DANOBAT GROUP
3 - 5
Applications
6 - 7
· Tower
8
· Wind Turbine Blade
9
· Hub
10 - 11
· Nacelle
12 - 13
· Gearbox
14 - 15
· Generator
16 - 17
· Pitch & Yaw Gear Motors
18
· Bearings & Flanges
19 - 20
Machines
21
· Fully Automated Composite Parts Manufacturing Process
22
· Sawing & Drilling, and 3D Plasma Cutting Machines
23
· Turning Machines
24
· Boring Mill Centers
25
· Grinding Machines
26 - 27
Index
Your Global Business Partner
DANOBAT
GROUP
, with more than fifty five years of experience, offers a range of advantages which
help your company to satisfy your manufacturing needs.
DANOBATGROUP is the largest machine tool manufacturer in Spain. Over the last 55 years, DANOBATGROUP has supplied machines to highly reputed customers, consolidating a worldwide presence.
DANOBATGROUP is the machine tool division of one of the most important Spanish industrial holdings, MONDRAGON corporation.
DANOBATGROUP is specialized in different manufacturing technologies (boring & milling, grinding, turning, bandsawing, fully automated composite parts manufacturing process, drilling and punching).
This wide range of products are marketed under two world renowned brands: SORALUCE (boring & milling)
and DANOBAT (lathes, grinders, punch presses, bandsaws and composite processing machines). With top class manufacturing plants in Spain, Germany and UK and sales and service offices all over the world, DANOBATGROUP is a reliable global supplier of proven solutions for different manufacturing and machining processes. A determined commitment to become YOUR GLOBAL BUSINESS PARTNER.
TOTAL: 15,526 TOTAL: 91,511
* 2008 data
One Leading Machine Tool Group, two distinguished brands
13,989 6,282 9,162 13,989 6,282 9,162 38,868 48,687 1,045 2,911 38,868 2,911 48,687 1,045
and Capital Goods are focused sectors of DANOBATGROUP’s industrial strategy.
DANOBATGROUP offers the wind energy sector customized solutions for the manufacturing of blades, hubs, nacelles, gearboxes, rings, towers and other components of an aerogenerator.
The combination of different machining technologies such as sawing, turning, boring & milling, grinding and composite process automation allows to DANOBATGROUP to provide complete turn-key projects to our customers.
The Group is highly focused on the Wind Energy Sector, as being member of “Spanish Wind Energy Association” (AEE),“American Wind Energy Association” (AWEA) and founding member of “Spanish Energy Supply Chain” (ESC).
4
around the World
100 50 0 2004 2005 2006 2007 2008 personnel 1400 1200 1000 800 600 400 200 0 2004 2005 2006 2007 2008 1007 1033 1036 1300 1330 international sales 0 2004 2005 2006 2007 2008 109 104 119 139 176 (M €) 250 200 150 100 50 OEM ALSTOM ENERCON GAMESA GENERAL ELECTRIC SIEMENS SUZLON VESTAS OEM SUPPLIERS ALFONS DIECKMANN A+S ATA GEARS BECKMANN VOLMER B+S ECHESA EIKHOFF EMUSI ENDAKI EOZEN EUSKALFORGING EUSKO FEST SPAN
References
MOVENTAS PERKEO RENK REXROTH SE FORGE SEW STORK GEARS WÜSTHOFF WUXI SANWEI WUXI WANLI Z+F FLENDER GET GAMESA HC HELDECO INGETEAM INDAR JIANGSU WENHUI J. M. MENDIOLA KERSTEN KINKELE KLINGELNBERG LAKBER MAN DIESEL MOL-MATRICThe Ultra-precision shop of Ideko ik4 (see above), temperature and humidity controlled, is dedicated to carry out research projects and development of machines, components, measuring systems and contains testing equipment for ultra-precision applications.
The prototype shop of Ideko ik4 (800 m2), is dedicated to research
projects on machining processes; its major activity is with partnership projects with machine end users. The shop, temperature controlled at ±0.5º, serves as a showroom of the technological capacity of DANOBATGROUP; carrying out trial tests, developing research projects for the members of the Group, optimizing traditional processes and developing new ones.
sawing
turning
drilling
grinding
BEARINGS &
FLANGES
page 19 - 20grinding
PITCH & YAW
GEAR MOTOR
page 18
HUB
boring & milling
page 10 - 11
page 9
manufacturing process
WIND TURBINE BLADE HUB
NACELLE GEARBOX GENERATOR
PITCH & YAW GEAR MOTOR BEARINGS & FLANGES TOWER
Automated
Composite Parts Sawing Drilling Turning Boring & Milling Grinding Production
Technologies
GENERATOR
turning
grinding
boring & milling
page 16 - 17
milling
sawing
drilling
plasma cutting
TOWER
page 8boring & milling
NACELLE
page 12 - 13
turning
grinding
boring & milling
GEARBOX
By two opposed moving column milling machines, the complete
machining of the tower edges metal-sheet is carried out in one set-up.
The combination of SORALUCE’s Digitmill software and special tooling allows both high accuracy and productivity, achieving high quality chamfers for subsequent automatic welding, avoiding manual adjustment and reducing manpower costs.
.
DIGITMILL
enables the correction of the machining program of big size componentsaccording to the deformation error on them, providing high quality chamfering.
Advantages:
· Assistance to the operator
· Improvement of the performance of the machine
8
TOWER
sawing · drilling · milling
Sawing & drilling, and plasma cutting lines for the internal
metal structures of towers.
The extensive know-how acquired over many years of product development has enabled DANOBAT to expertly design, manufacture and comission fully automatic sawing and drilling lines for metal structure applications such as internal structures of towers.
WIND TURBINE
BLADE
fully automated
manufacturing process
DANOBAT offer new technologically advanced solutions for
automating and controlling of the wind blade manufacturing process.
Automated stages
· Glass lay-up
· Glue & Gel-coat application · Edge trimming & Surface grinding · Measuring & inspection
Working in consonance with its customers/partners to boost their competitiveness, will increase output and cost efficiency:
Danobat introduces autocontrol procedures in each step in order to achieve a high fabrication process reliability.
• lead-time reduction > 45%
• human labour reduction > 60%
• material consumption reduction > 10% • blade repeatability & quality improvement > 60%
10
HUB
boring & milling
SORALUCE provides high performance, reliable and accurate
machining of hubs, one of the most complex and critical part of a
wind turbine, providing:
SORALUCE multi purpose boring mill centers offer a full machining and verification
process of hubs, including simulation, milling, boring, drilling, tapping and measuring
operations.
· Machining of the blade support face · Machining of the generator support face · Machining of the nose support face
- Top quality machining heads, which are robust, flexible and reliable - Development of new heads to suit special manufacturing requirements - Automatic head changing systems for unattended machining processes - Rigid high powered machines for heavy stock removal
- Thermal stability and dynamic adjustment of the machine
- A wide range of accessories to ensure the machine is exactly matched to the customer’s requirements
- The complete machining of a hub in only 2 set-ups
- Turn-key projects: clamping fixtures, cutting tools, CAD-CAM processing, simulation, training, production launch support is always at your disposal.
SORALUCE provides complete machining solutions with the
following available at your disposal:
12
boring & milling
SORALUCE introduces the verification procedure in order to detect
and avoid beforehand possible errors, potential collisions, or areas
of inefficiency by machining process simulation. This process
enables errors to be detected and corrected even before the program
is loaded into the machine control, thereby removing the need of
manual prove out.
Furthermore, the verification allows for the optimization of program cutting speeds to ensure a more efficient machining process.
The SORALUCE machining process provides both the reliability and the level of performance required in the manufacture of high-value components in the wind power sector.
Main operations carried out in the nacelle:
· Machining of the tower point face. · Machining of the jaws bore face. · Machining of the generator fitting face.
GEARBOX
Shaft
Gear
Housing
turning · grinding
boring & milling
High precision OD grinding machines
HG-62/72/92 are flexible solutions for universal or production grinding. They can be used for components from 600 to 6,000 mm length. The HG-62/72/92 grinding machines offer reliable and accurate customer-specific solutions providing:
· Different grinding operations in one clamping
· DANOBAT made electro spindles on “B” type swivelling wheelheads · Wide range of compact swivelling wheelheads
· MDM absolute measuring system is available
14
Turning Centers
DANOBAT has within the TCN family a wide range of turning centers for the turning of gearbox shafts. Configuration of lathes may be adjusted according to each particular requirements due to the modular design concept, which provides the most cost effective machine solution. Keyways may be also finished accurately on the same clamping using the Y axis.
Gear
Vertical Turning Centers
The DANOBAT VTC range of machines provides solutions for high precision applications. The VTC features ensure optimum performance accuracy and repeteability.
· Ram size:
250 mm x 250 mm – 300 mm x 300 mm · Table drive motor:
60 kW – 80 kW – 100 kW
Housing
The SORALUCE multi-purpose boring mill centers offer exceptional versatility and enhanced productivity benefits for gearbox components. The automatic head changing systems together with accurate rotary and travelling tables allow high precision machining of components in a single set-up, enabling to achieve high concentricity requirements demanded on those parts.
Vertical Grinding Machines
DANOBAT offers high capacity vertical grinding machines for the machining of wind turbine gears. The DAN-VTG series provides: · Internal, external and surface grinding · “B” axis and automatic tool change · Probing software
· Hard turning option
· Size and taper gauging · Pre-grinding measuring cycles · Interrupted process measuring cycles · Post process measuring and
comparison with grinding tolerances
High precision
Accurate profiled tapers
Post process grinding report
16
GENERATOR
Stator & Rotor
Shaft
Support
Stator & Rotor
Vertical Turning Centers
The VTC range of machines combines high turning performance and high accuracy over the machine lifetime.
The modular design enables a wide range of specifications to be configured in a short time and to be produced quickly, efficiently and cost effectively.
· Maximum turning diameter: 6,000 mm · Table drive motor: 60 kW – 80 kW – 100 kW
High precision grinding machines
· Longitudinal travel: 600 – 6,000 mm · Swing 900 mm
· Twin wheel on “B” axis
· MDM absolute measuring system
Support
SORALUCE boring & milling machines are prepared to reach the most difficult-accessible areas of a generator frame. The wide range of milling heads and the automatic head changing system turns the boring & milling machine into a flexible machining center ready to machine different materials, shapes, requiring various stock removals.
B2
B1 B6
B8 B9 B10 B11
Turning Centers
DANOBAT lathes allow the possibility to remove high chip volume with the special configuration for generator shafts, featuring a double turret lathe. Driven tools may be also incorporated, enabling to combine different operations in a single machine.
High precision “B” axis
The European patented Danobat’s exclusive high precision integrated swivelling “B” axis, provides accurate wheelhead positioning:
· Driven by a torque motor · Direct read out of axis position · High rigidity
· Maintenance free
For the grinding of pitch & yaw systems, DANOBAT proposes external and
internal/external high precision grinding machines equipped with natural granite bed and linear motors technology.
.
Internal/External grinding machines:· Turret with up to four spindles · Radii grinding
· Post process gauging
grinding
.
High precision grinding machines:· Longitudinal travel: 400 – 600 mm · Swing 300 mm
· Wheelhead on “B” axis
· MDM absolute measuring system · One finished part in one clamping
18
PITCH & YAW
sawing · turning · milling
Accurate milling and drilling operations, working in pendulum loading, resulting in massive cost savings.
BEARINGS &
FLANGES
High production horizontal cutting machines to start the process of manufacturing of rings.
There are two different solutions: a wagon system to support very heavy components or gantry type sawing machine with portable sawhead.
· Maximum sawing diameter: up to 2,500 mm
· Length: 2-3…12 meters. According to customer's requirements.
Milling & Drilling
Vertical Turning Centers
Proven performance in combining turning and drilling operations with high precision and productivity.
Possibility of adding a second Ram for simultaneous machining and maximum metal removal.
· Maximum turning diameter: 6,000 mm · Table drive motor: 60 kW – 80 kW – 100 kW
BEARINGS
& FLANGES
Grinding Machines
Production
Grinding
Machines
Internal
Grinding
Machines
Vertical
Grinding
Machines
page 27 page 26 page 27Boring Mill Centers
page 25
Turning Machines
Horizontal
Lathes
Turning
Centers
Vertical
Turning
Centers
page 24Sawing & Drilling, and 3D Plasma Cutting Machines
page 23
Fully Automated Composite Parts Manufacturing Process
page 22
Sawing
machines
Sawing &
Drilling
lines
3D Plasma
cutting
machines
page 23 page 23 page 2422
Highlights:
· Own new developed technology
. Fabric Automatic Deposition (D.A.F.), either dry or impregnated, onto the mould under set-up pressure
. Ultrasonic based cutting system . Auto-controlled roll storage · Automatic reel feeder
· In-line impregnation possibility · Auto-control systems · In-machine curing · Mould extraction Longitudinal travel Vertical travel Cross travel Resine type Fibre type Fabric type
Fabric reel diameter Fabric reel length
units DAF
m 8 - 200
m 2 - 7
m 2 - 20
- Poliester / Vinil-ester / Epoxy - Glass / Carbon / Basalt - Unidirectional / Multiaxial / 3D / Mat
mm 10 - 1000
mm 10 - 2000
Fully automated manufacturing process of large structural composite parts.
Close to our customers, Danobat offer especially customised machines, critical in production lines, covering the complete machine life cycle, which results in a REPEATABILTY & QUALITY improvement as well as a LEAD TIME reduction.
. Auto positioning with respect to the mould · Flexible to customer requirements . Modularity concept
· Teleservice. Quick diagnosis and remote problem solutions
· Offline simulation and programming
· Advance data managing and control solution · Traceability of manufactured parts
· Safe-working conditions assured by the implantation of protections according to CE Standards
Highlights:
· Machine prepared to work with bimetal & carbide blades · Automatic cutting parameters software “'PASO A PASO” · Intelligent cutting deflection control
· Automatic running in process
Max. cutting capacity Band sizes
Main motor power
units GH/CP-TV mm 2,500 mm 54 / 67 / 80x1,6 kW up to 25
Sawing Machines
Highlights:· CNC mitre cutting machines -45º/+60º
· Machine prepared to work with HSS and carbide · Loading / unloading customised solutions
Max. cutting capacity Max. drilling diameter
units CPI/T3CH
mm 1,500
mm 50
Sawing & Drilling lines
3D Plasma cutting
machines
Highlights:· Possibility to cut round pipes · DSTV importer
· Marking system
Max. cutting capacity Max. cutting diameter Plasma source
units RPD-T
mm 1200 x 600
mm 500
24
Horizontal Turning Centers
Swing over bed Swing over saddle Max. turning length Max. main motor power Max. chuck diameter
units TH/TCN mm 600-1,100 mm 430-900 mm 7,000 kW 125 mm 250-1,000
Vertical Turning Centers
Highlights:· Fixed or elevating crossrail
· Live spindle or static tooling models
· Two ram models for maximum metal removal · Automatic tool setting units
· In process work gauging
· Tool force monitoring and tool breakage detection systems
· Coolant through spindle · Direct linear measuring scales
· Hydraulic counterweight for the vertical axis · Electric cabinet cooling systems
Max. turning diameter Table diameter Table drive motor Ram dimensions Live spindle power ATC units VTC mm 1,600-6,000 mm 1,400-5,000 kW 60-80-100 mm 250x250-300x300 kW 17-22-37 no. 18-24-40-60-80 Highlights: · Slant bed
· Ground & hardened steel guide ways · Ultraprecision headstock bearings · Automatic centralised lubrication · Optional “C” axis
benefits. The SORALUCE “F series” meets the continuing demand of wind power market for higher reliability, greater efficiency and increased manufacturing output.
Highlights:
· Design and manufacturing of Top Quality machining heads, being robust, flexible and reliable, focused on the Wind Power market · Automatic head changing system for
unattended machining process
· Robust machines with cast iron structures to provide maximized rigidity
· Complete accessories to match the machine to the customer’s requirements:
- Adaptative control to improve the cutting conditions
- Anti-collision system to protect the machine and the component - A wide range of integrated
rotary-travelling tables (loads / dimensions) - Operators’ platforms with vertical and
cross movement to allow the operator to gain greater access to the workpiece
Longitudinal Travel Vertical Travel Cross Travel Head Power
Automatic head changing ATC
units Boring Mill Centers “F” series
mm 4,000 - 30,000
mm 2,100 - 6,500
mm 1,300 - 1,900
kW 30 - 46
Automatic / Orthogonal / Horizontal no. 40 / 60 / 80 / 100 / 120
Orthogonal head 1ºx1º (1ºx0,001º) / 37 kW 4,000 (6,000) rpm
Fixed horizontal head 37 – 46 kW
3,000 (4,000, 5,000, 6,000) rpm
Special head designed as per customer´s requirements Automatic head changing system
- Pendulum working system for loading /unloading without interrupting the cycle time
- Splash guarding designed to the customer’s requirements
- High-pressure coolant through the spindle
· Other standard features to suit current requirements:
- Safety guarding in accordance with CE standards
- Automatic centralized lubrication - Direct linear measuring scales - Rapid traverses up to 25 m/min · Turn-key projects: clamping fixtures, cutting
tools, CAD-CAM processing, simulation, training, production launch support, etc.
26
Highlights:
· Wheel head on a “B” axis
· Different wheel head configurations · Absolute MDM measuring unit · Various In-Process gauging
possibilities
· Post process dimensional and geometric report
· Very high flexibility
· One finished part in one clamping
Distance between centers Swing over the table Max. weight Max. wheel size Peripheral speed mm 600 500-1,500 1,000-2,000 1,500-4,000 2,000-6,000 mm 350 450 450 650 1,050 kg 100 150 500 1,500 7,000 mm 600x150 760x250 508/610x150 915x300 1,060x150 m/s up to 100 50-60 45-60 units FG PG HG-62 HG-72 HG-92
Production Grinding
Machines
Vertical Grinding Machines
Highlights:· Internal and external grinding with high frequency spindles · "B" Axis:
- Automatic Tool changing - Optional tangetial head · Probing software · Hard turning option
Max. diameter Max. height Swing “B” axis units VG mm 1500 mm 500-1000 mm up to 1600 option
Internal Grinding Machines
Highlights:· Radius grinding on “B” axis · Turret with four spindles on “B” axis
· In process measuring and post process grinding & geometric report Max. diameter Max. height Swing “B” axis units ID mm 460 mm 300 mm up to 600 option
DANOBAT Tel. +34 943 748044 E-mail: [email protected] www.danobat.com DANOBAT-OVERBECK Tel. +49 2772 801-0 E-mail: [email protected] www.danobatoverbeck.com SORALUCE Tel. +34 943 769076 E-mail: [email protected] www.soraluce.com BIMATEC SORALUCE Tel. +49 6431 97820 E-mail: [email protected] www.bimatec.de
Arriaga Kalea, 2
E-20870 Elgoibar (Spain)
Tel. +34 943 748300
Fax. +34 943 743674
E-mail: [email protected]
www.danobatgroup.com
Tel. +55 11 3082 9080 E-mail: [email protected] Tel. +86 10 64673639 E-mail: [email protected] Tel. +91 20 6609 4531 E-mail: [email protected]