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REDEX and IBARMIA an alliance that promises to remain synonymous with success

REDEX and IBARMIA an alliance that promises to remain synonymous with success

Added to MTDCNC by MTDCNC on 20 August 2014

REDEX and IBARMIA, an alliance that promises to remain synonymous with success

In the last ten years, the success of IBARMIA, a Basque firm manufacturing innovative machining centres for

different sectors, is thanks to REDEX, who has provided the company with rack and pinion systems for the

X-axis of their machine tools. Recently, IBARMIA selected the KRPXng model of gears. They have just fitted

two machines with this system: the ZVH55-L8000 Extreme machining centre and the ZV58-L9200 Classic

machining centre.

 

KRPXng is the renewed range of rack and pinion systems by REDEX, especially designed

for gantry-type or moving column machine tools.

IBARMIA is a family-based company, mainly operating in the machine tool sector, offering high value-added

solutions to meet the needs of their customers by adapting to their requirements. This customer-oriented

approach has allowed them to evolve and survive in the market since their foundation, six decades ago, to

the present day.

With a team of young, dynamic, committed and motivated individuals, IBARMIA enthusiastically accepts the

challenges posed on a daily basis from a double product-market perspective: in regards to the product, a firm

commitment to innovation and a customer-oriented approach, and, with respect to the market, aiming to be

present in those destinations with the greatest consumer potential (the European Union, the United States,

China, India…). The dynamics emerges from an ambitious strategic plan which, in turn, is directed at the

everyday activity of the company in order to minimise downtimes, risks to workers and environmental impact.

Their range of products and services for the different industrial sectors includes fixed table and moving

column machining centres, universal machining centres with moving table and column, and machining

solutions for circular pieces. Their customers include leading manufacturers from the following sectors:

aeronautical, automotive, flanges and bearings, railways, cranes, machinery, moulds and dies, Oil & Gas,

subcontracting and valves and pumps.

In the last ten years, IBARMIA’s success has, in part, been due to their work alongside REDEX, who have

provided, in addition to other solutions, the rack and pinion systems for the X-axis for a number of machining

centres with high dynamic requirements. Recently, the Basque Company selected the KRPXng model of

gears. They have just fitted two machines with this system: the ZVH 55-L8000 Extreme machining centre

and the ZV 58-L9200 Classic machining centre.

REDEX’s contribution and the application of the machining centres

As suppliers to IBARMIA for approximately 10 years, REDEX has provided “peace of mind from knowing we

 

 

are in good hands,” says Iñaki Murua, Head of Engineering for New Developments at IBARMIA: “There is a

very high level of collaboration with the Design Department. We have direct access to the design office at

REDEX at the headquarters in Paris, which helps to reduce the design times for new models and machines

with special specifications”. This helps to guarantee access to the latest market proposals. “REDEX is a

pioneer company in the world of drive systems, giving us access to the latest developments in the world of

drive systems,” he concludes.

For example, “the ZVH Extreme model was designed as a general purpose machine while also being a high

quality, capacity and accuracy machine,” explains Murua. “The integration of machining processes into the

IBARMIA MULTIPROCESS Series minimises the number of machines used and significantly reduces the

machining time of complex pieces. The efficiency associated with MULTIPROCESS centres improves the

quality of the piece, by using fewer machines and therefore, having fewer constraints; it reduces the cost of

the initial investment as fewer machines are required, and the necessary floor space, and eliminates the

transfer of pieces between machines, simplifying the industrial management,” he concludes.

Rigidity as a key factor in the accuracy of linear and rotation axes

“The movement of linear and rotation axes is critical in machine tools,” says Arrate Olaiz, Director of

Innovation for IBARMIA. “It allows the effective and controlled positioning of the tool and the pieces to be

machined. Therefore, we are aware that rigidity is a key factor, and even more so in this machine, as the

drive system has to move more than 8 t at 4 m/s2 and 45 m/min. With the REDEX drive systems, we have a

positioning accuracy of about 0.005 mm”.

“Moreover,” continues Arrate Olaiz, “the rack and pinion system has a lower moment of inertia, increased

rigidity and performance. A major advantage with respect to ball screws is its modularity. Installation times

are reduced, resulting in increased reliability. Given these displacement length conditions and levels of

accuracy, ball screw transmission technology was rejected for use in such a dynamic machine, and so we

selected the REDEX solution as a strategic supplier,” he explains.

“60% of the total rigidity in a rack and pinion system is provided by the radial component of the gear, an area

in which REDEX solutions stand out from their competitors”, confirms Pedro

Rebolledo, director of ANDANTEX Iberia, the associate of REDEX in Spain. This extreme rigidity is an

intrinsic aspect to the unique design:

-Concept of pinion integrated into the planetary system, where the cogs are machined directly on the axis.

-The distance between the contact point of the rack and the bearing support is as small as possible.

-The bearings are generously oversized.

Thanks to these features, the REDEX rack and pinion systems have very high values of natural frequency.

This allows development engineers to fit their machines with more solid bases in order to obtain high natural

frequencies that result in higher accuracy levels and dynamics.

This is also true for the rotation axes (rotary tables and face plates), where the gear rim is placed in the most

technologically and commercially suitable position with respect to the worm gearbox and motor torques for

diameters greater than 1 m. In this type of application, REDEX is also a pioneer in the market, and for

several years IBARMIA has been benefitting from this in their machining centres for large diameter circular

pieces.

KRPXng: The advantages of the cubic concept by REDEX

KRPXng is the renewed successful range of rack and pinion systems by REDEX, especially designed for

gantry-type or moving column machine tools. The KRPX planetary gear is one of the best-known examples

of the close collaboration between REDEX and their partners OEM, leaders in the machine tool sector.

Consisting of two planetary gears, the KRPX – TwinDRIVE solution is designed to adapt perfectly to both

sides of the carriage or column of the machine. The electrical precharge guarantees the complete

cancellation of angular play in the rack and pinion system. The values of radial rigidity cannot be equalled

thanks to the already successful integrated output pinion-axis solution, exclusive to REDEX. The new version

is already available in all sizes and includes the new HQ-GF gear finishing technology, which helps to reduce

energy consumption thanks to a saving in performance losses of up to 15% in comparison to gears in

accordance with the DIN 6 quality standard obtained from the cutting, saving thousands of kWh over the

machine’s service life.

 

 

The use of the KRPXng gears in the ZVH55-8000 Extreme machining centre has resulted in significant

savings in design and assembly. “REDEX has a variety of assembly configurations unique to the market. For

this application, REDEX recommended the KRPX model. The exclusive cubic design of the KRPX gear

casing resulted in significant financial savings with respect to the assembly of the cylindrical flange that we

fitted in the first machine some years ago, as we have been able to dispose of the intermediate pieces used

to fasten the gears, such as the brackets and adapter plates. In addition to saving on these components, we

have simplified the design, attaching the gears directly to the carriage, as if they were part of the structure of

the machine itself, thus improving the rigidity of the assembly. This has resulted in further savings in design

and assembly hours”, explains Ander Aizpitarte, Industrial Director of IBARMIA.

Leader in mechatronic solutions

With a consolidated turnover of 50 million Euros, seven associates around the world, 320 employees and

50% of the turnover outside Europe, REDEX is a European leader in mechatronic solutions that provide

critical components for ultra-high accuracy machines all over the world. Aircraft, cars and boats, in addition to

wind turbines and energy plants are manufactured by the latest machine tools equipped with REDEX drive

systems.

REDEX offers engineering experience in a full portfolio of avant-garde products, that include: low-play

planetary gears, high torque drive heads, rack and pinion systems for linear axes and pre-charged drive

systems for milling and turning tables.

“REDEX offers integral solutions with a high technology value, including eco-design, energy efficiency and

recyclability of components, aspects which, in today’s world, are key factors for the leading machine tool

manufacturers”, explains Pedro Rebolledo: He goes on to say, “our manufacturing and internal test

protocols give us total control over the level of product quality and help us to provide a better service to our

customers. REDEX products are specifically conceived, designed and manufactured 100% in accordance

with the machine tool quality and manufacturing standards. Consequently, together with continuous

innovation and product improvement (8% of our turnover is allocated to R&D), this means that reliability and

a long service life have become aspects that our customers take for granted.”

“Beyond these aspects, our greatest advantage is our deep engineering know-how and our proven sales

engineers”, highlights Rebolledo. “Our product is especially technical. As a complement, we offer our

customers an added value consisting in an integral technical service, from the selection of the drive system

to assistance during assembly. We sell solutions, not only the product,” explains Pedro Rebolledo.

In addition, REDEX has three strategic service centres in Europe, the USA and Asia, which form an ideal

structure for the manufacturers of machines aimed at the global market, with respect to offering customers

maintenance, training and local services. Ander Aizpitarte, Industrial Director of IBARMIA, positively values

the pre- and after sales services of REDEX: “In order to offer our customers an efficient and competitive

response, the service provided by our suppliers is essential and is something that we appreciate. Moreover,

we value the exclusive approach adopted by the engineers and sales representatives from REDEX towards

the machine tool market. Firstly, we have the unconditional support of local engineers just 40 minutes away

who always give us an immediate and personalised response. This is not in vain. The offer of a suitable

service when selecting a drive system obviously helps to optimise the cost-performance ratio.” The levels of

costs and services offered by REDEX are an essential advantage for the new markets.

The director of ANDANTEX Iberia is clear: “2013 is, undoubtedly, the year of mechatronics for REDEX.

Breaking through the walls between Measurement and Mechanical and Electrical Engineering is an

avant-garde tendency that is revolutionising the sector. The automotive industry is leading the way with its

hybrid cars and the construction of machines will continue along the same path. Energy efficiency,

compactness and higher yields are the main vectors in which work is being carried out, and we are

well-placed to meet these challenges. This is a commitment we have to our customers and we will show

them in situ if they visit us at the EMO”.

HIGHLIGHTED TABLE

 

ZVH Extreme fixed table and moving column machining centres

“Since 2001, we have turned our heads but face forwards,” explains Arrate Olaiz, Director of Innovation for

IBARMIA. “In 2001, we decided to include the B-axis or continuous head rotation in the significant

advantages of our fixed table and mobile column machining centres. We applied the latest technology

available in the market: transmission through a motor mounted on the rotation axis itself and direct

 

measurement of the rotation in the same axis”.

The result was an extraordinary dynamic automatic recovery in the event of collisions and maximum

accuracy in positioning and repeatability.

Technical specifications of the ZVH 55 Extreme model

-Longitudinal travel X-axis: 1600 - 12,000 mm

-Transversal travel Y-axis: 800 mm

-Vertical travel Z-axis: 1100 mm

-Head rotation travel B-axis: +/- 105º

-Maximum tilting diameter: 1200 mm

-Cone housing (main spindle): SK-50 (optional: BT-50 / HSK A-100)

-Electrospindle head: Up to 35 kW and 12,000 rpm

Sectors of application

-Aeronautical

-Automotive

-Railway

-Crane

-Moulds and dies

-Oil & Gas

-Subcontracting

-Valves and pumps

 

Building Location

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