energy

Starrag machinery at NGC

Higher productivity through complete machining thanks to integrated drilling and milling drive

> Berthiez

Starrag S.A.S from Saint-Ètienne (France) has made a very good name for itself throughout the energy industry worldwide with its large vertical Berthiez turning and grinding machines, because grinding takes on an important task in the manufacture of drive elements. Therefore, the new factory in Huai’an received four vertical grinding machines (RVU) from the Berthiez product range. The advantage of these machines is their high-precision grinding in the μm range, which always takes place with extremely high repeat accuracy. NGC uses the grinding quartet primarily for finishing planetary gear bores. Both, integrated roller bearings and the increasingly used plain bearings make high demands here. The high required surface quality of the bearing raceway can only be achieved by grinding the hardened surface. The four turning and grinding machines have 25 kW and 35 kW motorised grinding spindles, turning tool holders for Capto C6 tools and measuring probes for workpiece measurement. The machine concept is rounded off by adjustable dressers, tool magazines (4 places for grinding wheels and 8 places for turning tools) for automatic changing of grinding wheels and turning tools.

> Dörries

Higher productivity through complete machining thanks to integrated drilling and milling drive is what characterises the eight vertical lathes (VCE/VC) of the Dörries product range, which are in use in all three NGC factories. The company uses them to machine planetary carriers, ring gears and torque supports in a single clamping operation. The new three vertical lathes (VCE) in Huai’an are designed for the effective machining of planetary carriers. For this purpose, they were equipped with rotary tables with two very powerful AC servo motors with 59 kW each and 2-stage gearing (max. torque: 74,000 Nm; max. speed: 224 rpm), milling spindles with 37 kW drive (max. 1,200 Nm; 3,000 rpm) integrated in the tool slide and a column magazine with handling unit for Capto C8 or HSK 100 tools. Collisions of tools with workpieces are monitored by a monitoring system from Brankamp.

> Heckert

This is where it all started: We are talking about the horizontal machining centres of the Heckert product range (HEC), which, thanks to their large interference circle, are designed for the economical machining of XXL workpieces weighing up to 13 tonnes with a maximum edge length of 3,300 millimetres. Since 2009, the NGC main factory in Nanjing has been using four Heckert horizontal machining centres, all with quills. The new factory in Huai'an has been machining gearbox housings with two Heckert horizontal maching centres since 2023. Starrag also supplied both machines with the tried-and-tested quill spindle. With a diameter of 150 millimetres and an extension length of 760 millimetres, it meets the special requirements of the wind power industry.

The new duo has two pallets (1,600 mm × 1,800 mm) each and a compact tower magazine with 375 places for heavy, large and extra-long tools with HSK-A100 tool holding fixture. Low non-productive times are ensured by a tool handling system that automatically changes tools (diameter: 500 to 950 mm; tool length: up to 800 mm; max. mass: 50 kg) from the tower magazine to the main spindle, whose powerful AC servo motor with an output of 48 kW (S1 operation), a speed of up to 5,000 rpm and 1,200 Nm maximum torque is also suitable for 4-sided complete machining of very heavy XXL gearbox housings. For deep drilling, the Heckert horizontal machining centres (HEC) were equipped with high-pressure cooling. The scope of delivery also included: workpiece measurement, cooling lubricant supply and extraction device.

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