Cogsdill increase efficiencies on manufacturing hydro energy parts.

Detailed Specification

Hydropower has been used since ancient times to grind flour and perform other tasks. At the beginning of the 20th century, hydroelectric power stations were being constructed by commercial companies. Hydroelectric power stations continued to become larger throughout the 20th century due to the rising demand for electricity, which is still increasing.

According to comparative studies hydroelectricity produces the least amount of greenhouse gases and externality of any energy source. Using hydropower prevents approximately 200 million tons of carbon pollution in the U.S. each year – equal to the output of over 38 million passenger cars.

On a hydroelectric dam, a wicket gate helps to control the flow of water as it reaches the generator, which in turn determines how much power the dam can generate. These gates are very important to the dam’s performance and operation. The connecting pin, as a part of the wicket gate, has an estimated life span in excess of 40 – 50 years, which is the average life of the turbines and generators.

On average reconditioning these parts is much more cost effective than producing new ones from scratch. But because these components come in a large variety of sizes and also due to the complex unsymmetrical shape and heavy weight they are not easy to handle within a CNC machining shop.

Cogsdill designed and manufactured a special ZX O/D turning head to simplify the problem!! By completing the overturning process of the connecting pins on a borer, they have eliminated the need for a heavy lathe or special machine for the machining process.

Down times are reduced to a minimum!

The cut diameter of this special ZX tool is accurately controlled by the CNC function of the horizontal boring mill – between 79mm – 348mm and with a tool overall length of about 1500mm. The boring head and cutting inserts can be changed rapidly by utilising a Capto-C5 tool holder.

The Cogsdill ZX system requires a programmable inner spindle, such as those found on horizontal borers, that rotates in unison with the outer spindle, or milling sleeve.

The axial movement of the inner spindle is converted within the tool into radial cutting stroke for diameter control. Movement of the table, or machine column, on a parallel axis controls the axial location of the cutting edge relative to the part. In most horizontal boring mills, these two axes are referred to as “W” and “Z”.

For more information on the Cogsdill ZX range of tooling, please visit our website

www.cogsdill.com