Their low-backlash design ensures extremely precise and repeatable positioning of the machining unit with up to 20 standard and special tools at the various machining points. The TP⁺ 050 also has several other advantages such as its high dynamics or, in particular, the fact that it is available with a ratio i=21, enabling optimal controllability of the axis by the machine control. 

The TP⁺ 050 with output flange was selected on the basis of the loads and motions that occur when the profile machining center’s tool unit is moved. In addition to this, the theoretical downsizing potential and the coupling factor λ (lambda) – the ratio of the mass moments of inertia of the gearbox and the load – was checked using the cymex^® 5 sizing software.

With around 700 employees as well as subsidiaries and dealers in over 50 countries, elumatec AG – at home in the small town of Mühlacker in south-west Germany – is a global market leader in the manufacture of machines for processing aluminum, PVC and thin-walled steel profiles. Its customers range from small, quality oriented craftsman’s businesses to industrial profile processors such as automotive suppliers, sports goods manufacturers, yacht and sailing boat builders or wagon and facade construction companies. elumatec’s portfolio enables flexible and individual industry solutions for organizations and customer groups of any size.

A rack-and-pinion system moves the machining unit of the SBZ 151 along the profile in the X direction together with the integrated tool changer and stops it at every single machining point.

For example, if threads have to be made for screwing individual elements together later, the machine first drills all of the required holes prior to changing the tool and then cuts threads in them one at a time. 

Even this relatively simple process clearly illustrates the importance of maximum possible positioning accuracy and repeatability for precise profile machining. Furthermore, both the acceleration of the tool unit from one machining point to the next and deceleration and positioning are executed with very high dynamics, in order to optimize the machine’s output and reduce the machining costs per profile to a minimum. 

The maximum torsional backlash of less than 3 arcmin and the specified torsional rigidity of 145 Nm/arcmin assure the required positioning accuracy of 0.1 mm and repeat accuracy to match. Among other things, the maximum movement speed of 66 m/min and acceleration dynamics of up to 1.5 m/s² while moving the machining unit – which can weigh as much as 3.5 t – are achieved by the gearbox owing to the maximum 660 Nm torque and acceleration torque as well as the maximum input speed of 6250 rpm. 
The high-quality helical toothing provides smooth running at the output and minimizes the influence of mesh frequencies. This combination results in 96 percent efficiency plus low-noise operation – even at speeds of 3000 revolutions per minute, the noise intensity never rises above normal conversational level.