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50% higher energy efficiency and productivity and increased process dependability

HELLER solutions at Power-Hydraulik GmbH

Task Setting

  • Saving energy in the production of valve blocks,
  • especially drilling operations requiring large amounts of coolant
  • Saving energy in terms of the high-pressure coolant pump
  • Increasing pressure to over 85bars
  • Pressure-monitored tool breakage detection
  • Increased feed rate

Project scope and solution

  • One HELLER 4-axis machining centre model H 2000
  • Pressure increase to over 85bars without using a larger motor
  • Sensor-controlled leak monitoring
  • Control modifications: start loop for deep hole drilling operation, pressure monitoring by means of frequency converter => predictive tool breakage detection

Result

  • Energy savings of 50% at increased process dependability
  • Reduced heat input into the coolant, extended coolant pump life
  • Reduced leakage of < 5 l/min
  • Pressure-monitored tool breakage detection suitable for all machining operations => higher process dependability
  • Increased feed rate possible due to reliable tool breakage monitoring
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