Case Study

The build-up of metal chips and debris in CNC turning machines can cause damage, affect precision, and shorten the life of the products. In addition, it can cause problems when attempting to dispose of the machine’s coolant water waste.

 Effective removal of the metal debris has been a problem in the past, but a Brazilian manufacturer’s specialist conveyor system, integrated with variable frequency drive technology, is ensuring the quick and safe removal of the scrap.

Cobsen Hennig, a specialist engineering company providing solutions for machining manufacturers, has integrated Invertek Drives Optidrive E3 VFD onto a conveyor removing debris from coolant water in a two-axis, single turret turning machine.

Accurate motor control of the conveyor ensures continued production

The conveyor system captures the metal debris within the machine, removing it into external bins for safe disposal. Working in tandem with the turning machine, it ensures continued production, reducing any downtime.

“The conveyor has to be accurately controlled for a number of reasons. The first is to remove the debris at a speed relevant to the amount of debris being produced, which can vary between the type of products being machined,” said Marcus Silva, Head of Sales for Invertek Drives in Latin America.

“The second is to detect any overloads on the system caused by a blockage and placing the conveyor into reverse to remove it. If necessary, an emergency stop can be performed should an operator be forced to remove a blockage manually.”

The Optidrive E3 VFD can control a set of conveyors on the system, as well as individually, controlling the speed, the emergency stop, and lubrication.

IP66 enclosure allowed direct mounting onto the conveyor

In this case, an IP66 rated enclosure was used allowing the VFD to be installed directly on the side of the conveyor, eliminating the need for a cabinet.

“The drive was set up to monitor and detect any overloads on the conveyor that could be caused by a blockage of debris. If this happens, the VFD stops the conveyor and puts it into reverse before returning it to forward motion.

“If the same problem occurs, it’ll repeat the operation again up to five times. If the overload continues and the lock is not released, the drive stops the process and an operator can then remove the blockage,” added Marcus. “This system means there is less downtime.”

Ease of set up and commissioning

The conveyor has been used on the Puma GT 2600M turning machine manufactured by Doosan Machine Tools. Its integration into the machine has ensured the smooth operation of the whole process.

Celso Pavanella Carneiro of Cobsen Hennig, said: “We wanted a VFD capable of accurate control, including a safe stop option. In addition, its size and IP66 enclosure meant it was easy to install and commission onto the conveyor itself rather than a separate cabinet.

“The set-up, installation and commissioning have been very successful for us and our customer. We’re very pleased with the solution.”