In November 2006 Ingramatic settled in the new plant of Castelnuovo Scrivia.
The new building is 5.600 mq on a total available surface of 40.000 mq and it has been realized using the most modern structural solutions.
Fixtures and fittings such as 4 gantries of 5,15 and 25 tons capacity, a very rational and simple lay-out, an important warehouse capable of 700 pallets for a semi automatic picking and 3.000 small boxes for the handpicking (for a potential production of 50 thread rollers), the new offices area are just some of the mark out of this new productive settlement.
The strategy of the new management has been realized and the full integration and industrial synergy with the head office of Sacma has been completely reached.
One of the most difficult challenges for Ingramatic was the completion of the range of thread rollers, in order to cover all the models of the Sacma progressive headers.
We may affirm today that this target has been achieved with the new thread roller RP92: this model can be supplied combined with the Sacma progressive headers of the series “6” (SP660 and SP670).
The RP92 is the first thread roller of this size, to be mass-produced in Europe and represents the best solution for the large diameter bolts up to M36, rolled before or after heat treatment. Some of the potential final users are bolts manufacturers for big infrastructures, railway and shipbuilding industries, construction and equipment for energy production (aeolian towers).
A further possible use of this machine is for the earth-moving and trucks industry, whenever the large diameter is not the only reason of large stresses; also the length of the thread of high tensile fasteners rolled after heat treatment, is a large stresses generating factor. Until now many of these bolts were rolled on hand feed machines, like two rolls machines, at a very low production speed and with high cost of tools: the high productivity of the RP92 translates into an important reduction of tooling costs and a great improvement of the threaded product.
Sacma Group invested two years of hard work to develop this important project: Ingramatic took care of the design, the organization, the planning and the assembly stage. Sacma and OBM produced all the components, from the smallest mechanical parts up to large main frame.
The main frame, rigid and rugged in construction has been designed using steel fabrication 3D CAD and FEM SW analysis. It is an extremely rigid, assembled on a sturdy base that provides for support and oil tanks: this solution allows the whole machine to be shipped in one piece and facilitates the installation at the customer’s works.
Particular attention has been paid to the construction of the enclosure and soundproof cabin. In consideration of the dimension of the machine we studied solutions able to ease the access to the adjustment points: wide sliding doors and special collapsible platforms to avoid any effort or risk for the operator inside the cabin.
A jib crane is fitted to ease substitution of the dies.
The main slide, made of a special aluminium alloy has a special high pressure lubrication system for distribution of the lubricant in specific areas to obtain a hydrostatic support of the slide for all the length of the travel. The lubrication oil is completely reclaimed and filtered in two subsequent stages and recycled to the machine.
A new adjustment system of the fixed die pocket will guarantee a perfect cylindrical parallelism of the threads on the shank of the part and the complete die holder is securely held in place by hydraulic clamping.
Considering the large dimensions and blanks (a M36 blank can weight up to 2 kg), a special servo assisted rail feeding system has been introduced for automatic adjustment of the high position and width of track with memory storage for the different part numbers.
An electronic hand wheel, already used on Sacma Headers, allows for “slow-motion” set up and match of the threading dies and for the correct timing of the introduction blades.
The high torque and power of the drive unit of the RP92 allows for jogging of the machine even when the largest size product is stopped between the thread roll dies.
The clutch-brake unit will stop the slide immediately, while the electronic brake will slow down the main motor to a final stop.
There is a wide range of options to allow for an accurate choice of equipment according to the different need of the customers.
The first batch of these Thread Rollers has already been produced and the first machine already shipped to an important Russian fastener manufacturer.
The Ingramatic and Sacma sales departments are at your complete availability to supply any further information or details you may require .
Post time: Jun-11-2017