A Solution for all needs

April 30 2012

Quality, reliability and precision expressed by several sector

Camozzi Group is an international reality that diversifies its activities into various divisions: automation, machine tools, textile machines and manufacturing processes. On the whole the Group employs about 2,000 people and is present worldwide with 19 production sites, 29 branches and a wide net of exclusive distributors.
The Machine Tool Division is represented by two historical brands: the Italian brand Innse-Berardi and the American brand Ingersoll Machine Tools.
The synergy between the two companies allows them to approach the international market with a wide range of products. The companies share their potentialities and know-how; this assures a commercial and technological growth to the entire division. The integration between the two companies assures concreteness,innovation capability and offers an ever-increasing design and implementation potential. Thanks to this relationship and exploiting the potentialities of the homonymous Group, the two companies are present on international markets with their own net that covers all areas and all production sectors diffusely. The division is directly present with two production factories respectively in Brescia (Italy) for Innse-Berardi and in Rockford (USA) for Ingersoll and through business branches in Germany (Alberhausen), China (Shanghai) and Russia (Moscow).

Direct presence Russia
The Moscow branch can offer logistic support to customers because it relies on skilled trade and technical personnel. Russian collaborators are assisted and have been trained by Italian personnel coming from the parent company. Customers receive a valid commercial,but especially technical, support: thanks to this organization the branch can go hand in hand with customers during the sale phase and the successive steps of implementation, design review, delivery, installation, commissioning, final testing, warranties and eventual after sales service interventions and delivery of spare parts.
Through remote access, specialized technicians can intervene on the machine even if they are not present in the productive site, with the aid of the tele-service “ePs Network Services”. This provides detailed information for the fast identification and the precise analysis of the causes of the failure, which can then be solved rapidly.

Machines and services
Over the years the two companies have evolved, adapting their production to today’s very attentive and demanding market. The structure can offer a wide array of services, such as the joint study of the machine before its manufacturing, the machine feasibility study, the machining cycle for the “turnkey” piece production,the real machine with all its customizations, the personnel training, the machine delivery and its commissioning and maintenance interventions, also abroad. The main application sectors addressed by the Group are naval, energy, general engineering, aeronautics, aerospace, earth handling,railway and iron and steel industry.  
Nowadays the product marketing is oriented towards some strategic sectors that allow the division to compete on the market with increasingly automated machinery and permit endusers to accomplish their productions in short times and with fewer setups and displacements of workpieces. This reality represents not only a simple supplier but also a technological partner for customers to be able to develop the project together providing a complete service and assuring innovative capability and concreteness. The energy market is steeply rising and customers require bigger and bigger machinery and plants with high technical performances.
For this sector are proposed various machine typologies such as horizontal milling-boring machines, fixed and mobile gantry vertical milling machines, special milling machines for turbine rotor slots or generators, turning and milling centres and special machines. The potential machine user produces pieces such as rotors, low, medium and high pressure stators in the thermoelectric energy ambit. Several other components of the energy sector, such as distributors for hydroelectric power and components for nuclear energy (vessels, reactors etc.) are successfully machined by the machines of the Group, which has recently entered a sector characterized by strong growth such as the machining of wind power components.


Outstanding applications
Among all so-called “special” machines, the horizontal drilling machine for deep drills is dedicated to the drilling of tube plates for heat exchangers of thermal-nuclear power plants. It is a special and very accurate machining. The workpiece calls for high precision: the drilling operation is automatically performed and it is monitored by a system that, upon demand, can execute also the adaptive control and self-teaching. The machine can be equipped with BTA system and/or Gundrill system.The naval sector is living a strong expansion, too. Innse-Berardi and Ingersoll offer their machines to the producers of components like big diesel engines. For such pieces can be used machines like gantry milling machines, horizontal milling machines, machining centres or special machines and FMS. Innse-Berardi and Ingersoll produce also “Flexible Machine System” or “Flexible Machine Cell”. Innse-Berardi in particular has realized an integrated expandable system composed by two machines with fixed gantry, mobile table and mobile cross beam. The system is equipped with pallet transfer shuttle and loading/unloading/parking stations of the workpieces to be machined. The plant has been designed for machining diesel engines in the naval sector but, thanks to its high flexibility, it can mill and bore any other general mechanics item. One of the great advantages provided by the system is the high productivity reached thanks to the drastic reduction of idle times (positioning,piece clamping, dimensional control, tilting, cleaning, assessment of possible defects). Besides, thanks to the thermal symmetry of the system and the management of compensations, you can obtain high-precision machining. Each machine features strokes of 13 m (X axis), 6 m (Y axis), 2.5 m (W axis) and 2 m (Z axis). The spindle supplies 100 kW power, 9,000 Nm torque and rotation speed of 2,500 rpm. Pallets have 3,500x10,000 mm sizes and 100 ton loading capacity. Each gantry is equipped with its own automatic tool magazine and automatic head magazine, mutually integrated, both managed and serviced by a robot that travels on a dedicated line. The tool magazine has a 450-pocket capacity with maximum loading capacity of 125 kg, maximum diameter of 400 mm and length up to 1,500 mm. The accessory magazine has 16-pocket capacity usable for the management of heavy accessories and tools; the accessories supplied with the system are of various typologies, such as angle, tilting and indexing heads for specific piece machining and universal head for interpolating machining.


Source : The Journal of machine tools - year 11 - nr. 1 - April 2012