Precision is no ‘pipe dream’ for Pipetronics

As a manufacturer of high-performance electric and hydraulic sewer pipe rehabilitation robot systems, Pipetronics GmbH & Co. utilises two in-house CNC machining centres fitted with a wide range of BIG KAISER tools and tool holders that are available in the UK from Industrial Tooling Corporation (ITC). With headquarters in the South German town of Stutensee, Pipetronics uses the BIG KAISER range of products for the production of their robots’ turning and milling components.

Founded in 2016 and currently employing around 100 people, the company offers a comprehensive portfolio of electric and hydraulic robots for modern sewer rehabilitation. “Currently, our robotic systems represent the most innovative, state-of-the-art technology in the field of sewer robotics, delivering maximum performance, return-on-investment and rugged durability for uncompromising daily use. A range of customised truck and trailer vehicle systems for trenchless sewer rehabilitation coupled with specialist pipe repair resins round out our offer,” describes Rolf Dettinger, Head of CNC Manufacturing at Pipetronics.

Industry specialist in intelligent robotic pipe rehabilitation systems

Pipetronics’ hydraulic and electric milling, filling and grouting sewer rehabilitation robots are characterised by their performance that delivers maximum reliability and work results even under extremely challenging work conditions. Retrofitted with an extensive set of milling, grinding and brushing attachments, these robot systems are equipped for the full range of sewer rehabilitation tasks. “The main function of these sewer milling robots is sewer rehabilitation preparation works on pipe liners and the opening of inlets after the liner has been set in place. Our milling robots take care of all the required work tasks, including the milling-off of edges, removal of stubborn deposits, repairs of sewer breakage points, damaged sleeves or even the milling of completely clogged sewers, all performed easily, safely and economically,” noted proudly Dettinger.

To ensure the economically-efficient production of their robots, Pipetronics installed two in-house CNC production centres at its Stutensee facility. “Since we have relatively small batch runs, in 2019 we installed CNC machines to achieve faster, more flexible and economic production. Now, three years later, there’s no question that this was the right decision as we’re able to manufacture all our milled and turned parts economically with top quality – all in-house,” Dettinger praised this important step.

In-house CNC production

To ensure complete coverage of all production processes, Pipetronics purchased a Grob G350 5-axis machining centre and a Mazak i400 ST turn/mill centre. “Both of these machines were equipped with robotic handling functionality, which increased productivity and output, while simultaneously reducing our reliance on human labour.”

“Currently, both machines run an average of 16 hours per day. We mill large parts on the Grob because it has a very long Z-axis. The Mazak is used to produce complex turned and milled parts,” Dettinger adds. To mill very close to the clamping device along the spindle, a slim, stable and precise tool holder is required – and this is where the tool holder specialist BIG KAISER comes into the picture.

BIG CAPTO tool holders

“From my previous job, I have significant experience with BIG KAISER spindle tools and BIG DAISHOWA tool holders. After being repeatedly disappointed by the quality of the default chucks used on the Grob, I finally contacted BIG DAISHOWA, and they kindly provided us with the Mega Double Power Chuck for testing,” says Dettinger.

Christian David, Key Account Manager at BIG DAISHOWA adds: “Thanks to its exceptionally high holding force, the Mega Double Power chuck is perfectly suited for high-chip-volume rough machining operations. Importantly, it is low maintenance, as it is perfectly sealed against coolant ingression and contamination. Thanks to the enlarged contact diameter on its clamping nut and tool flange, the Mega Double Power chuck achieves a holding force of up to 3200N/m, whilst its high stability ensures vibration-free high-performance machining operation.”

Seeing the impressive results during the test phase, the CNC production manager was so impressed that he ordered several Micro collet chucks from the Mega Chuck series for the Mazak machine in addition to the tested power chuck.

“The Mazak has a CAPTO C6 machine interface, which is ideal for turn/mill operations. For our application, the BIG Micro Chuck collet chucks offer optimal performance characteristics for machining hard-to-reach workpiece areas, where conventional collet systems fail to deliver. Thanks to its groove-free collet nut, vibration at high speeds are prevented. The key is that this BIG KAISER micro collet system is slim enough to implement in all our machining operations. We mill at 12,000rpm on the Mazak and all BIG KAISER collet chucks have a guaranteed runout of less than 0.001mm at the collet mouth. That’s why we chose the slim Mega Micro Chuck. Initially available in only one size, we now run our Micro Chucks in a wide variety of lengths and diameters,” explains Dettinger

Our cooperation with BIG KAISER has delivered excellent results. We currently produce over 890 different parts on our machines. The tool holders from BIG KAISER make our processes faster, more flexible and reliable, whilst being more cost-effective,” Rolf Dettinger concludes. Christian David adds: “We cannot stress enough how pleased we are with our BIG KAISER spindle tools. The power chucks and collet chucks have made a significant contribution to the production of intelligent robots for the harshest of environments.