成功故事

高大、噪音低、产能高

多利斯 CONTUMAT VCE 2000 阀门制造车床

对于石油和天然气行业的专家而言,豪达不仅是奶酪的天堂。它还因高压控制阀和截止阀而闻名于世,这些阀门由 Mokveld 针对专用机床制造。

立式车床按照人体工程学设计,其突出特性在于不同寻常的塔式结构。工作台(60 千瓦传动能力;19,300 牛米扭矩,S1)可用以加工重量不超过 12 吨、最大高度 2,450 毫米且直径不超过 2,000 毫米的工件。此外,机床经过扩展,配带校正工作台和机动对齐台的专用托盘台,确保可在加工工件的同时设置另一工件。

在 VCE 2000 上,Mokveld 主要加工铸钢、铬钢、双相不锈钢和超级双相不锈钢、铬镍铁合金以及钛合金(偶尔),单次夹紧,生产能力明显更高。集成式刀库配 90 个刀位,在整个加工过程中也起到重要作用。由于约 80% 加工操作为车削,因此刀库含 50 个车刀,而 Mokveld 已通过专用保持架技术将其转变为 300 个车刀。然而,铣削和钻削作业比例也至关重要:荷兰阀门专家赞赏,目前可在机床上通过单一夹紧次数制造钻孔。因此,缩短了加工时间,并降低了成本,而且特别是降低了能耗。

机床配有众多测量仪器,对于车削和加工中心在单一夹紧次数实现粗加工、抛光、铣削和钻削非常重要。此外,对于校准站,加工区域还配有雷尼绍探头和自动校准装置。该设备可在安全框架内确保较高的精度和质量,因为阀门在高压范围为 20 至 900 巴内工作。

The Dutch company uses the VCE 2000 predominantly to machine cast steel, chrome steel, duplex, super duplex, Inconel and occasionally titanium. Two round valves, each weighing around 5.5 tonnes with 80-mm flange holes, were produced from Inconel in a complete machining process. The integrated tool magazine with 90 pockets also plays an important role in the complete machining process. As around 80% of the machining operations are allotted to turning, the magazine contains 50 lathe tools that Mokveld has transformed into 300 lathe tools using a technological trick with special holders. However, the percentage of milling and drilling operations also plays a crucial role: The Dutch valve specialists appreciate the fact that bores can now also be manufactured on the machine in a single clamping position. This reduces the long machining times, as well as costs and energy consumption. 

mokveld

The expenditure on measuring devices is remarkably high: Both the aligning station and the machine room are equipped with a Renishaw probe and automatic calibration device. This function is important in a turning and machining centre that roughs down, finishes, mills and drills in a single clamping position. There is even a finishing process of exactly 30 µm for very large workpieces, whereby grinding is omitted. "For safety reasons, precision and quality are very important to us", says the expert. "After all, our valves work at high pressures of 20 to 900 bar". "Our customers expect a high level of performance from us in every respect", adds Marketing Manager Chris van Assem. "The requirements have increased in the standards that we need to observe". 

Another special feature is the extended retraction and stopping function, which Mokveld ordered for two reasons: Firstly, if there are impending collisions, then the tool is directed out of the machining area and into a safe position. The Siemens 840 D sl control system controls the movement of one or two drive axles during this extended retraction. These drive axles provide various individual retraction distances depending on the situation at hand. Secondly, Mokveld responds with the extended retraction and stopping function in the event of a power failure. The necessary energy comes from the DC bus of the drive system, which is controlled in a way that ensures the energy does not fall below or exceed the voltage limits. Thanks to this clever control, drives do not spin out and can be brought to a standstill. 

But what are the aspirations of an experienced production expert who machines challenging valves on a daily basis? Bart van den Bosch: "I hope that one day we will also machine small housings on a machine tool in a complete machining process". 

bart van den Bosch

Profile

The Mokveld Valves BV valve factory (with 370 employees worldwide) was founded as a small machine repair shop in Gouda in 1922 by N.J. Mokveld. The company has been manufacturing its own products for 70 years: It produces high-pressure control and stop valves that operate on the axial flow principle. The development of axial valves received a major boost with the discovery of the gas field in Groningen, the Netherlands in 1950. Mokveld initially produced valves for the Dutch gas company Nederlandse Aardolie Maatschappij (NAM) BV from Assen, and then specialised in high-quality, customer-specific valve systems for the global gas and oil industry. 

http://mokveld.com

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