Powermill G3 HPC3: EMCO Mecof's gantry milling machine combines robustness and versatility

When we talk about Italian manufacturing, adjectives such as ‘reliable’ for its attention to build quality, ‘robust’, linked to Italian engineering and mechanical tradition, ‘versatile’, typical of Italian design flexibility, “innovative”, for the all-Italian ability to combine tradition with the search for technological solutions, and ‘excellent’, for its extreme attention to detail and design. It is no coincidence that the Powermill G3 HPC3 was chosen by an Italian customer in the general engineering sector, because this machine combines the robustness of large mechanical structures with the innovation and versatility of the solutions offered by Mecof to meet the customer's requirements for precision and reliability. Because for both of them, it is important to achieve one goal: excellence.

Impressive dimensions, millimetric precision
The machine we are describing here is built to handle the accurate machining of large workpieces: with strokes of 18 metres in X, 4.5 metres in Y and 1.75 metres in Z, the Powermill G3 HPC3 offers a working capacity that places it among the highest-performing solutions in its category.

The machine is equipped with a class II work surface in accordance with DIN 876, 18 metres long and 3 metres wide, with a load capacity of 15,000 kg/m²: figures that speak of extraordinary robustness.

The chain tool magazine with 80 positions and sliding exchange arm, ISO 50 connection, completes the picture, reducing downtime and ensuring maximum production continuity.

The versatility of the dual-rotating head
At the heart of the machine's operational flexibility is the universal dual-rotating head with automatic millesimal positioning, 38 kW and 615 Nm, capable of reaching 6000 rpm with ISO 50 connection. The head is designed for automatic changeover, an operation made even easier by the support system, with a protective cradle equipped with positioning references that can be quickly removed when not needed,optimising space.

Automation and connectivity: Industry 4.0 on board the machine

Equipped with Heidenhain TNC 640 HSCI numerical control, the same supplier also provides the options for the Industry 4.0 package, which includes:

                       - Heidenhain TNC Remo, for remote loading of instructions and programmes,
                       - Heidenhain DNC, which connects the machine to the company's logistics systems,
                       - CAPR, adaptive control that optimises machining cycles in real time.

Control and measurement always at hand
Precision is guaranteed by a complete package of control tools: Renishaw RMP60 radio probe, kinematic measurement and laser system for detecting tool length and diameter. All this helps to reduce errors and increase the reliability of machining operations.

Smooth management and chip evacuation
The customer raised the issue of proper chip evacuation, given the machine's need to perform heavy- duty machining. The solution was quickly found by integrating a dual-delivery cooling system, both external (6 bar, 28 l/min) and internal to the spindle (40 bar, 20 l/min).

This is supported by 2000-litre filter and collection tanks and a chip evacuation system with two ramp conveyors along the entire work surface.

Safety and ergonomics
Safety does not necessarily mean that a machine must be subject to strict construction and design rules.technology also comes to the rescue in this area, giving the user full freedom to control and manage the Powermill G3 HPC3 via the Heidenhain HR 550 FS wireless keypad and the integrated video surveillance system with Bosch cameras and 19" touchscreen monitors, which allows real-time monitoring of the work area, with additional protection against chips and coolant.

The Powermill G3 HPC3 is not just a generously sized gantry milling machine: it is a complete machine, designed to guarantee productivity, precision and digital integration. For Italian and international general engineering companies, it represents a strategic investment that combines mechanical robustness, versatility and connective intelligence.

 

EQUIPMENT:

Powermill G3 HPC3

CNC                             Heidenhain TNC 640 HSCI
Travel in X                    18.000 mm
Travel in Y                    4.500 mm
Travel in Z                    1.750 mm

Universal bi-rotating head with automatic millesimal positioning 38 kW, 615 Nm, 6000 rpm, ISO 50 tool connection. Designed for automatic head change operations

Support for automatic head change, consisting of a cradle with head protection. Precise references and micro-sensors for automatic stroke limitation are mounted on the work surface or foundation. The support can be quickly removed from its position.

Industry 4.0 option package: Heidenhain TNC Remo, which allows remote loading of instructions and part programmes; Heidenhain DNC, which allows automated connection of the machine to the factory logistics system; CAPR, adaptive control option.

80-position tool changer, consisting of a chain magazine with a capacity of 80 tools, fixed to the rear of a crossbeam shoulder, with an exchange arm that slides on a guide, also fixed to the shoulder. Fully ISO 50 tool attachment.

Heidenhain wireless remote control panel, model HR 550 FS, as an alternative to the remote control panel model HR520 provided in the base machine.

Renishaw RMP60 radio measurement probe

Kinematic measurement

Laser device for measuring tool length and diameter, permanently installed on the X-axis structure. Includes control tool.

Chip evacuation system, consisting of two ramp conveyors located longitudinally to the work surface.

Dual-delivery cooling system: 1) delivery near the spindle (pressure 6 bar, flow rate 28 l/min) via manifolds and rigid adjustable nozzles; 2) supply through the spindle (pressure 40 bar,flow rate 20 l/min) via a hole coaxial with the spindle for use with tool holders with a central hole (tools according to DIN 69871/A)

2000 l filter tank

2000 l collection tank

Coolant flow rate adjustment

Work surface (class II according to DIN 876); load capacity 15000 kg/m² dimensions 18,000x3,000 mm

Closed-circuit video surveillance system (STANDARD) consisting of: 2 Bosch IP4000i cameras and 1 19'' colour touchscreen Panel PC

Additional protection of cameras against coolant and chips.