Redesigned screw compressor range provides even better performance and energy savings

Atlas Copco Compressors has redesigned its smallest oil-injected screw compressor range - the GA 5-11/GA 5-15 kW Variable Speed Drive (VSD). The new range sets a new industry standard for this size and type of compressor as it delivers greater performance, workplace flexibility, component reliability and significant energy savings.

The product of the most advanced development techniques, this new range offers a host of innovative features: a new-generation compression element, an 8% increase in air delivery, noise levels as low as 60 dB(A), new VSD voltage variants, an extended operating range, a new Elektronikon^® controller, and an additional tank-mounted GA 15 VSD model.

Greater performance and energy savings
Energy consumption accounts for up to 70% of a compressor's lifecycle costs and so Atlas Copco is committed to reducing this cost with every new compressor generation it develops. With the redesigned GA range, Atlas Copco's engineers have succeeded in lowering SER (Specific Energy Requirements) by up to 8%, achieved by the introduction of a new screw compressor element within an enhanced package.  At the same time, FAD (Free Air Delivery) has also been increased by up to 8%, resulting in significant savings in users' annual electricity bills.

In addition, for applications where the compressed air demand fluctuates, the advanced control algorithms of Atlas Copco's VSD (Variable Speed Drive) create average energy savings of up to 35%. The entire GA 5-15 VSD range has been equipped with new saver cycles on both fan and dryer, to increase the average energy savings even further.

Workplace flexibility
Installation flexibility is a major characteristic of the new GA 5-11/GA 5-15 VSD range. Atlas Copco's WorkPlace Concept is reinforced with operating noise levels starting from as low as 60 dB(A), making this new range the quietest in the complete GA-portfolio and subsequently allowing for installation close to the point of use.  Installation cost is further minimised by extending the standard operating range in ambient conditions up to 46° C, thereby eliminating the need for a dedicated compressor room. More VSD models, including a tank-mounted GA 15 VSD and new standard Voltage 200/575 variants, reduce installation costs further.

Component reliability
The newly developed compressor element in the redesigned GA range has been designed for optimal performance and long service life.  Compressor reliability is further increased by the improved belt-driven drive train, developed in accordance with the highest industry standards.

The introduction of the Elektronikon^® MkV Graphic Controller in the GA 5-15 (VSD) allows for remote online monitoring through a simple Ethernet connection.  This internet-based compressor operation visualisation increases both equipment reliability and efficiency by offering a great variety of control and monitoring features.  The graphic controller (a standard feature for the VSD unit) is capable of simultaneously controlling up to six compressors. 

Reliability is further improved by the introduction of a new integrated dryer range.  By guaranteeing excellence in air quality, downstream equipment is protected from contamination; even in the most demanding environmental conditions.

With the GA 5-11/GA 5-15 VSD range, Atlas Copco reinforces and extends its premium offer in the smaller kW range. The drive for innovation has generated continuous product improvements, setting the highest standards in the field of oil-injected air. There is now a compressor in this new GA 5-15 (VSD) range to suit each specific duty and compressed air requirement, throughout a range of industries. For further information, e-mail: gba.info@uk.atlascopco.com  Refer to page 65

Energy chain solution for unsupported travels up to 50m

Energy chain specialist igus has developed a horizontal guiding system called Guidelok. The new system allows totally new energy chain solutions and is ideal for use in the machining industry; particularly where unsupported travels of up to 50m are required and metal chip debris makes a gliding system difficult.

Guided in a lightweight aluminium trough, the energy chain radius passes through the igus Guidelok system - a spring-loaded roller support bracket, which moves away from the moving radius allowing a smooth movement. The roller bracket then springs back out behind the radius to support the upper energy chain run. Due to this design no debris can settle between the sliding surfaces of the upper run and lower run of the energy chain and the open guide trough prevents a build up of swarf or chips.

New energy chain Guidelok support from igus is ideal for long travels up to 50m - no debris or chips can settle between upper run and lower run of the chain.

The Guidelok gliding energy chain solution has recently been prototyped by a leading machine tool manufacturer, replacing a conventional heavy steel chain. "Previously an igus E-Chain solution would not have been viable," explained Justin Leonard of igus UK, "as metal chips, roughly the size of a pound coin, could have settled in the inner radius between the upper run and lower run causing severe problems. The new Guidelok system overcomes such issues."

Along with the main benefit of protecting the system against chips and debris, this Guidelok design offers a number of other advantages. The enormous improvement of the unsupported energy chain length allows OEMs to choose a smaller chain, saving overall costs. Secondly, by using a smaller and unsupported energy chain, the required drive force is reduced. Thirdly, the upper and lower run of the new Guidelok are separated from each other - minimising friction and wear and increasing the overall life span of the system.

The igus Guidelok energy chain system is available with or without support troughs. For further information, view website: www.igus.co.uk   Refer to page 70

Kitagawa's new chucks and workholding products

High clamping torques, extreme rigidity and fast operation are key features of Kitagawa's new GT series heavy duty rotary tables. Available in three models with tables from 200 to 320 mm diameter, the new units incorporate a novel piston design that delivers component clamping torques of up to 2800 Nm. Productivity is further enhanced by the tables' rigid yet compact design, which allows maximum metal removal rates to be combined with high indexing accuracy and repeatability. The GT series also features a rapid clamping action for reduced cycle times and maximum production throughput. (The GT 320 is pictured on the left).

In parallel, the company's new MXM series rotary tables offer reduced clamping time and rotational speeds of up to 75 rev/min, making them ideal for high speed or mass production machining operations.

Kitagawa's DXR240 rotary table, the first of a new generation of compact, low energy units incorporate high efficiency direct drive motors to achieve increased torque at lower power consumptions. The prototype model provides rotational speeds of up to 75 rev/min with no backlash - for maximum productivity and precision. (Refer to picture on the right).

Kitagawa's new NV chuck range has been developed to meet demands for large vertical lathe power chucks. Produced in eight models for components from 62 to 1000 mm diameter, NV series units feature a protective jaw cover and scraper system that prevents the ingress of swarf or coolant into the chuck mechanism. They have maximum speed ratings from 800 to 2900 rev/min and are designed for use with standard range Kitagawa jaws and Y2035R type cylinders.

The new BBT208 2-jaw chuck, (pictured on the left), features a 66 mm through hole and is ideal for machining irregular shaped workpieces at up to 5000 rev/min. It is designed to be directly interchangeable with Kitagawa's popular BB208 Chuck, (pictured middle left), without the need for special adaptors.

An updated version of the company's DL 200 chuck is more versatile than conventional draw down chucks. The DL200 series units feature an innovative 2 stage gripping action. In operation, the jaws initially clamp in a radial direction before pulling the workpiece back for seating confirmation. The DL chuck also includes a dust proof sealed body design for low maintenance and long service life.

Kitagawa's new QJR08, QJR10 and QJR12 quick change chucks, (pictured bottom left), are designed to be interchangeable with the company's popular large through-hole B208 / B210 / B212 and BB208 / BB210 / BB212 models. The new units' base jaws are quickly and easily changed using a manually operated wrench and feature metric serrations to accommodate a wide variety of popular jaw types.

The high capacity VE125LWN is the latest addition to Kitagawa's range of VE125 power-operated workholding vices. Its compact, low profile design provides three levels of clamping force and a jaw stroke of up to 405 mm for maximum production versatility. In addition, extremely close manufacturing tolerances ensure that individual vices in the range have a maximum height variation of just 20 microns - for ultra consistent set ups and manufacturing consistency.

Examples from Kitagawa's long established and proven machining and workholding products ranges, include  BB200 chucks, SS cylinders, DH collet chucks and the company's MR series NC rotary tables. Details of all these and other products from this company can be obtained via the e-mail address or website address given below.

Kitagawa Europe Ltd in profile
Based in Wiltshire, Kitagawa Europe offers one of the most comprehensive ranges of workholding and productivity solutions in the UK. The company draws on more than 60 years chuck development and manufacturing experience - and has established its B200-series units as the world's most popular power chuck range.

For further information, e-mail: enquiries@kitagawaeurope.com or view website: www.kitagawaeurope.com