COMPLETE SOLUTIONFOR VALVE MACHININGVALVECENTER

2 | V A L V E C E N T E R 3 | V A L V E C E N T E R

V A L V E C E N T E R V A L V E M A C H I N I N G

DANOBATGROUP is a leading global solution provider for valve bodies manufacturers and one of the largest European machine tool manufacturers.

DANOBAT offers extensive experience in the manufacturing of lathes. With the development of emerging technologies and a skilled workforce commited to total quality, DANOBAT can competitively achieve the objectives to comply with the quality required by its customers.

VALVECENTER

VALVE MACHINING

VALVECENTER -VALVE MACHINING

The VALVECENTER machine range implements a new flexible and economical concept of manufacturing complete valves. It provides a solution, with a high reliability, in the turning, milling and drilling processes.

The VALVECENTER is an autonomous flexible CNC machine which consists of:

• A turning unit for the turning, facing and boring operations.

• A drilling unit of 2 horizontal CNC heads, for drilling, milling, thread cutting and slotting operations.

These machining units, and the single clamping set up, using an automatic indexing chuck, result in high performance levels.

4 | V A L V E C E N T E R 5 | V A L V E C E N T E R

V A L V E C E N T E R V A L V E M A C H I N I N G

MAIN VALVECENTER CHARACTERISTICS

The uniquely designed VALVECENTER has a perlitic cast iron bed, heat treatment stabilized, assuring an extraordinary high stiffness and stability.

Hardened and ground prismatic slides are fitted in the bed and they ensure the accurate movement of the drilling and turning units and allow high stock removal capacity during roughing and finishing operations.

All the slides are protected by telescopic guards in order to facilitate chip and coolant removal from the working area.

MAIN VALVECENTER CHARACTERISTICS

The workhead is also manufactured using perlitic cast iron and fitted directly onto the bed. The main characteristic of the workhead is its high stiffness.

The workhead incorporates very high quality bearings, giving a capacity to machine valves bodies up to 800 Kg. The bearings are lubricated and cooled with an oil circulating system and ensures full power utilization in all speed ranges from 100-600 rpm.

Supplied as standard, the workhead includes a C axis, driven with an independent motor, as well as a hydraulic brake in order to position the part in an exact angular position.

TURNING UNIT

Due to its design, the indexing chuck has very high stiffness, it indexes automatically in the 4 positions at 90º and this allows machining the 4 faces of the valve with only one clamping operation.

The reduction of clamping operations to just a single operation, eliminates inaccuracy sources, such as multiple clampings and potential relocating inaccuracies which will result in a better performance and a higher quality machined valve.

INDExING CHUCK

Located on very rigid cast iron slides with x and Z controlled movements.

Designed with HSK-B tool clamping system (mechanical clamp/hydraulic unclamp) and incorporates a tool clamping safety system.

Tool coolant at high pressure (25 bar).

DRILLING UNIT

The machine is designed with two drilling heads located on one slide. This slide has a movement in the Z axis.

However each drilling head has its own independent movement in the x-axis, and its own motor for the tool rotation. This configuration reduces drilling time by 50% as two holes can be drilled simultaneously.

Both drilling heads are provided with the HSK-A clamping system. Tool coolant at high pressure (25 bar).

The tool changing is done by automatic robot.

TOOL MAGAZINE WITH ROBOTThe 48 tool magazine is positioned in the rear of the machine, the safest area to avoid any coolant or chip contamination. The machine user can load and unload the tools via a service door, without interrupting the machining process.

6 | V A L V E C E N T E R 7 | V A L V E C E N T E R

V A L V E C E N T E R V A L V E M A C H I N I N G

VALVECENTER machine range advantages

MAxIMUM PRODUCTION AND PRODUCTIVITy

VALVE (forged steel) Ø 2 1/16” Ø 3 1/8” Ø 4 1/16” Ø 5 1/8” Ø 6 1/16”

5000 psi 1h. 10 min 2h 2h. 30 min 2h. 50 min 3h. 30 min

10000 psi 1h. 50 min 2h. 15 min 2h. 50 min 3h. 15 min 3h. 40 min

Some other advantages of the VALVECENTER:• Quality improvement: due to the single clamping machining process, expensive setting operations (such as the centring of the valve) are avoided and the quality of the part is improved.

The HSK clamping system, with a double contact design and high repeatability, results in a very reliable clamping operation within a very high range of tolerances.

• Total flexibility: minimum adjustments are required within a wide range of valves. In addition to the indexing capacity of the chuck, the machine has another 5 axes controlled by the CNC.

• Maximum production: the turning head provides the machine with a high machining capacity. The two drilling heads can reduce drilling operations by 50%.

• Stock reduction: The Valvecenter requires less floor area than other traditional alternatives such as a lathe and a machining centre combination.

• Lead time reduction: the high productivity and flexibility permits working with customers who have short delivery times.

• Shop floor reduction: the VALVECENTER requires less floor space than other traditional alternatives such as lathe, machining centre or a transfer line solution.

• Profitability: the VALVECENTER guarantees a reduction in the cycle time, in stock removal and in intermediate operations. The number of required machine operators is reduced. The result is a higher quality product, better customer service and lower manufacturing cost.

SPECIFICATIONS 5VT 6VT

GENERAL

Ground centers heightSwing over bedMaximum chuck diameter recommended

1250 mm1100 mm1000 mm

1450 mm1270 mm1200 mm

MAIN SPINDLE

Front bearings diameterSpindle steeples speedSpindle nose type

280 mm0-800 rpm

A20”

360 mm0-600 rpm

A28”

TURNING UNIT

Longitudinal Z strokeTransverse X strokeTool holder system

1130 mm480 mm

HSK-B 125

1230 mm480 mm

HSK-B 125

DRILLING UNIT

Longitudinal Z strokeTransverse X stroke of each unitTool holder system HSK-A-63

1130 mm310/295 mm

HSK-A-63

1230 mm310/295 mm

HSK-A 63

MOTOR

Main spindle motor power (100% / 40%)Drilling Units motors power (100% / 40%)X axis drive ( Nm / rpm )Z axis drive ( Nm / rpm )

45/60 kW22/30 kW22/4000 40/4000

60/75 kW 22/30 kW22/400040/4000

STORE 5 VT 6VT

TURNING TOOLS HSK-63 A HSK- 63A

Nº Tools 16 16

Max. length 530 mm 650 mm

Max. weight of tool 20 kg 40kg

DRILLILNG TOOLS HSK-63 A HSK- 63A

Nº Tools 32 32

Max. length 200 mm 200 mm

Max. weight of tool 8 kg 8 kg

STORE 5 VT 6VT

One

set up/clamping

8 | V A L V E C E N T E R 9 | V A L V E C E N T E R

V A L V E C E N T E R V A L V E M A C H I N I N G

DANOBATGROUPDANOBATGROUP is one of the largest machine tools manufacturers in Europe. For more than half of a century we have supplied machines to highly reputable customers establishing a worldwide presence.

DANOBATGROUP is the machine tool division of one of the most prestigious Spanish industrial holdings, Mondragon Corporation with a workforce of nearly 100,000 people, and more than 15 billion Euros in turnover.

USA

BRAZIL

CHINA

JAPAN

INDIA

GERMANY

ITALY

UNITED KINGDOM

RUSSIA

SPAINHEAD QUARTERS

FRANCE

DANOBATGROUP has offices in 10 countries and our professional representation network completes our presence worldwide.

The technological heart of the company relies on IDEKO IK4 Research and Development Center. Its major activities consist on optimizing traditional processes, developing new ones, and designing the machines capable of working with these demanding processes.

World leaders in valve manufacturing such as AMPO-POyAM, AKER SOLUTIONS, CONSTRUCTORA NACIONAL DE VÁLVULAS, CONTROL FLOW , COOPER CAMERON, EMIRATES TECHNO CASTING, KORVET, MÉCANICA MILANESE, METARLÚRGICA SCAI, MOTOMECÁNICA ARGENTINA, NATIONAL OILWELL, PH NIx ARMATUREN, SOMEPAL and STREAM FLO INDUSTRIES among others, have placed their trust in us throughout the world in Europe, South and North America, Africa and Asia.

DANOBATGROUP is always next to its customer, providing the best attention and offering a customised service in local language and timetable.

MORE INFORMATION ABOUT DANOBAT VALVECENTER

www.danobatgroup.comIf your mobile phone has the QR code reader tool you will be able to go directly to our site at www.danobatgroup.com

DANOBATArriaga kalea, 21E-20870 ELGOIBAR (Gipuzkoa) Spain

Tel.: + 34 943 74 80 44Fax: + 34 943 74 31 38sales@danobat.comwww.danobatgroup.com

OUR COMPANy, yOUR PARTNER

Project management:

Together during the complete machine lifecycle:

· Technical assistance by local service engineers.

· Teleservice.

· Hotline.· Preventive maintenance.· Spare parts available.

· Machine set-up & commissioning.· Personnel training.· Production assistance.

This

doc

umen

t is

not a

con

trac

t. D

AN

OBA

T re

serv

es th

e rig

ht o

f mak

ing

chan

ges

to a

ll m

odel

s w

ithou

t prio

r not

ice.

The

illu

stra

tions

in th

is c

atal

ogue

rem

ain

prop

erty

of D

AN

OBA

T.©

DA

NO

BAT

2012

01/2

012

SPECIALIZED MULTI-TECHNOLOGICAL SOLUTIONS

Grinding machines Band sawing machines and drilling units

CompositeVertical lathes Horizontal lathes

· Local sales service team at your disposal.· Production process analysis by local product engineers.· Feasibility analysis.· Technical & economical study.

· Customised machining solutions.

· Improving machining process study.

· Fixturing.

· Tooling.· Software.· Acceptance trials machining

customer’s parts.

Next to the customer from the beginning:

Customized solutions:

In DANOBAT we offer a service to perform a machining test on our machines with your workpieces. you can check the capacity of our process team and DANOBAT machines, thus making an investment with a guarantee.