News

INTEGRATED OPEN DIE FORGING COMPLEX

  • P3500 PRESS with HP3®3200 Drive
  • R205 Integrated Rail bound Manipulator [20ton]
  • G305 Mobile Manipulator [30ton]

Fully designed and manufactured internally in around 12 months, this integrated complex defines the new benchmark for modern open die forging plants into Russian Market.

The combination of Push Down press design within HP3® Hydraulic Drive (patented) Integrated with Rail Bound Manipulator and Electronic Mobile Manipulator, guarantee extreme flexibility and high forging performances both in cogging and finishing, with reduced installed power and lower CO2 emission ever.

The press has the following features:

  • Forging force 3.500 ton
  • Deformation speed 120 mm / sec (max)
  • Finishing rate 120 strokes / min
  • Controls Manual / Semi-Auto / Automatic
  • Installed power 1700 kW (cosfi = constant 0,85)
  • Automatic upper die locking/unlocking device
  • Movable die slide
  • Die storage 5 positions
  • Pop up table
  • In line Pyrometer
  • Tele-Service

Thanks to combined performances of Press & Manipulators in the cogging and finishing phase, the complex is very versatile both for processing conventional steels (i.e. carbon steel, low alloy and QT high alloy) and for efficiently forging of tool steels, stainless and nickel based alloys, allowing the production mostly in a single heating cycle (hot)

The benefits are in lower electricity consumption during the process and in the reduction of gas consumption per ton produced (OPEX); this last data has also an impact in the reduction of CO2 quotas, substantially decreasing the annual disbursement required by the Emission Trading ETS - 2003/87/CE.

 

 

All the machines have been designed and built in-house based on the innovative design of the Vecchiato Off. Mecc .

The 4.0 integration of equipment has allowed interconnection to the company logistics system with clear benefits of programming, tracking and quality of any single work piece.

The installation, commissioning & start-up phase was handled by VECCHIATO SERVICE and lasted only 2 months from starts of erection at site, with enormous customer satisfaction

Despite the COVID pandemic indeed, the plant has been put into production in just 16 months from contract sign.

G124HD MOBILE MANIPULATOR

Manufactured and Commissioned in less than 12 months, the mobile manipulator G124 HD is designed both for the transport of high temperature ingots and to undergo the high stresses generated during open die forging.

The equipment has the following characteristics:

  • load capacity 15 tons
  • loading moment 24 tons * m
  • Air-conditioned and soundproofed operator's cabin
  • Ergonomic hydraulic controls and comfortable seat
  • Compact design with reduced turning radius to operate into tiny environments
  • TIER 4 diesel engine
  • Proportional hydraulic drive control

 

The new investment, synonymous with stiffness, reliability and high performances, was engineered and manufactured into Vecchiato Workshops.

Despite the Covid-19 Pandemic, the supply and start-up of the machine took place within 12 months from the contractual date, with large customer satisfaction.

  

AUTO MANIPULATOR G306 E – Integration 4.0

Following the recent installation on customer’s site during last Christmas 2019, the Vecchiato Service has pursued the 4.0 integration with the existing press (also Vecchiato since 3000TON)

Through a CANBUS / WLAN wireless communication, the press and the manipulator are now able to communicate and exchange data such as:

  1. spindle rotation with position control, preset positioning and zeroing
  2. tilting with position control and zeroing
  3. variable clamping pressure with torque preset
  4. Tele-Service

 In addition, however, remote control functions have been implemented, through the activation button on the press pulpit and enabled by the manipulator operator, which allow the following management functions:

  • AUTO REMOTE:
    The press automatically coordinates the spindle retraction and rotation position synchronized with the forging cadence pre-set on the work cycle
  • FULL REMOTE:
    Complete Command Control (remote joystick + automatic) The press controls movements/main functions of manipulator from the press joystick, including automatic function

As an option, the G306 E manipulator is equipped with a surround view system (SVS) to monitor the entire operating area by "top-view”; through a display in the cabin, the operator has complete/prompt control of the operating areas, with significant benefits in terms of safety at work.

The G306 E manipulator, which claims high quality and reliability standards, was engineered and built in the Officine Vecchiato in Gonars (UD) Italy.

 

FOR X-MAS ... AN AUTO MANIPULATOR G306 E - 4.0 Ready

For these holidays, Santa Claus has decided to bring the gifts across the valley on board the new manipulator Vecchiato type G306E

Manufactured and installed in 12 months from order, the forging auto-manipulator type G306 E has the following characteristics:

  • Lifting Capacity 30 ton
  • Loading Moment 90 tons * m
  • compact design to operate in limited / restricted areas
  • 4.0 Ready through CANBUS / WLAN communication with Press:
    a) spindle rotation with position control, preset positioning and zeroing
    b) tilting with position control and zeroing
    c) variable clamping pressure with torque preset
  • Tele-Service

As option, the G306 E manipulator is equipped with a surround view system (SVS) to monitor the entire operating area by "top-view”; through a display in the cabin, the operator has complete/prompt control of the operating areas, with significant benefits in terms of safety at work.

Thanks to Electronic Controls on-board (version E) the new investment allows high operational versatility, permitting an easily handle both of large objects (up to 30ton x 6 meters) and small pieces of 800/1000 kg, reducing costly handling down-time.