UK-based PTG Holroyd Precision has introduced what it claims to be the world’s most versatile and high-performance machine for precision grinding of helical profiles used extensively in the air and refrigeration compressor industries.
The new machine, named the HG500, is designed to cater to manufacturers with diverse production needs, including the ability to handle some of the largest helical rotors used in refrigeration and air compressor manufacturing. The HG500 is capable of rough and finish grinding rotors ranging from as small as 50mm in diameter up to a maximum of 510mm diameter, with profile depths of 130mm and weights reaching 1,500 kilograms.
Mark Curran, Sales Director at PTG Holroyd, explains the motivation behind the machine’s development: “Following feedback from customers after upgrading our successful TG series of thread grinding machines, we identified a clear demand for a large-capacity helical rotor grinding machine. The HG500 not only supports a broad range of rotor sizes but also accommodates the largest and most energy-efficient helical profiles on the market.”
Flexible Production Options for Varied Manufacturing Needs
The HG500 offers multiple grinding wheel options to maximize production flexibility. Its standard configuration includes a 500mm vitrified dressable aluminium oxide grinding wheel, ideal for varied production strategies and product development. For cost-efficient volume manufacturing, plated CBN (Cubic Boron Nitride) roughing and finishing wheels are also available. Additionally, manufacturers focusing on grinding larger helical components can opt for a 600mm vitrified dressable aluminium oxide wheel, extending wheel life and durability.
Advanced CNC Controls for Precision and Ease of Use
A key feature of the HG500 is its integration of the Siemens Sinumerik One CNC system, known for its powerful yet user-friendly interface. PTG Holroyd was the first UK machine tool manufacturer to adopt this advanced control, having previously implemented it in its HG350 and TG series machines.
“Partnering closely with Siemens enabled us to customize the CNC system to meet our exact requirements,” says Curran. “This collaboration has resulted in industry-leading safety and fail-safe measures, enhanced machine health monitoring, robust industrial security, and improved connectivity through Profinet and OPC/UA interfaces. The PLC operates up to ten times faster than previous Siemens controls, significantly boosting performance.”
Innovative Design Enhances Efficiency and Accuracy
The HG500 replaces the conventional grinding table with a travelling grinding head, allowing for maximum probing capabilities even on the longest components. Equipped with the Renishaw OSP60 scanning probe featuring Sprint technology, the machine ensures precise measurements and adjustments.
Cooling efficiency is maintained through a variable frequency, high-pressure coolant system with wheel scrubbing, while programmable eco modes reduce energy consumption between cycles. These features underline PTG Holroyd’s commitment to creating a highly efficient and user-friendly machine.
Curran adds, “True to our philosophy of ‘making the complex simple,’ the HG500 is designed for intuitive setup and operation. Batch setups are rapid thanks to stored data and program files, while the CNC-controlled dressing system automatically corrects the wheel profile for each dress cycle and adjusts feed rates for roughing and finishing.”
Holroyd Profile Management System Included
The HG500 comes standard with PTG Holroyd’s Holroyd Profile Management System (HPMS), a suite of advanced software tools for developing, manipulating, and analyzing helical profiles. HPMS supports a wide range of applications, including screw rotors, vacuum, and pump screws.
During production, HPMS facilitates automatic in-cycle profile updates, dresser path corrections, in-process lead and profile measurements, and precise CBN wheel adjustments, ensuring consistent quality and precision throughout manufacturing.
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