton supplied to an important automotive company three machines, 2 Xceeder 900 and 1 Ultrix 800, with pallet change system served by a robot on rails collecting pieces and fixture from a big storage. Breton was responsible for the complete FMS solution and the final acceptance criteria were very severe but they have been achieved. The robot gives the system an higher flexibility respect to a classical FMS solution, in this way it will be possible to change easily the production in the future.

For further information, please write to mail@breton.it

Thanks for your attention!

Sergio Prior

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EAGLE - Customized Efficiency

High-speed 5-axis machining centre for milling, boring and trimming small to large size work-pieces in composite materials, sandwich structures, light alloys, resin and plastic.

Wide choice of configurations for customized performances 

Various solutions for the best machine configuration to satisfy each need:

- Standard model with one working area

- Model with two working areas for pendular machining

- Model with automatic loading/unloading of the workbench.

Easy access and perfect visibility

Great accessibility and visibility of the working area thanks to the machine gantry structure with moving bridge and wide frontal doors.

Precision, Dynamics and Flexibility when machining at high speed with 5 continuous axes

A superior head

The electrospindles offer always the best machining

performance thanks to the cast-iron fork designed head which offers structural rigidity with efficient vibration damping properties.

High-speed, Performance and Precision

The carriage and beam travel on properly dimensioned recirculating roller guideways en-sure machining precision and stability. Carriage and beam drive assemblies consist of a precision rack and pinion system, whereas the ram is driven by a ball screw and pre-loaded ball nut assembly. Axis motion is powered by ultimate generation digital ser-vodrives and brushless servomotors.

Wide choice of electrospindles

The EAGLE machining centre can be supplied with a wide range of electrospindles depend-ing on the type of material to be machined. Machining precision is always guaranteed by the thermal stabilising system which consists of a special software designed and devel-oped to compensate natural thermal expansion and drift in the electrospindles when ma-chining conditions vary.

M30/14

16KW electrospindle with a 30 Nm class S1 continuous torque and a rotation speed of 14500 rpm, the ideal solution for machining composite materials and resin from rough milling to precision finishing operations of light alloys.

M38/28

A 20 kW electrospindle with a 38 nm continuous torque in s1 and 28,000 rpm is the ideal choice for high-speed machining requirements for steel and light alloyprecision surface finishing operations.

M51/28

Electrospindle featuring a power of 40 kW, continuous torque of 51 Nm in S1 duty and 28.000 rpm: the ideal choice for customers requiring high-speed machining on either steel or light alloys, from rough-machining up to precision finishing.

Simple and reliable tool magazine

The wheel-type tool magazine can hold up to 30 tools with diameters of up to 140mm and 300mm in length. Completely isolated from the work area, this tool  magazine ensures the greatest reliability with reduced tool changeover times. Upon request EAGLE an be sup-plied with rack-design tool magazine for holding up to 150 tools. The tool magazine can be equipped with an automatic chip coding system containing tool data and information.

Dust extraction and ceiling enclosure

When machining composite materials and resin, EAGLE an be fitted with an efficient and effective dust extraction system which is installed on the spindle nose. In addition, top-roof bellows can be fitted to the machining centre creating a complete enclosure isolating the machine from the surrounding areas.

Monitoring and in-process inspections

EAGLE can be supplied with a laser tool presetter and a radio frequency probe for acquiring work-piece size and coordinates.

The ideal cooling system

Depending on the type of machining operation, the tool cooling system can use a coolant liquid which flows inside and outside the spindle (60 L/min) at an internal operational pressure of up to 40 bar, or incorporate a spray mist system, or simply use compressed air.

So, why don’t you request a quotation for a EAGLE?

Write to mail@breton.it

By-by

Sergio Prior

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breton eagle, breton vertical machining centres, carbon fiber, light alloys, milling machine, milling resin

The photos of the Breton Open House 2012 can be found on Facebook profile: Bretonspa

Like us on Facebook and you will receive news, information, event communications with real-time updates!

By-by

Sergio Prior

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breton vertical machining centre, high speed cnc machining centre, milling machine

Carbon fibre monocoque chassis machined by Breton “MATRIX” vertical machining centre

Click here for more INFO

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Breton Flymill working mould

 

Write to mail@breton.it to know the price and receive additional info regarding  Breton FLYMILL.
See you next time.  
By-by
Sergio Prior

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5 axis machining centers, aerospace, automotive machining centre, breton cnc 5 axis, flymill, high speed cnc machining centre, milling machine, mould

Breton Eagle, a gantry machining centre for high speed milling operations on engineered materials and alloys

Eagle is our new gantry machining centre specifically designed for high speed milling operations on aluminium and engineered materials.  The 5 interpolated-axis mobile beam makes this new Breton product the perfect choice for machining complex 3D components used in the aerospace and civil aviation industries.

 

Discovermore about Eagle

Efficient and flexible 

Even the most demanding  jobs are no obstacle for Eagle. Thanks to the flexible configuration of this work centre you can deal with the most demanding milling operations with maximum performance.  

Eagle has a working range which spans from 2500x2000x1000mm up to 20000x5000x2500 mm and over with the double crossbeam and double ram and is ideal for pendular operations.

High speed machining and maximum milling performance 

The twist head, which can be positioned at any angle, allows for mounting 40kW spindles with rotation speeds of up to 28000 rpm providing this work centre with improved milling efficiency and performance. 

This symmetrical twist head with continuous axis C rotation and 0° up to +115° rotation of axis A give Eagle extraordinary and unsurpassed performance ideal when machining complex profiles with 5 axes.  The linear axes which travel 85m/min provide this work centre with maximum speed and precision even when milling undercuts.

Safety and improved productivity

This work centre is completely enclosed and all the various assemblies are mounted on the upper part of the machine  allowing the operator to work with maximum precision and in total safety.

Discover more about Eagle

To learn more about Eagle  please contact us at Breton.  Write to mail@breton.it or simply fill in the form provided on our Sales Inquiries page or if you prefer  call us on +39 0423 769220.

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EAGLE 5 axis vertical high-speed machining centre designed for light alloys, composite materials and resin

EAGLE is a 5 interpolated axes work centre with a gantry structure and mobile crossbeam: the perfect solution when high-speed machining operations are required for milling aluminium and engineered materials.

This machining centre is specially designed for machining complex 3-D components for the aviation industry.

EAGLE has a choice of configurations enabling to perform even the most demanding jobs with maximum flexibility, performance and efficiency, with work ranges spanning from 2.500x2.000Fthe twistx1.000mm up to 20.000x5.000x2.500mm and over, with a twin crossbeam and twin ram for pendular works.

Rigidity and high dynamics are distinctive features of this work centre, which make it ideal for machining a wide range of components and products at extremely high speeds and with maximum milling performance.

Thanks to the speed of the linear axes which reach up to 85m/min and to the symmetrical rotary tilting head with continuous rotation of the "C" axis and 0° to +115° rotation of the "A" axis, EAGLE offers the operators the possibility of performing the 5-axes machining of complex profiles, ensuring maximum precision and machine dynamics when milling undercuts.

The twist head, which can be positioned at any angle, allows for mounting a spindle up to 40kW and with rotation speed up to 28.000 rpm, providing this machining centre with outstanding milling efficiency and performance.

The closed structure and drive assemblies which are all mounted on the top part of the machine, ensure maximum operator safety and remarkable precision, performance and reliability during the machining.

For info and requests about the vertical machining centre Breton EAGLE write to mail@breton.it.
We’ll get back to you promptly.
Well, that’s all for today, thanks for your attention.
Bye-bye
Sergio Prior

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IT GIVES YOU WINGS

Another victory for Red Bull with Mark Webber at the Spanish Grand Prix !

Red Bull uses two Matrix 1300 and one Matrix 800 for the most sophisticated machining of the carbon fibre car body and chassis.

Breton and Red Bull, a winning partnership!

Please visit our site www.breton.it

Matrix at work

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Piaggio Aerospace Goes for Breton - Six for Space

In order to increase its component production capacity to meet a major work order, the Ligurian company opted for the multi-functional cells manufactured in Castello di Godego.  (by Paolo Beducci)

What can you do with a company that makes airplanes on the coastline? Located on a strip of land that is better known for tourists than aeronautical enthusiasts? This was what we were asking ourselves as we followed engineer Luca Tagarelli, Manufacturing manager for Piaggio Aero Industries SpA through a labyrinth of roads and galleries and tunnels leading us through what seemed to be a maze to the building where his office is located. 

We were given our answer before we were even able to ask the question. We obviously look surprised because, as Luca Tagarelli told us, “Piaggio was incepted in 1884 by Rinaldo Piaggio to manufacture fittings for the shipbuilding industry and later for the railway industry. 
The company’s first dabble in aeronautics was in 1915, when it began manufacturing aeronautical motors, followed a decade later by the first aircraft. In actual fact they were flying boats. And this is why we are located right between the land and the sea at Finale Ligure."

Two great engineers Giovanni Pegna and Giuseppe Gabrielli joined the founder Rinaldo in leading the company’s venture in the aeronautical industry, and they were to be fundamental to the development of the company’s aeronautical engineering division.

The most noteworthy fruit of their work is the first helicopter, made according to very advanced standards and performance for its time, the first rotorcraft opening the skies to the development of the modern helicopter. 

Piaggio was also the company that spurred the branch of another Piaggio product, one that is perhaps better known and, coincidentally, was designed by an aeronautical engineer. We are talking about the Vespa and Corradino D’Ascanio who built the company’s first scooter around an engine used as a starter for large aeronautical engines. 

The destines of the Vespa and Piaggio aircraft would continue to overlap for another 20 years until 1966, when the two industrial companies split for good. The aero segment then continued its adventure with the construction of aircraft, motors and structural components. 

There were however another two fundamental moments in the history of Piaggio Aero. The first was in 1990 when, after 10 years of work, the P180 was launched, a truly extraordinary and cutting-edge airplane that is still sets the benchmark for executive aviation. 

In the month of November 1998, Rinaldo Piaggio S.p.A. was bought by a group of entrepreneurs headed by the Di Mase and Ferrari families. The company was renamed Piaggio Aero Industries and became, in just a few years, the leader in the production of executive airplanes. 

-Its growing success led to international interest that increased the number of shareholders of Piaggio Aero, thanks to the participation of two of the most important strategic and industrial investment groups in the world: Mubadala Development Company (a strategic investment group owned by the Government of Abu Dhabi) e Tata Limited, a British company in the Tata group. Piaggio Aero has a division that specializes in the production of engine parts, and it is headed by Tagarelli. 

“In our business area” Tagarelli told us, “we do not limit ourselves to making engine parts for our clients who manufacture aeronautical engines, but we go beyond to work with these clients also as partners to develop the product, aid design development and also contribute to the constant development that all aeronautical products undergo in the course of their life cycle on the market. In addition to our work with new products” the Manufacturing manager for Piaggio continues, “our job is also to periodically overhaul a number of aeronautical engines. These are routine control and maintenance operations required after a certain number of hours in operation.” 

Although originally this activity was started for the most part to serve the military, today things have turned around and most machining production and maintenance volume at Piaggio Aero is generated by the field of civil aviation, which has very different logistics from the military. This has brought about some major changes to operations at the company. Piaggio Aero’s machining department was recently awarded a major work order for the production of PW 200 parts.              

In fact, Piaggio produces a significant percentage of engine parts for the PW206 and PW207, assembling them in modules that then make up the engine, and delivering the product to the final client. In addition, it provides maintenance, repair and overhaul of the engines in their lifetime. “A contract of this scope for us was a real novelty that brought significant changes. In fact" Tagarelli continues, “we have always been used to small production volumes in the aeronautical field, while the PW200 family entails much larger production runs. We are not at the level of car making, this is clear, but in any case we are dealing with quantity production to all intents and purposes which also requires a higher quality and production level when it comes to equipment.

Because on the one hand we need our products to be quality certified, on the other we must be able to guarantee our client availability and output standards that are comparatively high for the aeronautical industry. To give an idea of the production leap that we are facing in order to be able to guarantee the required production, we make about one piece a month for Pratt America, while the PW200 is already an established engine and we have to produce more than 500 pieces a year."

 

For the PW200 Piaggio Aero series the company had to make a total of six pieces: four parts and two vanes, and to do this correctly we decided to dedicate a manufacturing cell to the specific request in order to avoid the new job order interfering with the company’s existing production).   

“In addition, for the first time in our history, we decided to ask potential suppliers also to provide industrialisation of the manufacturing process. Basically, we were looking for a supplier who was best able to follow us for the long haul with regard to our operations taking productivity to the highest peak. In the past, it was common to purchase the machinery and then, once the pieces to be machined were defined, to develop the post processor and the process. In this case, on the other hand” Tagarelli continues, “it was essential to find a true partner who was competent in these matters.” 

The open tender contract was, as mentioned above, for a turnkey solution and involved big names in the machine tool industry. These names also included Breton, a company that had already been familiar to Piaggio Aero for a decade, but which had never supplied equipment to Piaggio. “In fact, we had visited Breton when they had first entered the machine tools sector” Tagarelli tells us, “and at that time they successfully passed the tests, so we decided that at the first concrete opportunity that arose for them to supply the right type of machinery, we would put them to a solid test. 

So we went back to visit them and we realized straight away that over the decade the company had grown and consolidated its technical experience in this sector.” 

To make the parts in question, Piaggio needed to perform turning and milling operations. It decided therefore to look for a machine that could perform both turning and milling with the inevitable advantages that a single machine set-up would bring in terms of accuracy, product quality and manufacturing times. “I have to say” Tagarelli goes on, “that from a technological standpoint, even with all the differences between the various machines, all the solutions proposed were worthy of our interest. 

“The structure of the machine was another very important factor for us. We currently do not have an air conditioned workshop and therefore the machinery is subject to considerable changes in temperature. We were interested in identifying such changes in order to be able to compensate for seasonal changes in the machining stage. For this reason we decided, for example, to not take machinery with atypical structures into consideration.  

An additional point in Breton’s favour was the ergonomics of the machine and accessibility to the piece. I do not believe that today there is a machine tool with the characteristics of Ultrix that is more user-friendly for the operator. It should also be noted that Breton was able to perform certain grinding operations on the pieces in question, further reducing the time the piece remained in the workshop. 
A decision such as this was in many ways considered something of a gamble. In the sense that what Breton was offering was really different from what we were used to and what is more we had never had a machine made by Breton, so we did not know how their organization would do working with us. I can however say that the gamble clearly paid off.”

 

Today, Piaggio has three Breton Ultrix installed, each equipped with five pallets, but in the coming months, when Piaggio Aero moves to the new factory it is building in Villanova d’Albenga, the number of Breton cells will rise to six for a total of 30 pallets. The Ultrix takes care of machining a family of four parts. 

One is an aluminium part, while the other three are made up of Inconel. The light alloy part is made entirely on the Breton cells, starting with the raw pieces and concluding with the part ready for assembly.

This is a tangible possibility thanks to the quality of the machine which is comparable to the quality of measuring machines, and it has made dimensional and geometric certification of the pieces directly on the machine possible.
“The goal for these parts” Tagarelli continues, “is unattended machining that I think we will achieve soon, thanks to the multi pallet solution which moreover features a particularly compact layout with six machines set out in a semi-circle with the palletising area extremely compact despite the considerable size of the whole cell.” 
Aluminium and Inconel are materials that react differently and thus require a differentiated approach. Despite the fact that the Breton spindle, reaching 18,000 rpm, may seem more appropriate for the machining of light alloy than for Inconel, it handles the latter material confidently thanks to the high torque the spindle is able to deliver.

The last of the many elements deemed to be positive on the Breton Ultrix is the special feature of double ram. In fact, to avoid having a machine that is not perfect in turning or milling, therefore to avert critical issues of any kind even in just one of the jobs, the two operations have separate management inside the same machine: “With this solution, Breton has developed a product that offers advanced levels of performance with both machining operations.”

Thanks to Tecnologie Meccaniche magazine.
Bye-bye
Sergio Prior

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