The goal was to develop a large-scale machining centre capable of carrying out multitasking processes, with the aim of machining the finished piece in the least possible number of positioning operations, while guaranteeing the high quality expected by our clients. The result was the new range of CNC machine tools designed by Innse-Berardi, offering a broad spectrum of solutions capable of catering to specific requirements in terms of large production batches and the size of the pieces to be machined. Our solutions are inspired by the long history of experience acquired over decades by the mechanical engineering company based in Brescia, specialised in the development and commissioning of high-tech systems, which has become a leader in the heavy mechanics, energy, transport, aerospace and defence sectors.
The idea behind the development of this product line originates from the characteristics that typify a machining centre in the traditional sense, i.e. a small machine in a contained unit that is completely automated and provides a high level of operational flexibility. A few years ago, designs for the first large systems began, which have always been defined as milling machines, vertical gantry machines or horizontal milling and boring machines designed for managing large production batches.
“Today, we believe that these systems are true machining centres, because they are automated solutions equipped with different types of functionality in terms of machining processes, which makes them genuine CNC systems. They are capable of exchanging the current piece simultaneously, automatically swapping tools both on the main spindle and on any optional heads, as well as recognising and monitoring in real time the tools and optional heads installed by the machine,” stated Sergio Leoni, Product Development Manager at Innse-Berardi. “Whether for our horizontal or vertical machines, the typical piece size starts from 5x2,5x2 metres, and can be even larger, without any specific limit. For example, we are currently developing a system capable of machining a cylinder of 17 metres in diameter and 9 metres in height, which in the same work position can also handle a prism-shaped piece measuring 13x6x9 metres, with a power range spanning 50 to 150 kW and spindle torques from 1,500 to 32,000 Nm.”
Even on larger machines, the operator's function should be to supervise the production cycle, but in this case, greater attention is needed precisely because of the large pieces machined on these systems which, in light of their size, have a much greater intrinsic value.It is becoming increasingly common to wish to carry out unsupervised tasks on larger machining centres, which must therefore be equipped with all the necessary features to ensure the correct execution of the process. In the event of accidents, the CNC unit must be able to safely stop the machine without damaging the component currently being machined, which could cause significant economic losses as explained above
“In terms of machine configuration, even if a rotary table is not always a requirement, operations similar to turning or processes using specific optional heads are required, without detriment to the original aim, which is to manufacture components entirely automatically, limiting all possible involvement of operators and repositioning of pieces,” he added. “This is the philosophy that has guided us over years of developing machine tools with highly sophisticated automation systems, capable of controlling the machine in an efficient and quick manner. Moreover, another important role is played by all the devices needed to safely automate a lot of operations, which previously had to be carried out manually by an operator, such as the measurements on the piece with electronic tracers or laser scanners, as well as monitoring the machining process with real-time relay of the cutting parameters according to the working conditions, in order to avoid damage to the machine or the piece being manufactured.”
In order to satisfy the demands of Industry 4.0 technology, as already takes place on smaller machining centres, large Innse-Berardi machining centres are also equipped with specially engineered systems to integrate production flows in a connected digital system. The hallmark of Innse-Berardi’s large machines is the high-level of product customisation that they cater to, which is always gauged according to the client’s specific manufacturing needs, while maintaining the gamut of application possibilities that is typical for multitasking systems. “In addition to the high quality of our systems, we also offer a range of services, starting from the pre-sales phase, managed by our area application staff whose expertise enables them to propose the right system in light of the specified requirements, with the best production quality capabilities and in the shortest possible timeframe,” commented Sergio Leoni. “Our offering is rounded off with aftersales technical assistance performed by qualified technicians, coached in supporting clients during the entire lifecycle of the system, from the start-up and training phase to routine and unplanned maintenance - even remotely, wherever possible.” Innse-Berardi provides a 24/7 telephone contact service for its clients, aimed at identifying first response strategies to any issues, followed by the most suitable maintenance to solve the problem, also through the IB 4.0 package, which directly manages the connection between the system and its cloud area, where big data is collected and saved from the system's sensors, which can be analysed according to specific needs.