When we talk about Italian manufacturing, adjectives such as ‘reliable’, for its attention to build quality, ‘robust’, linked to Italian engineering and mechanical tradition, ‘versatile’, typical of Italian design flexibility, ‘innovative’, for the all-Italian ability to combine tradition with the search for technological solutions, and ‘excellent’, for its extreme attention to detail and design. It is no coincidence that the Powermill G3 HPC3 was chosen by an Italian customer in the general engineering sector, because this machine combines the robustness of large mechanical structures with the innovation and versatility of the solutions offered by Mecof to meet the customer's requirements for precision and reliability. For both of them, it is important to achieve one goal: excellence.

Impressive dimensions, millimetric precision

The machine described here is built to handle the accurate machining of large workpieces: with strokes of 18 metres in X, 4.5 metres in Y and 1.75 metres in Z, the Powermill G3 HPC3 offers a working capacity that places it among the highest-performing solutions in its category.

The machine is equipped with a class II work surface in accordance with DIN 876, 18 metres long and 3 metres wide, with a load capacity of 15,000 kg/m square: figures that speak of extraordinary robustness.

The chain tool magazine with 80 positions and sliding exchange arm, ISO 50 connection, completes the picture, reducing downtime and ensuring maximum production continuity.

The versatility of the dual-rotating head

At the heart of the machine's operational flexibility is the universal dual-rotating head with automatic millesimal positioning, 38 kW and 615 Nm, capable of reaching 6,000 rpm with ISO 50 connection. The head is designed for automatic changeover, an operation made even easier by the support system, with a protective cradle equipped with positioning references that can be quickly removed when not needed, optimising space.

Automation and connectivity: Industry 4.0 on board the machine

Equipped with Heidenhain TNC 640 HSCI numerical control, the same supplier also provides the options for the Industry 4.0 package, which includes:

·         Heidenhain TNC Remo, for remote loading of instructions and programmes,

·         Heidenhain DNC, which connects the machine to the company's logistics systems,

·         CAPR, adaptive control that optimises machining cycles in real time.

Control and measurement always at hand

Precision is guaranteed by a complete package of control tools: Renishaw RMP60 radio probe, kinematic measurement and laser system for detecting tool length and diameter. All this helps to reduce errors and increase the reliability of machining operations.

Smooth management and chip evacuation

The customer raised the issue of proper chip evacuation, given the machine's need to perform heavy-duty machining. The solution was quickly found by integrating a dual-delivery cooling system, both external (6 bar, 28 l/min) and internal to the spindle (40 bar, 20 l/min).

This is supported by 2,000-litre filter and collection tanks and a chip evacuation system with two ramp conveyors along the entire work surface.

Safety and ergonomics

Safety does not necessarily mean that a machine must be subject to strict construction and design rules; technology also comes to the rescue in this area, giving the user full freedom to control and manage the Powermill G3 HPC3 via the Heidenhain HR 550 FS wireless keypad and the integrated video surveillance system with Bosch cameras and 19" touchscreen monitors, which allows real-time monitoring of the work area, with additional protection against chips and coolant.

The Powermill G3 HPC3 is not just a generously sized gantry milling machine: it is a complete machine, designed to guarantee productivity, precision and digital integration. For Italian and international general engineering companies, it represents a strategic investment that combines mechanical robustness, versatility and connective intelligence.