Industry specialist in intelligent robotic pipe rehabilitation systems

Pipetronics' hydraulic and electric milling, filling and grouting sewer rehabilitation robots are characterized by their second-to-none continuous performance, delivering maximum reliability and work results even under extremely challenging work conditions. Outfitted with an extensive set of milling, grinding and brushing attachments, these robot systems are equipped for the full range of sewer rehabilitation tasks. "The main function of these sewer milling robots comprises of sewer rehabilitation preparation works on pipe liners and the opening of inlets after the liner has been set in place. Our milling robots take care of all the required work tasks, including the milling off of edges, removal of stubborn deposits, repairs of sewer breakage points, damaged sleeves or even the milling out of completely clogged sewers, all performed easily, safely and economically," noted proudly Dettinger. 

To ensure economically-efficient production of their robots, Pipetronics installed two in-house CNC production centers at its Stutensee facility. "Since we have relatively small batch runs, in 2019 we installed a set of CNC machines to achieve faster, more flexible and economic production. Now, three years later, there's no question that this was the right decision since we're able to manufacture all our milled and turned parts economically and in top quality, all in-house," Dettinger praised this important step.

All MEGA Chuck tool holders are precision ground finished to ensure perfect concentricity for high-speed machining tasks.

In-house CNC production

To ensure a complete coverage of all production processes, Pipetronics purchased two highly-automated machines, i.e., a Grob G350 5-axis machining center and a Mazak i400 ST turning-milling center. "Initially, we actually planned to buy four machines, however, since it is quite difficult to find qualified personnel with the right skill set in our region, we ended up installing just two machines. Both of these machines were equipped with robotic handling functionality, which increased productivity and output, while simultaneously reducing our reliance on human labor.

Currently, both machines run an average of 16 hours per day. We mill the large parts on the Grob center because it has a very long Z path along the spindle axis and is, therefore, ideally suited for this task. The Mazak is used to produce complex turned and milled parts," Dettinger described the division of labor. In order to be able to mill very close to the clamping device along the spindle, a slim, stable and precise tool holder is required - and this is where the tool holder specialist BIG DAISHOWA comes into the picture.

All MEGA Chuck tool holders are precision ground finished to ensure perfect concentricity for high-speed machining tasks.

BIG CAPTO tool holders

"From my previous job, I have significant experience with BIG KAISER spindle tools and BIG DAISHOWA tool holders. After being repeatedly disappointed by the quality of the default chucks used on the Grob, I finally contacted BIG DAISHOWA, and they kindly provided us with the Mega Double Power Chuck for testing," says Dettinger, and Christian David, Key Account Manager at BIG DAISHOWA adds, "Thanks to its exceptionally high holding force, the Mega Double Power chuck is perfectly suited for high-chip-volume pre-machining operations. Importantly, it is low maintenance, as it is perfectly sealed against coolant ingression and contamination.

Thanks to the enlarged contact diameter on its clamping nut and tool flange, the Mega Double Power chuck achieves a holding force of up to 3200 N/m, whilst its high stability ensures vibration-free high-performance machining operation." Seeing the impressive results during the test phase, the CNC production manager was so impressed that he actually ordered several Micro collet chucks from the Mega Chuck series for the Mazak machine in addition to the tested power chuck.

"The Mazak has a CAPTO C6 machine interface, which is ideal for turning/milling operations. For our application, the BIG Micro Chuck collet chucks offer optimal performance characteristics for machining hard-to-reach workpiece areas, where conventional collet systems fail to deliver. Thanks to its groove-free collet nut, vibrations at high speeds are prevented. The key is that this BIG micro collet system is slim enough to implement on all our machining operations. We mill at 12,000 rpm on the MAZAK and all BIG DAISHOWA collet chucks have a guaranteed runout of less than 0.001 mm at the collet mouth. That's why we chose the slim Mega Micro Chuck. Initially available in only one size, we now run our Micro Chucks in a wide variety of lengths and diameters," explains Dettinger.

High-performance robot for sewer pipe rehabilitation: Pipetronics eCutter - electric milling robot 

Conclusion

"Our cooperation with BIG DAISHOWA has delivered excellent results. We currently produce over 890 different parts on our machines. The tool holders from BIG DAISHOWA make our processes faster, more flexible and reliable, whilst being more cost-effective," Rolf Dettinger concludes and Christian David adds, "We cannot stress enough how pleased we are with our BIG DAISHOWA spindle tools. The power and collet chucks have made a significant contribution to our production of intelligent robots for the harshest of environments.