Rounding machine ots 550. OOO "Izhprest"

Rounding machine OTs-550 is designed for primary wood processing and performs the following operations:

rough processing of a log (barking of a log);
finishing of logs (rounding);
selection of a longitudinal mounting groove;
a selection of crown bowls;
direct milling (planing) of the inner surface, which completes the rounding of the log (optional operation);
milling of longitudinal compensation grooves of various configurations (to be ordered separately);
drilling mounting holes (optional).

All of the above operations, including log rounding, are performed in one installation of the log, with one set of tools.

Design

Structurally, the rounding machine OTs-550, with the help of which high-quality log rounding is carried out, consists of three sets of assembly units:

Bed (Rail way).
Equipment bed (rail track).
Movable portal with an actuator.

Rail track (bed) of the machine standard configuration consists of three sections of 3.0 m in length, providing in the basic delivery option the processing of logs (log rounding) up to 7.5 m. The rail track and the length of the processed log can be extended by equipping it with additional sections. The design of the rail track provides for its adjustment, both along the plane and the width of the guides, and also provides the ability to place the unit on slopes with an inclination angle of up to 15°. Attachment docking points ensure the alignment of the front and rear headstocks of the log fastening system and their mutual alignment with an accuracy of 10`-30`, as a result of which the log cylindering is carried out with high quality.

To ensure all possible operations log processing (including log rounding), the rail track is additionally equipped with the following units:

Log loader from the ground;
Two taper selection devices with log fixation along the axes of the front and rear headstocks.
Log drive hydraulic station with control valve.
Front and rear headstock, providing alignment.

The movable gantry with an actuating mechanism consists of a carriage on which a mechanism for vertical and horizontal automatic movement of the tool is located, an automatic feed mechanism and an electronic or manual control system. The control/control system allows you to smoothly position the coordinates of the position of the tool and the workpiece to be processed with an accuracy of 0.5 mm.

An aspiration system with a floor cleaning function is ordered additionally and provides for 95% suction of chips formed during the rounding of a log and inter-shift cleaning of the workplace from its residues.

Standard equipment

Rail track (frame) with a total length of 9 m.
Mobile portal with drives.
Headstock, clamping screw.
Universal groove-cup cutter (for ALL operations).

Additional equipment

Log lifters in the center are manual.
Hydraulic log loader on the frame.
Hydraulic drive (hydraulic station) with a distributor and a set of high pressure hoses.
Log lifters in the center are hydraulic.
Automatic feed of the machine is smoothly adjustable electromechanical.
Device for making longitudinal compensation grooves.
Device for making mounting holes (drill).

The mechanical part of the machine is made with the necessary margin of safety.

The load on the motors used in the machine does not exceed the limits of permissible values. In addition, the frequency converters used in the design provide soft start modes and economical operation of all electric motors.

Small components (belts, chains, bearings, hardware, etc.) are borrowed from automotive technology and can be easily and inexpensively purchased at any auto parts store. This is especially important when supplying equipment to remote regions.

Country of manufacture: Russia

Machining center with automatic tool change and rotary device OTs1I22 is designed for milling various surfaces (flat and curved), boring, drilling, countersinking and reaming holes, tapping, milling in parts made of hard-to-cut materials such as steel, cast iron, non-ferrous metals and their alloys.

The machines allow to measure and store the length of the tool with an accuracy of 0.01 mm, which provides the possibility of processing surfaces to merge, eliminates the need for manual tool setting outside the machine and simplifies the preparation of programs. The measured values are automatically stored in the memory of the CNC. The CNC device provides adaptive control of the feed rate according to the power of the drive of the main movement, as well as monitoring of wear and tool breakage.

Perform operations: four-coordinate machining of parts complex shape; processing of parts up to 250x250 mm from 4 sides on a faceplate; processing of long parts; processing of body parts; contour milling; processing of spiral grooves and windows on cylindrical parts; automatic control of the cutter radius, tool length and measurement of the machined part.

Specifications OTs1I22

Specifications	OTs1I22
Machine accuracy class according to GOST 8-82
Dimensions of the working surface of the table, mm
The greatest movement of the table relative to the spindle axis, mm
longitudinal (X-coordinate)
transverse (Y coordinate)
The highest speed of table movement, m/min, not less than
in the longitudinal direction
transversely
Limit dimensions of installed workpieces, mm
when fixed on the table

The largest mass of installed workpieces, kg
when fixed on the table
when fixed in a rotary device
Number of spindles
Distance between axes of spindles, mm
Spindle taper according to GOST 15945-82
Spindle speed limits, rpm
Maximum displacement (Z coordinate), mm, not less than
Maximum travel speed, m/min, not less than
Number of mechanisms automatic shift tools
The largest number of tools, pcs
The largest mass of the tool with a mandrel, kg
The largest diameter of the tool, mm	105 (160 with free adjacent magazine slots)
Automatic tool change time, s
Positioning accuracy, µm
Positioning stability, µm
Machining accuracy during contour milling, mm
The total power of all electric motors installed on the machine, kW
Overall dimensions, mm
length
width
height
Weight, kg

ROLLING MACHINE

"MASTER OTs-550"

1. PURPOSE

Rounding machine "Master OTs-550" is designed for primary processing of wood and obtaining logs, completely ready for the assembly of houses.

The machine performs the following operations:

log rounding;
selection of a longitudinal mounting groove;
cup samples;
plane milling;
milling longitudinal grooves of various configurations.

Log processing scheme.

All operations are performed sequentially, without reinstalling the log and cutter.

Besides, design features machine "Master OTs-550" allow you to set the clamping center (front and rear headstock) in such a way that at the output you get conical logs(with natural taper), which are used as power line pylons (TL).

All of the above operations are performed for one installation of a log, with one set of tools.

2. OPERATING PRINCIPLE

The processing of a log is carried out by a type-setting cutter, the axis of rotation of which is located perpendicular to the axis of rotation of the log.

Longitudinal trolley feed(when rounding and selecting a longitudinal groove) - manual or automatic with smooth adjustment of the feed rate.

Vertical feed cutter(when choosing a "cup") automatic also with smooth speed control.

3. DESIGN OF THE MACHINE

Structurally cylindering machine "Master" consists of three sets of assembly units:

Rail track (bed);
Rail track equipment;
Movable portal with an actuator.

4. STANDARD EQUIPMENT OF THE MACHINE

Rail track (frame) with a total length of 9.0 m.
Mobile portal with drives.
Headstock, clamping screw.
Universal groove-cup cutter.

5. OPERATION OF THE MACHINE

The following can be distinguished as the main stages of the work of the machine:

Log feeding to the loader;
Exposing the log along the axis of the front and rear headstock;
log clamp;
Finishing:

log debarking
Log rounding
Mounting groove selection
Obtaining crowns of the required configuration.

Rail track (bed) The machine in the standard configuration consists of three sections of 3 m in length, which provide processing of logs up to 7.5 m in the basic version of delivery. The rail track and, accordingly, the length of the processed log can be increased by retrofitting it with additional sections.

The design of the rail track provides for its adjustment, both along the plane and the width of the guides, and also provides the ability to place the unit on slopes with an inclination angle of up to 15.

Attachment docking points ensure the alignment of the front and rear headstocks of the system for fastening and centering the log and their mutual alignment with an accuracy of 10-30.

rail track. Mounting and equipment of the rail track

To reduce the amount of manual labor when processing logs, the rail track can be additionally equipped with:

log loader;
Two hydraulic or manual log lifters in the center (on the headstock and tailstock)
Log drive hydraulic station with control valve.
Front and rear headstock, providing alignment.

Mobile portal with an actuator includes a mechanism for vertical and horizontal (smooth automatic and / or manual) movement of the tool, suction system, automatic feed mechanism and electronic control system.

The control/control system allows you to smoothly position the tool and the workpiece (log) to the desired position with an accuracy of 0.5 mm or 30, respectively.

Aspiration system with the function of cleaning the floor (ordered separately) provides for the suction of most of the chips formed during the processing of the log, and inter-shift cleaning of the workplace from its remnants.

Auto feed mechanism provides smooth automatic (depending on the load on the main engine) or manual control of the feed rate of the machine portal from 1 to 30 m/min.

Circuit board. For better ergonomics, the board on which the processing tool is mounted is additionally equipped with a backlight.

In a noisy environment, this allows you to simultaneously monitor the status of the tool (voltage applied to the main motor or not).

TECHNICAL CHARACTERISTICS OF THE ROLLING MACHINE "MASTER OTs-550"

No. p / p	Parameter	Meaning
1	Maximum workpiece diameter, mm	550
2	Workpiece length, m	0.5¸6.0
3	Diameter of logs, mm	80¸550
4	Maximum thickness of the layer cut in one pass, mm	20
5	Cutter rotation frequency, rpm	4500
6	Workpiece rotation frequency, rpm	0¸150
7	Main engine power, kW	11,0
8	The power of the automatic feed motor of the machine portal, kW	0,75
9	Total weight of the machine, kg	2400
10	Regular dimensions of the machine, m	9.0´2.5´2.5
11	Number of attendants, people	2
12	Deviation of the longitudinal profile of round logs, mm	no more than 1

Additional equipment:

Hydrostation with hydrodistributor.
Log loader.
Hydraulic or manual log lifters in the center (on the headstock and tailstock).
Blocks automated control(setting the position of the cutter, choosing the location of the “cup” on the log).

The mechanical part of the machine is made with the necessary margin of safety.

The load on the motors used in the machine does not exceed the limits of permissible values. All motors and gearboxes installed on the machine are imported. 3 year warranty on the cutter drive motor.

The use of frequency converters (inverters) as part of the design ensures smooth start-up of electric motors, soft operating modes and energy savings.

The main components of the machine (belts, chains, bearings, etc.) are borrowed from automotive equipment, which has significantly increased the maintainability of the machine when delivered to remote regions.

7. TRANSPORTATION

Transportation of the machine is carried out by vehicles with a body length of at least 5.0 m or by a railway container of 20 tons.

8. INSTALLATION OF THE MACHINE

Installation of the machine includes: assembly of the frame, alignment of the guides along the plane and horizon, installation of carts on the guides, connection of power cables. Installation usually does not exceed 1 shift, and can be carried out by the Customer. No special foundation is required. Best Option- concrete platform.

Productivity of the cylindering machine

"Master OTs-550"

The processing time of one log depends mainly on the quality of the workpiece: a workpiece close to calibrated is processed in two or three passes (barking, roughing and finishing), if the diameter of the workpiece is very different from the diameter of the required cylinder, more passes are required (3-4 ), respectively, the processing time increases.
Completion with additional options for rounding machines (automatic lifting of logs to the center, automatic carriage feed, piece-by-piece issuance of logs, a chip conveyor) allow increasing the productivity of the machine by 30 - 50%.
The following factors affect the productivity and quality of the machine as a whole:
1. Complete set of equipment.
2. Qualitative and dimensional parameters of the feedstock.
3. Specification of the received products.
4. Way of organizing production.
The following are typical parameters for actual production on a single rounding machine.

Only cylindering

Rounding and polishing a log 6.2 m long: 8-10 minutes

Total, for one log: 12-15 minutes
Productivity in p/m: 195-250 p/m
Productivity in cubic meters, (diameter 200 mm): 6.2 - 7.6 cubic meters per shift
Productivity in cubic meters, (diameter 240 mm): 8.8 - 10.6 cubic meters per shift

Rounding and longitudinal groove

Installation / removal of a log: 4 minutes
Total, for one log: 16-20 minutes
Productivity in p/m: 144 - 180 p/m
Productivity in cubic meters, (diameter 200 mm): 4.8 - 5.8 cubic meters per shift
Productivity in cubic meters, (diameter 240 mm): 6.8 - 8.4 cubic meters per shift

Complete processing

Rounding a log 6.2 m long: 8-10 minutes
Longitudinal groove selection: 2 minutes
Sample of two crown bowls: 6 minutes
Installation / removal of a log: 4 minutes
Total, for one log: 25-30 minutes
Productivity in p/m: 98-120 p/m
Productivity in cubic meters, (diameter 200 mm): 3.2 - 3.8 cubic meters per shift
Productivity in cubic meters, (diameter 240 mm): 4.6 - 5.6 cubic meters per shift

Advantages of Master OTs-550 rounding machines over similar positional type rounding machines

"Master OTs-550"	Analogues
Heavier, stronger, stiffer frame designed to withstand years of use, shock loads and heavy logs. The bed is made of thick-walled profile pipes having a large margin of safety. The weight of the frame is more than 2 tons (total weight of the machine is 2.6 tons). (In woodworking machines, weight is one of the main parameters that determine quality, reliability and service life.)	The bed is much lighter, therefore, less durable, by weight much less than the weight of the logs being processed, therefore, mechanical deformations will inevitably occur, and, accordingly, a violation of the log geometry and a reduction in the service life of the machine. The total real weight of the machines is from 300 kg. up to 1 ton or slightly more.
bed optimal height- the log is at the level of the operator's belt, it is more ergonomic, the processing area is always in the visibility sector. It is also possible to install attachments that do not go beyond the dimensions (mechanisms are removed under the frame). There are various mechanized options for loading logs.	The bed is low (floor), which excludes the possibility of installing any attachments and mechanization. Few levels of adjustment. With possible mechanical deformation, the correction is laborious, expensive and ineffective. The operator has to bend down to control the operation of the cutter. Loading of a log only manually or a hoist.
Three degrees of bed adjustment, respectively, less requirements for the installation site and the ability to quickly restore the geometry, in the event of, for example, ground movements in the off-season.	Non-adjustable bed - the geometry is completely dependent on the base of the site (floor).
The presence of both constant and variable continuously variable speed of rotation of the log in the centers, which makes it possible to more accurate and clean cylindering and the ability to adjust to the parameters of a particular log and to the operation being performed.	The rotation speed of the log is constant.
More reliable and accurate worm gear for log rotation drive.	Chain transmission of the log rotation drive (it is possible to stretch the chains under such loads).
The guides are suspended independently from the frame, i.e. the weight of the log during operation and during the fall does not fall on the guides in any way and will not violate their geometry. The design excludes a touch of a log and guides. As guides, a special high-quality profile with a “work hardening” of the surface is used. The quality of the profile is unchanged throughout the life of the machine when processing logs of any length.	The guides form a monolith with a bed, i.e. in the event of a fall of a log, the geometry of the entire frame will be violated. As guides, a regular calibrated circle or a 6-sided square is used, therefore, when processing logs of different lengths, “steps” are formed on the guide (profile development) and further operation of the machine is difficult.
A large number of extra attachments (see description), which allows to reduce the number of maintenance personnel and automate the work process as much as possible.	Add. there are either no options, or few, not for all stages of work.
Smooth adjustment of movement in all directions. Thanks to this, a high angular movement accuracy of  0.5˚ and fast travel to the set value.	Smooth adjustment is either absent, or only in one direction. Low accuracy of angular movement, longer exposure of the cutter to the desired position due to the need for manual finishing.
The presence of a thermal stabilization unit to ensure the correct operation of frequency converters, which makes it possible to work in unheated rooms. The unit additionally protects the frequency converters from power surges and shows the temperature in the electrical cabinet in real time. Automation does not give permission to turn on the machine when the ambient temperature is dangerous for the operation of the converter. environment. (The operating condition of any frequency converter is a temperature not lower than -7-10˚ and no condensation.)	The lack of funds to provide a working temperature regime in the electrical cabinet and, as a result, the possibility of failure and reduced service life of expensive frequency converters.
Cutter fastening - on screws with protection against unscrewing.	Cutter attachment - on the thread. Unreliable, possible failure due to thread deformation, sawdust and dirt from the bark of logs getting into the thread, violation of the thread pitch and, as a result, the need to replace the fastening mechanism.
The presence of automatic (electromechanical) machine feed with smooth speed control. It greatly affects the quality and speed of processing logs. With manual feed, it is impossible to ensure a uniform feed of the carriage and, as a result, “risks” and “waves” on the log are possible.	Autofeed is either absent or does not have a smooth adjustment.
The headstock and tailstock (center), in which the log is clamped, are mounted on separate guides and, when processing logs of different lengths, move forward / backward with a slight movement. (In the working position are fixed).	The front and rear headstocks (center), in which the log is clamped, lie directly on the frame and, if necessary, they must be moved and lifted. Given the large weight, this causes certain difficulties and loss of time.
In the basic configuration, "Master OTs-550" is cheaper than analogues, despite the existing advantages.	Lower indicator "price / quality".