Comprehensive Design of 5-Head Multi-Boring Machine

FIVE HEAD MULTI BORING MACHINE – COMPLETE ENGINEERING DESIGN REQUIREMENT IMPORTANT DESIGN PHILOSOPHY This project is NOT intended to assemble purchased boring heads or purchased machine modules. This project is intended to DESIGN, ENGINEER, MACHINE, FABRICATE, ASSEMBLE and COMMISSION a complete industrial 5-head multi-boring machine from raw materials and standard industrial components. Every fabricated component must be designed. Every machined component must be dimensioned. Every assembly must have exploded drawings. Every mechanism must be fully explained. Every subsystem must be fabrication-ready. No black-box assemblies. No purchased boring units. No purchased gearbox assemblies. No purchased spindle banks. All major systems must be engineered. --- MACHINE TYPE Industrial Five Head Multi Boring Machine Applications: • Modular Furniture • Cabinets • Kitchens • Wardrobes • Office Furniture • Panel Processing Materials: • MDF • HDHMR • Particle Board • Plywood • Block Board • Solid Wood --- MACHINE CONFIGURATION 5 Independent Boring Heads Configuration: Head 1: Vertical Top Head 2: Vertical Top Head 3: Vertical Top Head 4: Horizontal Left Head 5: Horizontal Right Alternative configuration options must also be provided. --- CAPACITY Maximum Panel Length: 3000 mm Maximum Panel Width: 1200 mm Maximum Panel Thickness: 60 mm Minimum Panel Thickness: 9 mm Drilling Diameter: 3 mm – 35 mm Drilling Depth: 0 – 60 mm --- DESIGN DELIVERABLE REQUIREMENT Provide complete: A. Mechanical Engineering B. Fabrication Engineering C. Machining Engineering D. Electrical Engineering E. Pneumatic Engineering F. Control Engineering G. Assembly Engineering H. Manufacturing Engineering I. Maintenance Engineering --- DRAWINGS REQUIRED 1. General Arrangement Drawing 2. Complete Assembly Drawing 3. Exploded Assembly Drawing 4. Fabrication Drawings 5. Machining Drawings 6. Section Views 7. Tolerance Drawings 8. Sub-Assembly Drawings 9. Parts Identification Sheets 10. Service Drawings --- FRAME ENGINEERING Provide complete fabrication drawings. Material: 100×100×4 mm 100×50×3 mm 75×50×3 mm 50×50×3 mm Include: • Pipe cut lengths • Weld locations • Weld sequence • Frame leveling system • Foundation design • Structural load analysis --- WORK TABLE SYSTEM Provide: 1. Table Frame 2. Work Surface 3. Panel Supports 4. Fence System 5. Reference Stops 6. Panel Clamping System 7. Positioning Guides 8. Alignment Procedures Table Flatness: ≤0.10 mm --- VERTICAL BORING HEAD ENGINEERING Provide complete design. For each vertical head: 1. Spindle Housing 2. Spindle Shaft 3. Bearing Arrangement 4. Gear Drive 5. Belt Drive 6. Motor Mount 7. Depth Stop System 8. Quick Tool Change 9. Exploded Assembly 10. Machining Drawings --- MULTI-SPINDLE BORING BANK Provide complete engineering. No purchased boring bank. Design: 1. Spindle Layout 2. Spindle Gears 3. Gear Train 4. Housing 5. Bearing System 6. Lubrication 7. Tool Holders 8. Adjustment Mechanism 9. Exploded Assembly Typical Spacing: 32 mm System Provide: 11 Spindle 21 Spindle 35 Spindle variants --- HORIZONTAL BORING HEAD ENGINEERING Provide complete design. Include: 1. Spindle Housing 2. Drive System 3. Gear Train 4. Bearing System 5. Tool Holders 6. Depth Adjustment 7. Position Adjustment 8. Exploded Assembly --- HEAD POSITIONING SYSTEM Provide: 1. Linear Guides 2. Guide Rail Design 3. Bearing Blocks 4. Adjustment Mechanism 5. Locking System 6. Scale System 7. Position Indicators --- HEAD FEED SYSTEM Provide complete engineering. Options: Mechanical Feed Pneumatic Feed Servo Feed Include: 1. Cylinder Sizing 2. Feed Mechanism 3. Guide System 4. Return Mechanism 5. Force Calculations 6. Speed Calculations --- DRILL DEPTH CONTROL Provide: 1. Depth Stops 2. Scales 3. Micrometer Adjustment 4. Locking System 5. Repeatability Analysis Target: ±0.1 mm --- PANEL CLAMPING SYSTEM Provide: 1. Pneumatic Clamps 2. Pressure Beam 3. Clamp Cylinders 4. Mounting System 5. Air Circuit 6. Safety Interlocks --- DRIVE SYSTEM Provide complete engineering. Include: 1. Motor Selection 2. Pulley Calculations 3. Belt Calculations 4. Gear Calculations 5. Shaft Calculations 6. Bearing Calculations 7. Power Transmission Drawings Motor Range: 1–3 HP per head --- SPINDLE ENGINEERING Provide complete machining drawings. Include: 1. Spindle Shaft 2. Bearing Seats 3. Threads 4. Tool Interface 5. Runout Specifications 6. Heat Treatment Requirements Target Runout: ≤0.02 mm --- GEARBOX ENGINEERING Provide complete design. No purchased gearbox. Include: 1. Gear Calculations 2. Gear Drawings 3. Housing Drawings 4. Bearing Arrangements 5. Lubrication System 6. Assembly Drawings --- PNEUMATIC SYSTEM Provide: 1. Complete Pneumatic Circuit 2. FRL Selection 3. Cylinder Calculations 4. Valve Selection 5. Air Consumption Analysis 6. Safety Circuit Operating Pressure: 6–8 Bar --- ELECTRICAL SYSTEM Provide: 1. Single Line Diagram 2. Panel Layout 3. Motor Wiring 4. Contactor Layout 5. Overload Protection 6. Emergency Stop 7. Cable Routing 8. Terminal Layout --- PLC AND AUTOMATION Provide: 1. PLC Architecture 2. I/O Mapping 3. Sensor List 4. Actuator List 5. Machine Cycle Logic 6. HMI Screens 7. Alarm System 8. Diagnostic System --- MANUFACTURING DOCUMENTATION Provide: 1. Complete BOM 2. Raw Material List 3. Machining List 4. Bearing List 5. Fastener List 6. Gear List 7. Fabrication Sequence 8. Machining Sequence 9. Assembly Sequence 10. Commissioning Procedure --- CRITICAL SUB-ASSEMBLIES REQUIRING FULL ENGINEERING • Frame • Work table • Vertical boring heads • Horizontal boring heads • Multi-spindle boring banks • Spindle shafts • Gear trains • Gearboxes • Linear guide systems • Clamping systems • Pneumatic systems • Electrical systems --- FINAL OBJECTIVE Create a fully engineered industrial Five Head Multi Boring Machine where major mechanical systems are designed and manufactured from raw materials, including: • Frame • Table • Vertical boring heads • Horizontal boring heads • Multi-spindle banks • Gear trains • Spindles • Gearboxes • Clamping system • Pneumatics • Electrical system • PLC automation Deliver a complete fabrication-ready, machining-ready and assembly-ready engineering package comparable to Vitap, Maggi, SCM, Biesse and Weeke industrial multi-boring machines.

Project ID: 40487857