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Written by Hage SuperUser on . Posted in Rail vehicles.

FSW Production System for Aluminium Intermediate Floors

  • Meta (title): HAGEMATIC FSW 20-2-D
  • Einleitungstext: For the production of aluminium intermediate floors, HAGE realized an FSW production system for transverse and longitudinal welding of individual aluminium extruded profiles.
  • Inhalt/Text:

    The profiles are joined into complete floor elements using friction stir welding. FSW seams from above and below create a process-reliable welding concept for stable aluminium intermediate floors.

    The system combines a universal clamping fixture with two FSW spindles and RPT function. This allows different profile geometries to be clamped flexibly and welded with controlled process management. The 8-axis configuration enables precise motion sequences for longitudinal and transverse welding.
  • Vorschaubild:
    HAGE_Stadler_Visualisierung_web_original
  • Listen:
    • Titel: Technical Data, Auflistung (ul):
      • FSW production system with 8 axes
      • 2 FSW spindles: upper and lower
      • Welding force per spindle: 20 kN with RPT function
      • Spindle speed: max. 3,000 min⁻¹
      • Spindle torque: 36 Nm at 3,000 min⁻¹
      • Maximum weld seam length: 4,900 mm
      • Axial force Fz: 25 kN, radial force Fx: 7 kN, V-axis force Fv: 15 kN
      • Manually adjustable lead angle: ±4°
    • Titel: Highlights, Auflistung (ul):
      • Transverse and longitudinal welding of aluminium profiles
      • Double-sided FSW seams from above and below
      • RPT function for flexible process control
      • Universal clamping technology for different floor elements
      • 8-axis kinematics for precise welding movements
  • Bilder:
    fsw-anlage-zwischenboeden_original
    fsw-anlage-zwischenboeden-2_original
    fsw-anlage-zwischenboeden-4_original
  • Hits: 6

Written by Hage SuperUser on . Posted in Rail vehicles.

FSW System for Large-Format Floor Panels in Railcar Manufacturing

  • Meta (title): HAGEMATIC FSW 70-2
  • Einleitungstext: For the production of large-format floor panels in modern railcar manufacturing, HAGE realized a high-performance FSW system for aluminium extruded profiles and plate structures.
  • Inhalt/Text:

    The current workpiece dimension is approx. 5,000 x 2,300 x 300 mm; the system concept can be expanded for profile lengths up to 17,000 mm.

    An upper and an identical lower FSW spindle enable synchronized double-sided welding. This means components are welded simultaneously from above and below, reducing distortion, improving flatness and shortening takt times. Automatically adjustable special clamping fixtures ensure high flexibility for different assemblies and variants.
  • Vorschaubild:
    fsw-anlage-fuer-bodenplatten_original
  • Listen:
    • Titel: Technical Data, Auflistung (ul):
      • Gantry system with 70 kN and 6 axes
      • Lower spindle unit with 70 kN and 2 axes
      • Current workpiece dimension: approx. 5,000 x 2,300 x 300 mm
      • Expandable to profile lengths up to 17,000 mm
      • Maximum weld seam length: 20 m
      • Variable material thicknesses: 4.2–30 mm
      • Maximum welding force: 70 kN
    • Titel: Highlights, Auflistung (ul):
      • Double-sided FSW for large-format aluminium floor panels
      • Reduced weld distortion and improved component flatness
      • High flexibility through adjustable clamping technology
      • Machining of very long profiles and plate structures
      • Automatic weld gap control for process assurance
      • Automatically adjustable special clamping fixtures
  • Bilder:
    fsw-anlage-fuer-bodenplatten_original_copy_1
    fsw-anlage-fuer-bodenplatten-6_original
    fsw-anlage-fuer-bodenplatten-5_original
    fsw-anlage-fuer-bodenplatten-4_original
    fsw-anlage-fuer-bodenplatten-3_original
    fsw-anlage-fuer-bodenplatten-2_original
  • Hits: 8

Written by Super User on . Posted in Rail vehicles.

CNC Machining System for Butt-Welded Steel Rails

  • Einleitungstext: For the rail industry, HAGE realized a high-performance CNC machining system for fully automatic removal of excess weld material on butt-welded steel rails.
  • Inhalt/Text:

    Two milling spindles machine the rail joint from above and below using specially developed contour milling cutters, ensuring that the weld seam is precisely removed around the entire rail contour.

    A particular challenge lies in automated tool handling. The special tools, weighing up to 60 kg, are removed from a tool magazine by robot, fed to the main spindle and returned after machining. Before each machining process, the rail joints are measured and aligned on both sides using a 3D probe.
  • Vorschaubild:
    bearbeitungsanlage-stahlschienen_original
  • Listen:
    • Titel: Technical Data, Auflistung (ul):
      • Main milling spindle: 70 kW / SK-60
      • Below-floor spindle: 42 kW / SK-50
      • Torque of main milling spindle: 1,000 Nm
      • Tool magazine: 15 positions
      • Maximum tool weight: up to 60 kg
    • Titel: Highlights, Auflistung (ul):
      • Fully automatic machining of butt-welded rail joints
      • Two machining spindles for upper and lower-side machining
      • Machining process: milling off excess weld material around the rail
      • Robot-assisted tool change for heavy special tools
      • 3D measurement before mechanical machining
      • High process reliability with tight tolerances in rail manufacturing
  • Bilder:
    bearbeitungsanlage-stahlschienen-5_original
    bearbeitungsanlage-stahlschienen_original_copy_1
    bearbeitungsanlage-stahlschienen-2_original
  • Hits: 31

Written by Super User on . Posted in Rail vehicles.

Large-Format FSW System for Structural Components in Rail Vehicle Manufacturing

  • Meta (title): HAGEMATIC FSW 130-2-D
  • Einleitungstext: For large-format aluminium structural components in rail vehicle manufacturing, HAGE realized FSW gantry systems.
  • Inhalt/Text:

    Components produced include side walls, door frames, wheel arch supports, connection pins and end cross members. The systems are designed for 2D and 3D FSW welding and operate in two stations in shuttle mode.

    An additional FSW spindle unit from below enables simultaneous welding from above and below. This eliminates the need to turn large-format components while also improving flatness, process reliability and takt time. The system features process monitoring, an RPT tool interface and a flexible basis for different component variants.
  • Vorschaubild:
    fsw-anlage-schienen-strukturbauteile_original
  • Listen:
    • Titel: Technical Data, Auflistung (ul):
      • Gantry system with 130 kN and 6 axes
      • Additional lower spindle unit with 20 kN and 2 axes
      • System dimensions: approx. 40 x 12 x 7 m
      • Upper FSW spindle: max. 3,000 rpm, axial force 130 kN, radial force 80 kN
      • Lower FSW spindle: max. 6,000 rpm, axial force 20 kN, radial force 10 kN
    • Titel: Highlights, Auflistung (ul):
      • FSW gantry systems for large-format structural components
      • Simultaneous welding from above and below
      • Shuttle operation for high system availability
      • HAGE tool interface for retractable pin and combined FSW tools
      • Automatic tool change also for RPT tools
      • FSW process monitoring with HAGE WeldCheck
      • Flexible expandability for different components
  • Bilder:
    fsw-anlage-schienen-strukturbauteile_original_copy_1
    fsw-anlage-schienen-strukturbauteile-2_original
    fsw-anlage-schienen-strukturbauteile-3_original
  • Hits: 26