Grinding and polishing automatic machines for metallic surfaces

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1 Grinding and polishing automatic machines for metallic surfaces

www.cosmapsrl.it Grinding and polishing automatic machines for metallic surfaces Born in Padua, Italy in the late 70s, C.O.S.M.A.P. s.r.l. produces automatic machines for grinding and polishing metallic surfaces.

the required quality 2 Achieve the targeted productivity 3 Reduction of production costs by the processes automation 4 Product

supplier. confirm CO.S.M.A.P. s worldwide leadership.

3 Grinding and polishing automatic machines for metallic surfaces Born in Padua, Italy in the late 70s, C.O.S.M.A.P. s.r.l. produces automatic machines for grinding and polishing metallic surfaces. Developed on a concrete business idea, our company has more than 35 years of working experiences in the specific sector of metallic surfaces treatment. Our accumulated technical knowledge and our constant research of the best solutions by working for and with our clients 1 Achieve the required quality 2 Achieve the targeted productivity 3 Reduction of production costs by the processes automation 4 Product longevity 5 Our constant assistance and support 6 Our client s confirmation of the right investment and having a consolidated supplier. confirm CO.S.M.A.P. s worldwide leadership. Our approach allowed us to expand onto foreign markets with clients relying only on our solutions. C.O.S.M.A.P. has focused on long-lasting and consolidated partnerships, with substantial orders, with a large numbers of clients from around the world.

Only companies that find correct and constant over time solutions can reach this level of relationship and satisfaction with their clients Vision Answer our current clients needs by using the highest

Develop and use new technologies to automatize polishing processes by encouraging operators to feel and act as technicians with deep work esteem, and a professional always ready and able to handle

Even for particular parts where before only manual operators managed to finish them at a great expense of time and strength.

4 Only companies that find correct and constant over time solutions can reach this level of relationship and satisfaction with their clients Vision Answer our current clients needs by using the highest technological available in order to be, in the shortest possible time, the world s reference in polishing and grinding systems. Develop and use new technologies to automatize polishing processes by encouraging operators to feel and act as technicians with deep work esteem, and a professional always ready and able to handle high-level instrumentation. MISSION To obtain a high and constant quality with high productivity by creating polishing and grinding machines of the highest technology. Even for particular parts where before only manual operators managed to finish them at a great expense of time and strength. The competitive advantage Provide our clients with revolutionary solutions by constantly researching technological innovations. Looking towards the future in the field of the metallic surface finishing that leads companies in the search of higher quality performance products. From the moment of knowing our clients needs to the moment of answering beyond the simple solution of the requested problem, C.O.S.M.A.P. has an exclusive way of following its clients. C.O.S.M.A.P. is defined by its clients as a friend that can be trusted. Our clients recognise our suggested production processes reliability and our machines high degree of efficiency.

www.cosmapsrl.it ADDITIONAL TECHNICAL SOLUTIONS C.O.S.M.A.P.

predisposed for dust extraction systems Index rotary tables and

rotary table software We provide training courses for our

CONSTRUCTION DETAILS Our accumulated knowledge during the years,

led us to use the best techniques: - Our mechanical structures

We only use the best quality raw material for durability and

- The rotary tables are equipped with a mechanical divider for a

- The liner axes are composed of bushes and are protected to

5 ADDITIONAL TECHNICAL SOLUTIONS C.O.S.M.A.P. designs, manufactures and installs technical solutions developed during the years. We also provide: CE approved Acoustic Cabins All our machines are predisposed for dust extraction systems Index rotary tables and robotic cells loading/unloading automatic systems Own developed rotary table software We provide training courses for our machines operation, maintenance and programming IMPORTANT CONSTRUCTION DETAILS Our accumulated knowledge during the years, the continuous research in the mechanical and automation fields led us to use the best techniques: - Our mechanical structures are screwed, not welded, for a better precision. We only use the best quality raw material for durability and robustness. - The rotary tables are equipped with a mechanical divider for a high reliability and precision. - The liner axes are composed of bushes and are protected to avoid any dust getting into the mechanical components. - The spindles movements are totally independent and are program controlled. - We only us the best know and reliable brands in the electro-technical and electronic field for our automation systems

6 APPLICATIONS

www.cosmapsrl.it Polishing unit model C.

evolution in the metals automatic polishing field We are proud to introduce you

entirely planned and designed this innovative solution combined with its C.

axes (revolving and linear) and 2 more coupled to our rotary table which allows

With its high movement capability, combined with the rotary table s spindles

The pieces to polish or grind can be in any kind of complex shape or form which

to handle with a static polishing unit. C.

7 Polishing unit model C.N.C. (Computer Numerically Controlled) Our rotary table is a technological evolution in the metals automatic polishing field We are proud to introduce you to our latest technological evolution, our new rotary table. C.O.S.M.A.P. entirely planned and designed this innovative solution combined with its C.N.C. polishing units. Our C.N.C. polishing units are equipped with 5 electrical axes (revolving and linear) and 2 more coupled to our rotary table which allows the machine s high movement flexibility. With its high movement capability, combined with the rotary table s spindles movements, the brushes can work on any type of products. The pieces to polish or grind can be in any kind of complex shape or form which in the past could only be done by a manual operator. The rotating tables and our new C.N.C. units We developed this new solution in 2004 and since then it has been tested and improved. This solution allows a higher flexibility of the working unit which is impossible to handle with a static polishing unit. C.N.C. polishing units coupled with our rotary table transformed the way of polishing. With the use of our C.N.C. units there is no more need to divide the rotary tables with static polishing units in order to complete the product polishing cycle s operations. Thanks to the interpolation of the electrical axes, the C.N.C. polishing unit is distinguished by the possibility to perform an elevate number of movement sequences. Therefore the machine performs an articulated processing cycle without any interruptions, modifications or manual adjustments from the operator.

Polishing unit model C.N.C. The new technology can be adapted on wide range of metallic products. The use of the C.N.C. unit is extremely advantageous for polishing pieces with complex forms, achieving a high productivity and quality.

The significant differences are the productivity and the cost of the two installations. The rotating table with a C.

This means that it will correspond to the cycle time of a working unit, while the total cycle time of robotic cells will be the amount of

Programming facility with the auto-learning system We developed a user-friendly programming which lets you plan the work cycle of the C.

The operator will not have to learn any programming languages.

They can plan the geometrical values manually or with the autolearning key.

8 Polishing unit model C.N.C. The new technology can be adapted on wide range of metallic products. The use of the C.N.C. unit is extremely advantageous for polishing pieces with complex forms, achieving a high productivity and quality. Comparison: robotic cells The flexibility and the great number of operations that the C.N.C. polishing unit can do are comparable with the one from a robot cell. The significant differences are the productivity and the cost of the two installations. The rotating table with a C.N.C. polishing unit the cycle time of every single piece will be hidden. This means that it will correspond to the cycle time of a working unit, while the total cycle time of robotic cells will be the amount of time that every single operation will be taken on the piece. Programming facility with the auto-learning system We developed a user-friendly programming which lets you plan the work cycle of the C.N.C. unit. Thanks to the smart auto-learning system, the creation of the work cycle for every C.N.C. unit will be faster and instant. The operator will not have to learn any programming languages. They will only have to plan sequentially the movement typology that the unit has to execute. They can plan the geometrical values manually or with the autolearning key. Fast machine reset Every time that a work program is used the machine resets itself extremely fast, thanks to the unit s auto-learning. The industrial computer, which permits the interface between the operator and the PLC, can record a high number of programs. Each time that the production changed, a pre-recorded program simply starts and the machine pre-set itself to the right position.

movement polishing group Axis Z: rotating movement polishing group Axis U: approaching-detachment

9 The movements of every single unit are managed by 5 axes, which are controlled and interpolated with each other. These axes are: Axis X: transversal movement unit Axis Y: longitudinal movement unit Axis W: vertical movement polishing group Axis Z: rotating movement polishing group Axis U: approaching-detachment movement contact wheel unit, counterbalancing and recovery of the brush consumption (flap or polishing wheel). Therefore for each workstation there are 2 axes from the table (M R) and 5 axes from the unit (X Y W Z U) which are controlled and interpolated with each other. As mentioned before, with the presented characteristics, we can compare C.N.C. polishing unit to an anthropomorphous robot. However C.N.C. polishing units have higher productivity, reduced costs (of purchase, installation and usage) and space.

Polishing unit C.N.C. model Technical characteristics C.N.C. units are available in three versions.

The following are the approximate descriptions of the technical characteristics of the three different

N.C. UNIT MEDIUM C.N.C. UNIT HEAVY C.N.C. UNIT Vertical slide (W axis) 750 mm stroke 950 mm stroke 1100 mm

(Y axis) 400 mm stroke 500 mm stroke 600 mm stroke Recovery slide (U axis) 130 mm stroke 220 mm stroke 280

HP 7,5 / HP 10 (max) HP 10 / HP 12,5 (max) Brush rotation speed from 500 to 2400 rpm from 500 to 2200 rpm

The data in this chart is purely approximate and not binding. Rotary table with 5 stations and 4 C.N.C. units.

10 Polishing unit C.N.C. model Technical characteristics C.N.C. units are available in three versions. Each version has 5+2 axes but with different axes strokes sizes and a different tooling capacity. The following are the approximate descriptions of the technical characteristics of the three different versions: BUILDING DETAILS LIGHT C.N.C. UNIT MEDIUM C.N.C. UNIT HEAVY C.N.C. UNIT Vertical slide (W axis) 750 mm stroke 950 mm stroke 1100 mm stroke Based longitudinal slide (X axis) 400 mm stroke 550 mm stroke 750 mm stroke Based transversal slide (Y axis) 400 mm stroke 500 mm stroke 600 mm stroke Recovery slide (U axis) 130 mm stroke 220 mm stroke 280 mm stroke Rotating edge on vertical level (Z axis) Rotating engine power HP 5,5 / HP 7,5 (max) HP 7,5 / HP 10 (max) HP 10 / HP 12,5 (max) Brush rotation speed from 500 to 2400 rpm from 500 to 2200 rpm from 500 to 2000 rpm Maximum brush dimension Ø max 400 x 80 mm Ø max 500/600 x 100 mm Ø max 600 x 150 mm The data in this chart is purely approximate and not binding. Rotary table with 5 stations and 4 C.N.C. units. The automatic machine in the picture is to polish taps. APPLICATION COSMAP reserves the right to modify the design of the working unit as described above, without making any changes to this catalog

www.cosmapsrl.it C.N.C. unit with double flanked brush Another step forward into the development and innovation of the well consolidated C.N.C. column For C.O.S.M.A.P.

It was born from the idea to develop a polishing unit that contains the possibility to polish and buff with the use of a single column.

11 C.N.C. unit with double flanked brush Another step forward into the development and innovation of the well consolidated C.N.C. column For C.O.S.M.A.P. the double flanked brush is another step forward into the development and innovation of the well consolidated and confirmed C.N.C. unit. It was born from the idea to develop a polishing unit that contains the possibility to polish and buff with the use of a single column. It is perfect for the processing of small lots; the double flanked brush is also distinguished by: The extreme flexibility: This characteristic is the result of the high skills of the column, which supports the polishing groups. In fact using the C.N.C. column the unit of the double flanked brush is provided with n 7 axes, among which n 3 are supplied with the C.N.C column, and that are: X axis: transversal movement unit; Y axis: longitudinal movement unit; W axis: vertical movement polishing groups; N 4 axes are distributed for the distinct movement of the two brushes. In particular the movements deal with: Z-A axis: turning movement of polishing group A; Z-B axis: turning movement of polishing group B; U-A axis: advance-detachment movement, balance and recovery of the brush consumption of the polishing group a; U-B axis: advance-detachment movement, balance and recovery of the brush consumption of the polishing group b;

C.N.C. unit with double flanked brush For the reduced cost: The cost is reduced because it is possible to buy a unit with the same effective potentialities of two.

12 C.N.C. unit with double flanked brush For the reduced cost: The cost is reduced because it is possible to buy a unit with the same effective potentialities of two. The unit handles with a complete processing of polishing and buffering for the many different portions without having a reduction of the final quality and limiting the number of faceplates and speeding up the set up of the machine. The following is an example of Rotating Table, which has n 3 stations and has n 2 C.N.C. units with double flanked brush; the target is to polish and buffer taps and sanitary fittings. Rotating table with n 3 stations; it is tooled up with the overturning of spindle and provided with n 2 C.N.C. units with double flanked brush. the target is to polish and buffer taps and sanitary fittings. Model name: TR 3/2 C.N.C.2 APPLICATION COSMAP reserves the right to modify the design of the working unit as described above, without making any changes to this catalog

www.cosmapsrl.it Base structure and rotary table INDEX ROTARY TABLE Technical description At C.O.S.M.A.P. we design and manufacturer all our machines to satisfy our client s needs.

The base has the movement mechanisms for the rotary table and the faceplate spindles.

The table s rotation motion is performed through a gearmotor completed with clutch avoiding the divider to overload.

The faceplate spindles and fixed on the rotary table and each of them has independent movements. They are set and managed by the machine s program.

This latest technology allows temporary and independent rotation movements of the balancing system and the spindles.

It can rotate continually or stay in a position at different speeds. AXIS R: Used for the rotation of the balancing arm.

Each piece can be positioned horizontally and vertically, or in an angle ranging from 135 to + 215 indifferently from each working station.

13 Base structure and rotary table INDEX ROTARY TABLE Technical description At C.O.S.M.A.P. we design and manufacturer all our machines to satisfy our client s needs. The structure of our rotary tables is adapted to today s surface finish necessities. The supporting structure of the base is built in strong steel plate, welded and properly ribbed. The base has the movement mechanisms for the rotary table and the faceplate spindles. The rotary table, mounted on the base of the machine, is centrally supported by a dividing group equipped with quick release, high precision and performance multiple stations. The table s rotation motion is performed through a gearmotor completed with clutch avoiding the divider to overload. The pneumatic distributor and the electrical manifold are fixed to the centre of the rotary table. The faceplate spindles and fixed on the rotary table and each of them has independent movements. They are set and managed by the machine s program. The spindles are completed with pneumatic fixtures and/or with the loadless plates systems. We also developed an innovative and important index system for our rotary table. This latest technology allows temporary and independent rotation movements of the balancing system and the spindles. Our tables are equipped with two rotary electrical axes which are set and controlled by two brushless motors with resolver. The axes are: AXIS M: Used for the spindle s faceplate. It can rotate continually or stay in a position at different speeds. AXIS R: Used for the rotation of the balancing arm. It is realised with a mechanical divider supporting the spindle s faceplate. The axes allows the spindle s rotation and the overturning with a maximum of 350 degrees ( ). Each piece can be positioned horizontally and vertically, or in an angle ranging from 135 to indifferently from each working station. All variables of the working cycle can be memorised in the program making it faster to change production. Among the various solutions, depending on the area of application, axis R may not be necessary. In other cases, in absence of overturning, axis M can be directly positioned on the table in a vertical or horizontal position. Index rotary table with vertical spindle, possibility of a continuous rotation or positioning as programmed. Index rotary table with horizontal spindle and equipped with a faceplate quick system. It can operate in continuous variable rotation. Index rotary table with horizontal spindle. It can operate in continuous variable rotation. Faceplate equipped with a vacuum fixture.

Base group and rotary table Base and rotary table CONTINUOUSLY ROTARY TABLE TECHNICAL DESCRIPTION Ribbed supporting structure,

The movement mechanisms for the table and spindles are located at the base.

divider group. The table s different rotation speed is completed by a brushless motor with divider.

14 Base group and rotary table Base and rotary table CONTINUOUSLY ROTARY TABLE TECHNICAL DESCRIPTION Ribbed supporting structure, built in strong steel welded plate on which the rotary table is placed. The movement mechanisms for the table and spindles are located at the base. The rotary table is mounted on the base of the machine and is centrally supported by a high precision and performance continuous divider group. The table s different rotation speed is completed by a brushless motor with divider. The faceplate spindles located on the table and they are set on by a brushless motor with divider in order change the rotation speed. For polishing processes, we can install directly on the rotary table some centres with a manual adjustment with slide and a hand-wheel for interchangeable stations. It is also possible to add a light polishing unit positioned in the centre of the rotary table. The unit is complete with motorised vertical and horizontal adjustments and with an automatic brush consumption recovery system on the horizontal axe.

16 Grinding and polishing automatic machines for metallic surfaces COSMAP S.r.l. - Via L.Einaudi Saccolongo (PD) - ITALY - Phone: Fax:

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