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Any product aspiring to success in the world market and a strong competitive position needs be flexible in accommo-dating the market requirements, be al-ways one step ahead of its competitors and meet a wide range of specific customer re-quirements. Among the strong points of the company ŠKODA MACHINE TOOL a.s. is the capability to continuously in-novate its products and adjust its capac-ity, technology and organisation to facili-

NEW ŠKODA HCW MACHINE TOOL SERIEState timely product manufacturing and marketing. In the environment of harsh competition such capability is an absolute must for maintaining the prominent mar-ket position of the company.Regarding its HCW machine series, ŠKODA MACHINE TOOL a.s. is now introducing a significant product innova-tion. The HCW 3000 machine launched this year represents the best qualities of the well-established HCW series and, un-

like its predecessors, includes a coaxial spindle drive.The machine buyers will appreciate other improvements too, such as a larger work space (thanks to the increased extension range of both the sleeve and the work spindle) or the maximum spindle sped increased to 3,000 r.p.m. The sophisti-cated machine design resulted in decreas-ing the number of the machine compo-nent parts by 20% and a lower foundation

depth requirement. The customers may choose either telescopic covers or bellows for protection of the machine slide-ways.With HCW 3000, the customers will get a machine of state-of-the-art technology and superior performance. The opera-tional capabilities, high power and pre-cision of this machine tool make it an ideal solution for fast and precise milling, drilling, boring and turning of large and heavy engineering parts.

A LTA G r o u p E n g i n e e r i n g C o m p a n i e s I n f o r m a t i o n B u l l e t i n

September / 2013

type HCW3000Z axis (ram’s travel) 2 000 mmW axis (spindle travel) 1 400 mmZ + W axis 3 400 mmpoWer of main drive 103 kWmax. spindle revolutions 3 000 rpmBoring spindle diameter 180, 200, 225 mmram cross section 480 x 480 mmx axis (column along Bed) from 2 500 mmY axis (headstock along column) up to 7 000 mm

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ANOTHER HEAVY HCW HORIZONTAL MACHINE INSTALLED IN CHINAThe prevailing market requirements to-wards higher power rating and better efficiency result in construction of ever larger machines and equipment.

In response to this trend, the company ŠKODA MACHINE TOOL a.s. launched a new series of heavy quill-type horizon-tal machines ŠKODA HCW with spindle

diameter up to 300mm and vertical spin-dle headstock travel length up to 10m. The first two machines of this size with travel Y = 9 and 6 metres were installed

in China in 2010. Another machine with travel lengths Y = 8m and X = 26m and a turntable of loading capacity 160t has been delivered to a Chinese customer this year.

ŠKODA heavy machine tools find successful applicationin manufacturing the windmill power plant component partsThe growing interest in renewable power resources brings business opportuni-ties to the company ŠKODA MACHINE TOOL that supplies horizontal machines and lathes to the windmill power plant component manufacturers.Regarding horizontal machines, machi-nes of the type series HCW proved par-ticularly well suited for manufacturing of the windmill power plant component parts. To date, the windmill power plant manufacturers have ordered machines of the type designation HCW 1, HCW 2 and HCW 3.These sophisticated horizontal machi-nes are highly competitive concerning machining power, speed and torque, as well as the overall machining precision, machine control and workstation safety parameters. Machines are supplied with a wide range of accessories such as turn-tables or milling and boring heads that are very efficient in machining windmill power plant equipment and that can be designed to meet specific customers re-quirements concerning manufacture of particular component parts.

ŠKODA HCW MACHINE WITH 9M SPINDLE HEADSTOCK TRAVEL

The trend towards larger and heavier machines can be illustrated by the recent company contracts for HCW 3 machi-

nes with 9m travel in axis Y. One of these was delivered to a customer in Czech Re-public in August and another, ordered by

a prominent Dutch manufacturer, is near completion at the company production plant in Plzeň. This machine will be put

in service at the customer‘s site by the end of the year.

ŠKODA SR LATHES AT SIEMENS FACTORIESA review of the customer requirements in recent years shows a steadily growing demand for heavy horizontal lathes. This trend appears to be related to the growing worldwide energy consumption necessitating production of additional power generation equipment. Such equi-

pment is both conventional and non--conventional, particularly in countries investing in modern technologies for po-wer generation from renewable resour-ces.With its long-term manufacturing expe-rience and good references in the field

of heavy lathes, the company ŠKODA MACHINE TOOL has been successful in meeting the requirements of the le-ading engineering concern of Siemens. The company SEM DRÁSOV SIEMENS ELECTRIC MACHINES s.r.o. has bou-ght a ŠKODA SR 1 lathe. Another ma-

chine of the SR series, ŠKODA SR 2 is in operation at SIEMENS INDUSTRIAL TURBOMACHINERY in Brno. A few years ago, ŠKODA MACHINE TOOL upgraded two ŠKODA SUT 160 machi-nes installed at the SIEMENS AG opera-tion in Erfurt in Germany.

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ALTA launches a zinc-coating plant construction project in the Russian Federation worth EUR 17 million

The company ALTA, a.s. jointly with its affiliates ALTA RUS and ALVEL a.s. is working on a zinc-dipping plant con-struction project for the customer OOO «ЕТПК» (ETPK, Jekatěrinburgskaja tor-govo promyšlennaja kompanija) in Jeka-terinburg. An international agreement concerning co-operation in the project implementation was signed on the occa-sion of the official Czech government visit to Jekaterinburg in May 2013.

ETPK is an important business part-ner of groups UGMK (Uralskaja gorno metalurgičeskaja kompanija) and RMK (Ruskaja mědnaja kompanija) in the field of secondary non-ferrous metal supplies.The project consists of technology sup-plies, civil engineering work, equipment assembly and operational start of a mod-ern zinc-dipping line intended for surface treatment of steel structures and other engineering parts. The projected plant

capacity is 24 thousand tons a year in two-shift operation. The line will make possible zinc coating of steel structures up to 13m long. The raw material for pro-duction comes from the company‘s own resources which will positively affect the plant economy.The expected project deliverables, being original Czech products, are worth EUR 17 million. Czech companies will also participate in the project design and re-

alisation of the civil engineering work. At the moment the project work including specific contractual, design and techno-logical tasks is in progress. The basic con-tracts with the project investor have been executed and negotiations are in progress with the financing commercial banks and the EGAP insurance company.

MACHINE TOOL MODERNISATION PROJECTSSooner or later, every machine will need main-tenance and repair. The company ŠKODA MACHINE TOOL‘s policy of customer com-munication provides important unbiased feed-back information on the performance of the company products. At the same time, the cus-tomer communication is a valuable informa-tion source affecting the development of new machines. The development results are directly applied in overhauling and modernisation of heavy machine tools made by ŠKODA or other manufacturers. The machine modernisation projects are always conceived to meet specific customer requirements.Irrespective of the economic cycle fluctua-tions, the company customers feel the need to increase the machining operation efficiency. In many cases, the best solution to this problem is machine tool upgrading including installation of a CNC system.ŠKODA MACHINE TOOL a.s. offers general overhauls and modernisation of horizontal ma-chines of the ŠKODA W, WG and WH series including installation of CNC systems of the Siemens, Heidenhain or Fanuc brands. At the same time, all electric accessories are upgraded

to ensure meeting the requirements of standard ČSN EN 60204-1 (corresponding to IEC 204-1) and compliance with the CE regulations.Each modernisation project includes machine dismantling and subsequent assembly at the customer‘s manufacturing plant and special training programmes for the machine opera-tors, programmers and maintenance staff with the complete documentation on the upgraded machine. Upon the customer request, the mod-ernisation project may include spindle speed increase, extension of machine travel in axes X and Y or installation of separate drive systems for the spindle and quill travel. Supplied with the upgraded machines can be new milling and boring heads, chip conveyors and new turn-tables of the TDV series with loading capacity from 25 to 400t.The innovative combination of original hori-zontal machines of the W, WG and WH series with the latest HCW spindle heads will result in significant increase in workstation capacity and improvement in the overall machine precision.Surprising benefits can also be obtained by a combination of machine overhauling, mod-ernisation and investment into new equipment

consisting of installation of a new column with a HCW spindle head on a modified bottom part of the original machine column. Upon the pro-ject completion, the foundation, bed and ma-chine make up a modern workstation with pa-rameters comparable to a brand new machine.The company can also carry out general over-hauling and modernisation projects for ŠKODA lathes including installation of CNC systems and new electric accessories, swing-over-bed increase and delivery of new steadies or other special equipment. Each modernisation project includes machine dismantling and subsequent assembly at the customer‘s manufacturing plant, delivery of updated machine documentation

and special training programmes for the ma-chine operators, programmers and maintenance staff.The popularity of the machine modernisation services is documented by positive responses from the company customers in the Russian Federation, Germany and other countries. The customers particularly appreciate the techni-cal level, quality and reliability of the upgraded machine tools. On the other hand, for ŠKODA MACHINE TOOL a.s. the contracts for ma-chine overhauling and modernisation have be-come an important complement activity to the production of new machines.

ŠKODA MACHINE TOOL AT TRADE FAIRS AND EXHIBITIONS MEXIKOThe TECMA trade fair that took place in Santa Fe on 5 to 8 March 2013 was focused on ma-chine tools, forming machines, software and other products. Since 1991 TECMA has been the only trade fair in Mexico specialised in ma-chine tools. TECMA is biennial event.The trade fair venue was the Expo Bancomer Santa Fe area where 260 companies exhib-ited their products. ŠKODA MACHINE TOOL a.s. and other Czech companies participated in a common Czech show. The purpose of the company‘s presence at TECMA was to seek new customers in a territory with a development po-tential in metal processing industries.

CHINAŠKODA MACHINE TOOL a.s. exhibited its products at the China International Machine Tool Show (CIMT) on 22 to 27 April 2013.It was the 13th annual event taking place at an international exhibition centre in Beijing. This important trade fair attracts all leading world machine tool manufacturers. This year almost 1,400 exhibitors from 28 countries presented their products on the area of 120,000 m2. The visitor count exceeded 232,000.ŠKODA MACHINE TOOL exhibited a ŠKODA HCW 2000 E machine manufactured in co-operation with its Chinese subsidiary Eastern

SKODA (Shenyang) Machine Tool Moderniza-tion Co., Ltd.The company representatives held numerous discussions, found new business contacts and worked out new projects with the trade fair visi-tors.

BRAZILThe importance of the Brazilian ma-chine-tool market is growing. ŠKODA MACHINE TOOL a.s. acknowledges this fact and took part, as one of the Czech companies sharing a common stand of the Czech-Trade Agency, in the FEIMAFE exhibi-tion in Sao Paulo on 3 to 8 June 2013. Information on the ŠKODA machine tools was also avail-able at the PANAM-BRA stand.

RUSSIAAmong the trade fairs where ŠKODA MA-CHINE TOOL is a regular participant and presents its product scope is METALLOO-BRABOTKA in Moscow, the capital of the Rus-sian Federation. This year‘s event took place at the EXPOCENTRE Krasnaya Presnya area on 27 to 31 May 2013.This trade fair, the official purpose of which is to promote modernisation of the Russian in-dustries, attracted 1,146 exhibitors from 40 countries; the number of visitors exceeded 500 thousand. The growing number of the trade fair participants may indicate positive changes in the economic situation of the country and gives hopes for market revitalisation.

SLOVAKIAMSV Nitra, taking place on 21 to 24 May 2013, was the 20th exhibition fea-turing machines, tooling, equipment and technologies at the Agrokomplex Ni-tra area of 21,000 m2. The products of 405 exhibitors attracted 15,200 visitors. The company representatives used their presence at Nitra for establishing new business contacts and finding a trade representative for the Slovak territory.

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NEW SE-MI TECHNOLOGY PRODUCTS APPLIED ON ŠKODA MACHINES

The carefully selected acquisitions of ALTA, a.s. have brought positive syn-ergy effects to the ALTA affiliates including extension of the company product portfolios.Developed in co-operation of the com-panies ŠKODA MACHINE TOOL a.s. and SE-MI Technology, a.s. was inde-pendently travelling operator cabin for ŠKODA machine tools. The company SE-MI TECHNOLOGY included this product among its portfolio of min-ing and engineering equipment and

A successful operational start of a multi-function portal-type machining centre manufactured by TOS KUŘIM – OS, a.s.

In July 2013, the company TOS Kuřim-OS, a.s., using its long-term experience with development, design and manufacturing of portal-type ma-chining centres and clamping tables for vertical lathes, put in service a multi--function portal-type machining centre. This successful project marked the com-pletion of extensive development work on a machining centre making possible machining of large work pieces of com-plex shapes with minimum work-piece handling operations. With a multi-function machining cen-tre of proprietary design and manu-facturing, the company TOS Kuřim is in a position to offer to their customers self-contained technological workstati-ons combining all advantages and capa-bilities of a portal-type machining cent-re and a vertical lathe. Such workstation can perform a wide range of milling and turning operations. All rough-ma-chining, turning, milling and finishing operations can be performed on a single machine with half the acquisition price and minimum floor-space requirements compared to a conventional solution consisting of individual machine tools.An example of a work piece that can be machined on such workstation is the external blade ring of a hydraulic turbi-ne (part of the turbine casing including blades and their control mechanism). Regarding the operational conditions (temperature, humidity, pressure and mechanical stress), it is a large and tech-nologically demanding component part. The workstation customer, the company Mavel, a.s., specialised in manufactu-ring and commissioning of water-po-wer plants including Kaplan, Francis and Pelton hydraulic turbines, required that the ordered workstation should fa-cilitate complete machining of just that

type of work piece. The project solution proposed by the company TOS Kuřim consisted of a multi-function machining centre combining a travelling portal including a cross slide and automatica-lly-replaceable spindle heads, and an in-tegrated vertical-lathe table KEP of own production. The type designation of the machine is FRUFQ 300A – VR/7 + KEP. The basic technical parameters of the ma-chine are: X = 6,000mm, Y = 5,400mm, W = 2,000mm, Z = 1,500mm, clearance between the portal columns = 4,100mm, P = 37kW, 4,000 r.p.m., max. Mk = 2,000 Nm, low-and high-pressure cooling, a tool magazine with capacity of 40 tools in combination with a tool replacement equipment. Among the machine acces-sories are replaceable spindle heads VA 1 (direct head), VO (universal head), VK (fork-type head) with ISO-50 clamping cone, and cutting-tool heads IZN 1 and IZN 2 for turning operations using the CAPTO-6 clamping system. The machi-ne clamping area consists of an integra-ted vertical-lathe clamping table with hydrostatic ways. The table makes po-ssible machining of work pieces of dia-meters up to 3,700mm or, if extension arms are used, up to 6,000mm. The table loading capacity is 60,000kg and the ma-ximum rotational speed 80 r.p.m. (with stepless speed control). Apart from the table, available also is a fixed clamping plate of dimensions 3,000 x 2,000mm. Application of automatically-replaceable spindle heads IZN 1 and IZN 2 intended for turning operations is a completely new feature in the company products. Both heads have been developed in co--operation with another Group com-pany, ČKD Blansko-OS, a.s. IZN1 is a replaceable vertical cutting-tool head facilitating both horizontal and verti-cal tool clamping using the CAPTO C6

clamping system. IZN 2 is a replaceable horizontal cutting-tool head facilitating both horizontal and vertical tool clam-ping using the CAPTO C6 clamping system.In their order, the customer required as a product qualification condition milling of both contact surfaces of the external blade ring of a hydraulic turbine and, upon bolting together both ring parts, complete finish turning of the outer and inner ring surfaces. Here the first tech-nological operation consisted of milling of the ring contact surfaces including machining and recessing the connection holes. With the ring halves bolted toge-ther, another technological operation fo-llowed: turning of the outer surfaces (the top and bottom seating faces) and the inner ring surfaces where the machining precision of the inner casing areas and the attached blades has a direct effect on the turbine power output. The third and final machining operation consisted of milling the surfaces and holes for fitting the blades and their control mechanism. The customer, comparing the existing technology with that of the new machi-

ning centre was fully satisfied with the demonstrated milling and turning times and the meeting of the precision, surface roughness and other work criteria. The work-piece machining test confirmed the expectation that the new machining centre will find application with most demanding customers seeking price--effective solutions for their difficult machining tasks.

the frufQ 300a – vr/7 + kep multi-function machining centre

iZn 2 replaceable horizontal cutting-tool head

iZn 1 replaceable vetical cutting-tool head

systems. The first travelling operator cabins were included in three ŠKODA HCW workstations with vertical spin-dle-head travels of 4, 5 and 6 metres supplied to an Indian customer. The contract for these three machines is the result of active trading policy in the Indian territory. It is also a sign of renewed interest for ŠKODA machine tools in one of the fastest developing countries in the world. The new cabin offering high comfort to the machine operator helped to meet the require-

ALTA (jointly with its Russian affiliate ALTA RUS) signed a memorandum on co-operation with the companies „OOO Lenstrojdetal“ and „OOO Jelisenvarský combine“ specialised in processing of non-ore materials concerning prospect-ing and exploitation of construction stone deposit area. The project value

has been estimated at EUR 25 million (almost CZK 650 million). Part of the contract concerns construction of stone crushing and gravel grading plants. The contract is expected to generate orders for the companies ŠKODA MACHINE TOOL, TOS KUŘIM-OS and ČKD BLANSKO-OS.

Memorandum on co-operation with OOO Lenstrojdetal and OOO Jelisenvarsky kombinat

ALTA has executed a contract with the company „ZAO Kuznechno-mechanicheskij za-vod“. The contract represents the first stage in project design and construction of manu-facturing and storage facilities of a modern industrial enterprise specialised in forging and pressing of special steel grades. The value of the possible future contract for ALTA has been estimated at EUR 50 million.

Contract with ZAO Kuznechno-mechanicheskij zavod

ments of the Indian industry and win the contract against strong com-petition of other manufacturers. The SE-MI TECHNOLOGY, a.s. op-erator cabins used on machine tools will bear the trademark Škoda. The cabin will also be used with a hori-zontal machine, at the moment in production, including a unique 9m vertical spindle-head travel for a Dutch customer.

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TOS KUŘIM – OS a.s. successful in railway business There is no doubt about the fact the railwa-ys are undergoing a period of renaissance. Congested roads and motorways and dense air traffic bring attention to innovations of railway transport. The continents of Euro-pe, Asia and North America have thousands and thousands of kilometres of outdated railways not meeting the requirements on modern railway transport. The companies engaged in modernisation and construc-tion of new railway lines are experiencing a business boom. The company TOS Kuřim-OS a.s., aware of its prominent competitive advantage, deve-lops, manufactures and markets machine tools for the railway industries. High rigidi-ty and cutting power needed for machining the welded frames of railway stock and the

high-alloy rail steels and other properties of the machine tools manufactured by TOS Kuřim make them the preferred solutions for the industries participating in the rail-way infrastructure revitalisation.The latest company contract for the railway industry concerns a 16-metre portal-type machining centre of the FRU series (71kW, 6,000Nm) for the Polish company Kolejowe Zakłady Nawierzchniowe „Bieżanów“ Sp. z o.o. in Krakow. The machine including a unique system of magnetic rail clam-ping has been in operation for more than six months producing component parts of track superstructure. The company TOS Kuřim has been equally successful in selling its products to Indian and Chinese compa-nies producing trains and railway stock.

Two portal-type machining centres of the type designation FRFQ 400 VR-A12 have been delivered to an Indian business part-ner manufacturing machines for the do-mestic railway industry. Both machines will be used by the target customers for bogie frame machining. Thanks to the innovated concept of the portal-type machining cen-tre including, among other things, longer traverses, new power drive for the slide mo-vement in axis Y and a wider machine table, the company TOS Kuřim has won the con-tract in a very strong international compe-tition and, during the machine acceptance tests, proved to the customer the suitability of the machine solution for machining the component parts for the railway industry. Extremely rigid FRPF machines consisting

of stable portal, travelling slide and mova-ble table have been ordered by the Chinese company Tianjin High Power Electric Lo-comotive Servicing Co. The machines will be installed in the new factory manufactu-ring high-speed trains in the city of Tianjin lying on the coast of the Yellow Sea. The advantage of the company TOS Kuřim consists of its wide base of qualified engi-neering staff that makes possible meeting the demanding and often highly specific customer requirements. The company ma-nagement appreciate the dedicated attitudes of all TOS Kuřim employees participating in execution of the company projects. Bohumil Zámečník, Michal Šrámek Sales managers of TOS Kuřim-OS, a.s.

frpf machine in production

Bogie frame machining portal-type machining centre in operation at kZn Bieżanów

A new item in the ČKD BLANSKO-OS, a.s. product line - vertical lathe with travelling portalIn the autumn of 2013, the company ČKD Blansko-OS, a.s. will finish the production of the first large vertical lathe with travelling portal, an SKDY 50/80 D machine manu-factured on order by the Russian shipyard „Admiraltejskie Verfi“.This vertical lathe has been designed to facili-tate turning, milling, drilling and boring ope-rations and, provided the grinding accessory

is added to the machine, even grinding ope-rations. The lathe makes possible very precise machining of large and heavy work pieces of extremely complex shapes. The machine frame design solution is based on the experience of the company TOS Ku-řim-OS a.s. with development and production of portal-type machining centres. All machine guide ways, for both linear and rotating mo-

vements, are of the hydrostatic type ensuring long service life, high positioning precision and excellent dynamic properties of the ma-chine.The basic parameters of the vertical lathe are: diameter of the clamping table 4,770mm, ma-ximum machining diameter 8,000mm, maxi-mum work piece height 4,000mm and maxi-mum work piece weight 100t.

The portal travel length is 5,000mm (axis Y), the horizontal carriage travel length 10,000mm (axis X), the slide vertical travel length 2,000mm (axis Z) and the cross-slide lift 2,800mm (axis W). The maximum travel speed along linear axes is 15,000mm/min.The main table drive system includes two Si-emens motors of unit power rating 71kW; the maximum torque is 236kNm. The machine table can be operated as the main spindle with the maximum speed 63 r.p.m. or as the C-axis with the indexing precision of 0.001°.The machine includes a milling spindle with power rating of 37.7kW, torque of 1,200Nm and maximum speed of 3,000 r.p.m.The machine operation is fully automated including automated tool and tool-holder replacement. Located on the right side of the machine is a magazine for eight cutting tool holders. On the left side is a chain magazine that can accommodate forty ISO 50 rotating tools. Among the machine accessories are two milling heads - one fixed angle head and one single-axis NC milling head. Both heads are parked at the pick-up magazines found at the back of the machine. The milling heads can be used within any automated operational cycle of the machine.The vertical lathe control system is based on the SINUMERIK 840 D Solution Line pro-duct.The above machine is the first vertical lathe with travelling portal of such size manufactu-red by ČKD Blansko. The growing demand for machines of this kind is documented by the fact a contract for an even larger vertical la-the SKDY 63/80 D was signed with a German customer in the spring of 2013. Jaromír Daněk Technical Director of ČKD BLANSKO-OS, a.s.

3d view of complete machine skdY 50/80 d

skdY 50/80 d machine in production