Poseidon - Moving Bridge

Poseidon K - compact, powerful, 5 axis CNC milling machine

Poseidon K - compact, powerful, 5 axis CNC milling machine with:

• Monobloc base
• Increased number of supports
• Guide ways fitted directly to the structure
• Working area from 2,600x1,500 mm to 4,000x1,500 mm, Z = 1,300 mm
• Maximum axes speed 85 m/min Poseidon K offers waste extraction solutions for all machining process requirements:
• Removable collection tanks - For collection of waste when machining dry or with oil mist.
• Dust collection systems - When dry machining composite materials.
• Waste extraction system (belt conveyor) - For large chip volume when machining dry or with oil mist.
• Waste extraction system complete with filtered coolant management - For chip removal, when machining with flood coolant. Five-axis dust exaction hood adjustable in height via CNC

Basic Poseidon

Shot of a standard Poseidon 5 axis CNC machining center, showing its robust structure composed of two rows of heavy support pillars, joined by heavy shoulders on which the X axis guide ways are mounted. Spanning this longitudinal structure is Poseidon's massive moving beam (Y axis), driven from both sides by a master/slave set of servodrives. Rigidly mounted on the bridge is the vertical mast (Z axis) on which is located Poseidon's 4th and 5th axes used to articulate its powerful working spindle throughout the machining processes.

Poseidon's design is enhanced by CMS':

• Use of cellular design (honeycomb style) made from folded steel plate for high torsional stability
• Structural dimensioning through finite element computation programs (FEM - Finite Element Method)
• FEM application, ensuring high stiffness with reduced weight which results in high accelerations and finish quality
• Accurate analysis at the planning stage of first resonance frequency to ensure vibration free machining
• Normalizing by heat treatment of all structures to ensure maximum stability
• All machined surfaces created in one machine set up so as to ensure total accuracy and alignment
• Machine installation on large leveling supports to ensure ease of alignment and solid anchoring to the floor Top performance characteristics of speed, acceleration, the highest rigidity values and system reliability

The Poseidon 5 axis CNC machine is also designed with safety in mind to protect the operator and the environment. Poseidon is engineered to accept protective panels (also available with optional viewing ports) between its shoulders and various types of safety interlocking doors on both ends of the machine to provide security and convenient access.

Poseidon with Cast Iron work table

The Poseidon vertical machining center is available with a range of work tables, depending upon the customer's need. Here Poseidon is shown with a heavy cast iron work table (available according surface precision levels defined by DIN standards) with T-slots - for use where solid anchoring of fixtures and vibration dampening is required.

Also shown is the standard 16-place tool rack on the right hand wall (opening and moving out into the working envelope under CNC control for tool changing operations), safety interlocked doors at the back of the machine and viewing ports on either side of the protective walls.

Poseidon with flooded table cutting

Large volume, compact format, Poseidon 5 axis CNC machine with full flood, heavy duty, working spindle. Here the cast iron table is equipped with vacuum connections for fixtures, locating pins and recapture of cutting liquid. Also shown are safety interlocking access doors at the front and back of the machine with protective viewing Plexiglas.

Poseidon with Automatic Pallet Changing (APC) tables

Among the versions available for Poseidon is the Automatic Pallet Changing (APC) table, shown in this picture. The two APC tables make possible a protected non-stop (pendular) work cycle. The APC tables carry out a machining cycle as follows: 1) One of the APC tables is inside Poseidon and the machining cycle is being carried out, the other APC table has previously been extracted from the machine for loading, unloading or changing of the fixture for another type of work to be done. 2) At the end of the machining cycle, the Poseidon 5 axis CNC machine will raise its protective door and extract the APC table so that it can be unloaded and reloaded. 3) If the operator has pushed the "ready for the next cycle to begin" button on the table he has just finished unloading and reloading, then Poseidon will move it into the machine and begin the next machining cycle without any loss of time. If the "ready for the next cycle to begin" button has not been activated by the operator, Poseidon will wait until it has been pushed before it continues the cycle.

In this picture the tables are designed for heavy large work and provided with a grid of pin location holes over the table surface and vacuum connections points at the front of the table, which can be used to secure parts requiring holding by vacuum as part of the cycle. In addition, the tables are each provided with a protective belt, which covers all the moving parts for cleanliness and to avoid damage to its working parts.

This Poseidon version with long narrow APC tables is particularly well suited for machining work on Wind Turbine Blades.

Poseidon with two independent working units

Poseidon's structural strength and its range of sizes means that its productive capacity can be increased with the addition of another working unit. Here Poseidon is shown with a second completely independent CNC controlled working unit on the same bridge. This application was also provided with full flood and waste removal capability. The machining processes are being carried out on aluminum Aerospace components requiring large volume chip removal, accurate cutting dimensions and high quality side wall "rib" machining in these structural parts.

Poseidon double independent, double bridge - maximum power and productivity for Aerospace components

This version of the Poseidon vertical machining center doubles the productive capability yet again in this double independent CNC controlled working unit on double independent bridge configuration: a four-fold capacity increase over the standard Poseidon. Here the benefit of Poseidon's well engineered and carefully thought out range of ability pays off. Each bridge with double independent working unit works smoothly and easily in this configuration with central protective shield. Operators can set up for a project on one end of the machine in safety while both double headed bridges are working on the same type of parts on the other end of the machine, or Poseidon can machine different parts at the same time on both ends of the machine, and so forth. In this version work can be carried out independently and concurrently, as desired.

This Poseidon CNC 5 axis machining center is setup for full flood cutting, removal of large chip volume and recapture of cutting liquids for Aerospace wing spars and heavy structural elements in aluminum.

Poseidon's massive structure

An overview of the Poseidon 5 axis machining center's massive structure. The result of CMS' attention to the important preliminary engineering phase is evident here. Easily seen in this picture are Poseidon's heavy, robust, support pillars with wide stable anchoring surface to the foundation. The supporting shoulders resting solidly on this stable foundation run the entire length of the machine and provide a smooth, precision pathway for the moving bridge to carry its powerful working heads. In this picture, Poseidon has a double bridge for concurrent, independent, machining processes, if desired. In addition, the protective panels between the pillars are not shown here, since this Poseidon vertical machining center, which is installed in an Aerospace company, will be inside a complete enclosure not only for the safety of the operators, but to completely control all particulate released into the environment.

Drive system components - Racks and Guides

CMS uses the highest quality drive system components, which are hardened and precision ground, resulting in smooth, precise movement with long-life characteristics. During the assembly phase, laser systems are used to ensure the highest possible alignment standards for rack/guide parallelism.

The rack and pinion systems are specifically oversized to exceed the design life of the Poseidon 5 axis CNC machine. Additional durability is guaranteed by the use of high-pressure automatic grease lubrication and innovative ball-bearing cage protection systems.

FANUC servomotor providing Poseidon's kinetic power

In this photo one of Fanuc's precise, powerful and responsive servomotors is shown at one end of Poseidon's moving bridge.

The Poseidon vertical machining center’s standard precision control package is built upon the FANUC 31i-A5 system, using Fanuc's complete electronic devices: control, servodrives, servomotors, cabling, etc. A Fanuc servomotor drives each end of the bridge (as well as Poseidon's remaining axis strokes) to ensure precise control of its movements using a master/slave relationship between the two servomotors. The servomotors' kinetic forces are converted to movement through Poseidon's large, inclined, tooth rack and pinion system (specifically for better resistance and uniformity of movement), made of fortified carbon steel, tempered and rectified.

The Fanuc series digital control system is designed for high performance machines requiring a large number of axes, multiple-channels, complex and extremely fast functions, based on the demands of machine tool operators and the need to keep up with real world demands. Utilizing state-of-the-art technology, it offers many features, such as:

• Control of up to 40 axes, 24 of which may be simultaneously interpolated.
• Up to 8 MB internal program – ideal for large programs, for example, Die & Mould.
• 25-nanoseconds-per-step execution time for PMC (machine interface) programs.
• Up to three PMC programs executed at the same time, with up to 4096 digital inputs and outputs. Faster interpolation time and up to 1000 look-ahead blocks for accurate contour control.

Poseidon's central shields for safe and effective use of its large work envelop

The Poseidon 5 axis CNC machining center's large work envelope can be divided with various types of central shields to make it possible for setup work to take place on one end while machining operations continue on the other end. This picture shows a version of a central shield which is extended vertically for safety during the work cycle with a telescopic movement. It is also designed so that the central shield can be opened like a pair of doors, which when done disengages the electrical interlocks and makes possible the use of the complete work envelope for even larger projects.

Poseidon's powerful working units...

Poseidon shown with a pair of powerful KX5 working heads...

Poseidon's range of powerful 5 axis, universal, working heads provide the inclination and orientation of the cutting tool in any direction. The working unit's fourth axis rotates the spindle around the vertical axis. The fifth axis inclines the spindle in the vertical plane. The working head's rotating axes are driven by AC servomotors coupled with high precision reduction units. The working unit is equipped with pneumatic brakes for locking the B and C axes' position during machining moves which do not require these axes to be interpolated; allowing for high rigidity.

The PX5 working unit comes equipped with an automatic tool changing spindle with a power of:

• 12 kW (16 hp) - 12,000 rpm (S1) HSK63F connection, maximum speed 24,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle Poseidon's range of available working units continues with the KX5 equipped with an automatic tool changing spindle and power of :
• 15kW (20 hp) - 12,000 rpm (S1) HSK63E connection, maximum speed 24,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle
• 28kW (37.5 hp) - 4,300 rpm (S1) HSK63A connection, maximum speed 18,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle
• 28kW (37.5 hp) - 4,300 rpm (S1) HSK63A connection, maximum speed 24,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle Poseidon's design range also provides for multiple working units, the application of Direct encoders on the rotating axes (to compliment linear scales on the other axes), and various tool holding rack arrangements. Rack options:
• Second 16-place, lateral pick-up magazine (center distance 110 mm)
• 8-place pickup magazine, underside of the beam (center distance 80 mm; only for PX5) - maximum number of 2 30-place tool carousel (center distance 80 mm)

Poseidon: a range of tool rack options

Poseidon vertical machining center shown with a pair of powerful KX5 working heads...

Poseidon's range of powerful 5 axis, universal, working heads provide the inclination and orientation of the cutting tool in any direction. The working unit's fourth axis rotates the spindle around the vertical axis. The fifth axis inclines the spindle in the vertical plane. The working head's rotating axes are driven by AC servomotors coupled with high precision reduction units. The working unit is equipped with pneumatic brakes for locking the B and C axes' position during machining moves which do not require these axes to be interpolated; allowing for high rigidity.

The PX5 working unit comes equipped with an automatic tool changing spindle with a power of:

• 12 kW (16 hp) - 12,000 rpm (S1) HSK63F connection, maximum speed 24,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle The Poseidon 5 axis CNC machine's range of available working units continues with the KX5 equipped with an automatic tool changing spindle and power of :
• 15kW (20 hp) - 12,000 rpm (S1) HSK63E connection, maximum speed 24,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle
• 28kW (37.5 hp) - 4,300 rpm (S1) HSK63A connection, maximum speed 18,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle
• 28kW (37.5 hp) - 4,300 rpm (S1) HSK63A connection, maximum speed 24,000 rpm, liquid cooled with refrigeration unit, one air-blowing nozzle Poseidon's design range also provides for multiple working units, the application of Direct encoders on the rotating axes (to compliment linear scales on the other axes), and various tool holding rack arrangements. Rack options:
• Second 16-place, lateral pick-up magazine (center distance 110 mm)
• 8-place pickup magazine, underside of the beam (center distance 80 mm; only for PX5) - maximum number of 2 30-place tool carousel (center distance 80 mm)

Poseidon: a range of tool rack options

The Poseidon 5 axis CNC machining center has a range of tool rack options. On the left is Poseidon's standard 16-place tool holding rack (110 mm on center) mounted at the side of the work envelope. During a tool change the rack cover is opened and the rack is moved into the work envelope allowing the working unit to make an automatic tool change, putting away one tool and picking up another.

The picture to the right shows Poseidon's 8-place tool rack (80 mm on center) mounted underneath the bridge allowing for a quick, short, move to put away and pick up another tool. This option is only available for the PX5 working unit, maximum number of 2.

Poseidon - total machining environment enclosures

The Poseidon 5 axis CNC machine provides for several types of total machining environment enclosure...

To the left is shown a total enclosure of a Poseidon in which the machine is enclosed on all sides, including the top. The enclosure has provisions for external light, control of doors on both ends, a high flow total dust extraction system to remove harmful and irritating particulate from the air, noise deadening panels, internal lighting controls, and optional equipment for fire control.

To the right Poseidon is shown with a retractable roof enclosure (with a cut away view for illustration) to provide for total enclosure against harmful and irritating particulate. The retractable enclosure is attached to each side of Poseidon's bridge and expands and collapses like an accordion as the bridge moves in either direction. The roof can also be disengaged by Poseidon, as needed, for loading and unloading from above into the work area.

Cast Iron worktables

Cast Iron worktables with various surface flatness levels are available according to the DIN standard.

In general, a starting standard is as follows: height of the work plane 320 mm (height of the table 300 mm), supplied with American-thin-style-sheet flatness according to DIN 876/II with T slot (DIN 650) of 22H11, except the central reference one that is 22H7; the pass between T slots is 250 mm. T slots, as a standard, are placed parallel to the X-axis of the machine.

Standard cast iron table dimensions in width (Y direction) are: 1,500 mm, 2,000 mm and 2,500 mm, in the length (X direction) from 2,000 mm to 6,500 mm with a step of 500 mm. These modules also make possible large work plane dimensions utilizing coupling systems for a larger structure.

Table widths are recommended based on the presence or not of a chip take away belt, placed at the side of the table. Cast iron work planes require the creation of an appropriate foundation prepared according to CMS' engineering design.

Fabricated work table

In this picture is shown (with inset in the upper left corner) an example of a fabricated work table. A support structure is prepared on which the work table is placed. In this case a thick aluminum work plate is provided with vacuum, the vacuum can be communicated to various fixtures which require it as part of the machining process or for holding parts. In addition, the table is provided with a grid work for vacuum gasket and alignment reference pins for part or fixture location. The table is also designed to work with full flood cutting and recapture of the cutting liquid.

In general, fabricated work tables have two standard heights, 320 mm or 850 mm and do not require a particular foundation, but are fixed to the floor, and are available with the following surfaces:

• Smooth aluminum plane 30 mm thickness
  • Smooth aluminum plane 30 mm thickness with steel bushings
  • Vacuum plane in multi-layered phenolic 28 mm thickness
  • Vacuum plane in aluminum 30 mm thickness
  • Aluminum plane with T slots according to DIN 650 (the thickness of the plane depends on the T slot typology), the slots are machined directly into the plane Aluminum plane (foreseen for vacuum) with T slots in steel, according to DIN 650, (the thickness of the plane depends on the T slot typology)

Gridded vacuum work tables

Gridded vacuum work tables. In the picture on the left is shown CMS' standard multi-layer phenolic work table. The table is machined to receive 8 mm round gaskets and to quickly seal off various sections of the table as delimited by the gaskets. Every 150 mm is an access point with removable plug from a threaded bushing, which is used either for access to the vacuum plenum or for locating and anchoring fixtures to the table surface. The vacuum chamber is controlled by the CNC

To the right is shown an aluminum table surface with similar methodology which has been machined with a grid pattern to receive sealing gaskets which will delimit the required vacuum area. Vacuum clamping is controlled by the CNC.

T-slot tables

T-slot tables. In this picture two variations of T-Slot tables are shown. The one on the left shows a smooth aluminum table surface which has been machined to receive steel T-slots. The use of steel T-slots is preferred where high pressure demands are placed on the anchoring points. In the picture to the left, in addition to the aluminum table surface with steel T-slots, the area between the T-slots has been machined in a gridded pattern with access points to the vacuum for machining processes in which it is required.

APC tables (Automatic Pallet Changing)

A Poseidon 5 axis CNC machining center is here equipped with a set of Automatic Pallet Changing tables (APC). The large smooth aluminum tables are provided with a grid of reference holes across the surface of each table and vacuum connection points at the front of each table. Fixtures, even very large fixtures, can easily be referenced on the APC tables and the vacuum to the fixtures, for the parts held by them, can easily be connected.

In this case, the APC tables provide for a non-stop (pendular) work cycle, and complete safety for the operator. The protective door to front of the work area opens and closes each time a table enters or is extracted from the work area and the machining process continues inside Poseidon, while on the outside parts are either loaded and unloaded or a different fixture can be placed on the work table.

Pod and Rail tables under CNC control

In this picture the Poseidon 5 axis CNC machine is working with a set of Pod and Rail tables. Poseidon can be equipped with Pod and Rail tables as shown here and work in a non-stop (pendular) work cycle. Pod and rail tables provide an extreme range of flexibility and capability. Vacuum pods support the part to be worked above the work plane, giving free access to all exposed surfaces of the part during machining. The Pods and Rails can be moved under CNC control (or semi-automatically with LED indicator for the operator, or manually with readout position for location) to their respective positions. In addition, there is a wide range of modules available for use on the Pod and Rail table such as: vacuum pods of various sizes and shapes, clamps and vices for various requirements, reference devices and support devices for load/unload operations.

Chip take away (swarf removal)

For operations creating large volumes of chips that need to be removed, Poseidon 5 axis CNC machining centers can be equipped with swarf removal systems. In this picture a Poseidon K is equipped with a chip take away system, seen on the left side. Chip take away (swarf removal) can be a significant consideration for machine productivity impacting production time, man power and economic resources. Poseidon can be equipped with cutting liquid recovery and filtering, chip take away belts and conveyors, including waste handling systems.

Examples of Poseidon's work in high speed aluminum machining

Examples of some of the parts showing up from the Poseidon vertical machining center's work in high speed aluminum machining including: structural fairings, wing spars, connection elements and even an automobile tire mold for a leading manufacturer of tires.

Poseidon with double independent working units for heavy high speed aluminum machining

Poseidon CNC machining center utilized for processing the heavy aluminum structural parts for one of the world's most technically advanced and newly released airplanes. This Poseidon has a large, open, robust structure with double independent CNC controlled working units on its moving bridge. The working units are CMS' KX5 spindles with 28 kW (37.5 hp) at 4,300 rpm (S1) rating, maximum speed of 24,000 rpm. Along both walls in the middle is a tool changing rack for each working unit.

The work table is a precision cast iron type with space remaining on the sides for the chip take away belt conveyors, and fluid recovery and filtering system.

The Poseidon vertical machining center's safety interlocked viewing doors are seen located on the front and back of the machine envelope with protective enclosures on the sides.

Poseidon machines a heavy aluminum plate wing spar

Shown is a heavy aluminum plate wing spar, which Poseidon machines using CMS' high speed aluminum machining methodology. The part is machined two (2) per cycle on a heavy cast iron table with a full flood cutting, chip take away and cutting fluid recapture, filtering and recirculation. The Poseidon 5 axis CNC machine is using CMS' KX5 working unit with 28 kW (37.5 hp) at 4,300 rpm S1 rating, maximum speed 24,000 rpm, with top end material removal rates of about 4 cu"/min/hp.

The wing spar is fully machined on both sides with roughing (premilling), planning, flattening (recess work), bore milling, finish milling, pocketing, corner cleaning, stringer milling, stringer milling end radius operations top and bottom, grooving, chamfering, and stringer side wall drilling.

Poseidon's range of high speed aluminum cutting work…

The Poseidon 5 axis CNC machining center displays a range of its work. The photo to the left shows Poseidon's deep pocket milling work performed with CMS' high speed aluminum machining methodology, in which during the roughing pass operations the finished side walls are created at the same time significantly reducing the time for processing. This also shows Poseidon's level of dexterity since the side wall must be smooth and free from any steps created during the machining process which could ultimately become fracture points under stress. In the photo to the right Poseidon shows its light touch, bringing a tire mold's surfaces to a fine finish on a heavy aluminum block by finishing up with the company's logo which it has just carved.

Poseidon shown processing a heavy aluminum nose fairing

The Poseidon vertical machining center is shown in the middle of processing a nose fairing for a new generation airplane. The nose fairing will be machined on both sides, two at a time, using CMS' high speed machining methodology for aluminum. Here, Poseidon's CNC controlled 5 axis KX5 working unit can be seen making interpolated moves during a full flood cutting process. The part processing involves planning, milling, stringer pocketing, roughing (pre-milling) of pockets and flanges, corner cleaning of pockets, boring and drilling.

Poseidon executing a high speed horizontal milling process

Poseidon shifts from its heavy aluminum plate high speed machining work to heavy horizontal milling. The Poseidon 5 axis CNC machine performs a full flood processing cycle on a heavy aluminum plate used as a structural aerospace component with CMS' KX5 28 kW (37.5 hp) at 4,300 rpm S1 rating working unit, maximum speed 24,000 rpm. The work involves roughing (pre-milling), planning, pocketing, milling, boring, and drilling. Poseidon operates as easily in this horizontal milling position with a full range of CNC interpolated moves as it does vertically.

High speed aluminum machining - cutting fluid filtering system and other options

High speed aluminum machining generates a lot of chips which need to be easily and effectively removed. This pictures shows part of Poseidon's system for capturing the cutting fluid, filtering it and then recycling it. As the filter is performing its work it automatically advances the filter to maintain a constant, consistent, filtering of the cutting fluid; any chips or debris left on the filter are deposited in the waste tank at the end of the unit. In addition, Poseidon has available a full range of options for high speed aluminum machining including chip take away conveyors and chip collection.

Poseidon machines a carbon fiber fuselage

Poseidon machines a carbon fiber structural "rib" component used in the fuselage of today's new generation of airplanes. The part is fixtured on one of the Poseidon 5 axis machining center's specially fabricated work tables and held in a fixture so that the work can be carried out in a horizontal milling process using a "rasp" type cutting bit. The working head aids the cutting tool with air blown directly at the point of cut to help keep the tool cool and move the dust away from it. To contain the impact of the dust, when machining these types of materials, Poseidon is equipped with a special "carbon fiber" package. The Poseidon vertical machining center can also be equipped with a down draft dust collection system or total machine enclosure to contain dust that would otherwise escape into the operator's environment.

Poseidon machining 3D carbon fiber part

Poseidon 5 axis CNC machining center trims a carbon fiber part whose 3D forming took place earlier in an autoclave. The cutting tool is a "rasp" type bit with cooling air provided to the tool by Poseidon's working head, type KX5. Poseidon executes all the 5 axis interpolated moves smoothly and easily to bring the part to its final dimensions. Again control of dust to the operator's working environment is important so this Poseidon comes with a "carbon fiber" dust package and options for a down draft collection system for dust control or a full machine enclosure.

Poseidon cutting honeycomb materials

Poseidon 5 axis CNC machine is shown cutting several different types of honeycomb materials. On the left is a Nomex type of honeycomb usually cut with high frequency cutting tools to avoid fraying at the cut line and dust in the cells. CMS, in addition to supplying high frequency cutting tool technology, provides this important new solution for the Aerospace industry utilizing a new generation of router cutting tools. These tools provide a clean cut, do not create a problem with cell dust and have been demonstrated to lower cutting tool costs to about one-sixth (1/6) over traditional high frequency cutting tools, while, in addition, obtaining high rates of cutting speed. To the right Poseidon cuts an aluminum honeycomb material also cleanly and without effort.

Poseidon cutting EPS foam with special tools

For mold and model makers, a Poseidon vertical machining center provides an important step forward in a traditionally labor and materials intensive engineering and manufacturing process. The photo on the left shows Poseidon machining a block of EPS foam to the required 3D surface. The 5 axis surface geometry and machine ready program code can come from a wide range of today's CAD/CAM software. Poseidon here is machining a block of EPS foam with ease and at high speed using a special cutting tool that not only easily cuts the foam, but also has a hollow center, and is attached to a vacuum system to draw the dust through the cutting tool and into a dust collection system, making the machining and cleaning process an easy job. In the next tab about Marine and Wind Blade applications more information will be given about how the Poseidon can also apply a paste to this foam surface, which will later be machined into the mold's or plug's finished surface.

In the picture to the right the Poseidon 5 axis CNC machine is shown holding a "hot wire" cutting tool for use on a block of EPS foam. Instead of machining away vast amounts of foam material to obtain the finished surface and creating mounds of dust as well, a long and unproductive process, Poseidon picks up a frame on which a "hot wire" is attached (shown in this picture as the red line") and moves it through the necessary 5 axis paths to obtain the finished shape, a highly productive, yet inexpensive, option.

Poseidon finding the location of and trimming a fiberglass deck

In this photo a Poseidon 5 axis CNC machining center takes the next step beyond making the mold/plug, to machining a fiberglass deck that comes off of the plug. The finished surfaces perfectly reflect a great job done in preparing the plug's surface. But now the trimming of the parts that have been made on the plug takes place. It's not unusual for such deck or hull type parts to lose their precise 3D dimensions once they're removed from the plug, since, although they're designed for strength, they do have some flexibility and will move. Even when they are mounted in a holding fixture for trimming, they may not be exactly where expected by the operator or the machine.

In the picture to the left, Poseidon is shown holding a 3D scanning device. The information obtained in this brief but important process, tells Poseidon exactly where every feature that must be trimmed exists in the "real" world. With this information, the Poseidon vertical machining center will take its trimming program and make a 3D adjustment of it to fit the real world. Following this, in the picture on the right, Poseidon is shown trimming the fiberglass deck correctly and cleanly: no errors, no re-work necessary, and no loss of a significant investment up to this point.

Poseidon machining tooling board

A Poseidon 5 axis CNC machine is shown here machining tooling board, used for many mold and model applications today, with certain types being used for direct application in autoclave work at high temperatures. Poseidon's high accuracy and power perfectly suit the broad needs of mold and model makers. The same Poseidon is as comfortable and well suited to work in high speed aluminum machining as it is for foam or tooling board and can shift its cutting methods from dry, to mist or full flood, as needed.

Poseidon's unique advantages position it as leading solution for the Wind Energy and Marine industries

New developments in the Wind Energy and Marine industries have propelled CMS' use of Poseidon 5 axis CNC machines as a leading solution for these industries' requirements. In this photo can be seen several of these industries' most recent developments.

To the left of the picture is Maglev's new defining point and technology for Wind Energy plants, for which CMS is supplying the CNC controlled machining center systems to manufacturer its components. Maglev's Wind Energy power plant derives its unique advantage from the use of magnetic levitation to capture and harness all the latent power available in a light breeze. The center picture shows the more traditional concept of wind blade technology for which CMS is providing large format Poseidon 5 axis CNC machining centers capable of not only preparing the molds for these blades but also machining the blades themselves as well as the spinners and other components. In the picture to the right is an America's Cup yacht, highlighting CMS' role in providing the latest technology to the world's foremost boat builders, and even more its role as a proud sponsor and provider of the CNC technology for building the Oracle/BMW America's Cup Yacht.

Poseidon's involvement in these areas continues to provide a strong stimulus and aggressive development to its solutions for the Marine and Wind Power industries.

Large Poseidon shown working two different boat models within its envelop

A Poseidon 5 axis CNC machining center is shown here being adapted to the needs of today's boat builders. In this photo a very large format Poseidon is shown working two different projects within its large envelope. To the rear of the picture Poseidon is shown doing machining work on the EPS substrate of a new boat model. Though the models are long, wide and significantly high, Poseidon has no problem completing the roughing and finishing processes until the surface is completely and correctly finished and ready for the next step in the process chain. To the front of the picture (and with a protective central shield between both projects so that workers and operators can work safely within Poseidon's large work envelope) is another model that has had the putty (paste) already applied to the EPS foam surface. After the putty has dried Poseidon will begin its work of milling this surface to a fine finish. Since this Poseidon vertical machining center is very large, along the top are also walkways with protective railing on both sides to permit observation while work is taking place. Since such large projects as these can take some time, Poseidon's large work envelope also makes it possible for work to continue from one phase to another without the need of moving the model or interfering with workers and operators that need to work around the model.

Poseidon applying putty (paste) to a model under full, 5 axis, CNC control

When the machining of the substrate model surface has finished (in this case the EPS foam block), Poseidon applies the putty (paste) under full, 5 axis, CNC control, as needed. The thickness of the paste is controlled so that an even layer covers the entire model surface and as importantly the cost is controlled, since hand application may result in the thickness of the paste layer varying from place to place on the model surface. The paste consistency and formulation is such that it adheres well to the surface, flows together as one paste pass joins up with the next and does not sag, even as it is applied to non-horizontal surfaces. As shown in this picture, the Poseidon 5 axis CNC machine is using a paste application head and is applying the paste to the surface of two different molds. To the left of the picture, Poseidon is applying a layer of paste to a wind blade in smooth, even and continuous passes, which will result in even drying of the paste across the entire surface. In the picture to the left Poseidon is shown applying paste to a boat deck in circular expanding passes in one continuous flow. Depending upon conditions, the paste, which has been catalyzed just as it flows into the mixing line, will usually be dry in about 24 to 36 hours and ready for surface milling to begin.

Poseidon - CNC controlled milling of the putty on the wind blade

To the left of this picture the putty on a wind blade has finished drying and is ready to be milled. The blade is placed inside the Poseidon vertical machining center's work envelope and the program information to machine the surface is carried out in a full, 5 axis, CNC controlled process. Here again, depending on the "step-over-distance" instructions given in the CAM software and the diameter of the milling tool, in this case a ball end mill, the code which Poseidon executes will result in a very smooth surface, "hand-sanding" ready, requiring much less sanding time to arrive at a final surface finish. The picture to the right shows Poseidon carrying out that high speed milling process, a process controlled from design to final milling with precise CNC controlled instructions, resulting in "real world" parts that match that of the design, shortened time from idea to reality, reduction of skilled labor with an increase in precision, and accurate symmetrical parts.

Poseidon with APC tables for wind blades

This version of the Poseidon 5 axis CNC machine is perfectly adapted for wind blade mold creation and blade machining operations. Here a large format Poseidon is equipped with a pair of APC tables (Automatic Pallet Changing). These tables make it possible for Poseidon to carry out a non-stop (pendular) work cycle. One of the two tables is inside Poseidon and a milling cycle for making a mold or a machining process on a blade is being carried out. The other table is outside the work envelope, the automatic raising and lowering protective door is in the down position to keep the operator safe while Poseidon continues with its work, during which time the operator is unloading and reloading the table with the next part to be machined. When the operator has finished reloading that table, he pushes the "ready to begin" button and when Poseidon finishes its present work cycle, it will raise the protective door, move out the table with the finished part, bring in the other APC table with the next part to be worked and close the door again. The cycle continues in a non-stop fashion. If the "ready to begin" button has not been pushed, Poseidon will finish its cycle, extract the table, and wait to start the next cycle until the "ready to begin" button has been pushed.

With large parts having long work cycles, APC tables provide a significant positive impact on productivity, since the machine is never impacted by the operator's work of unloading, reloading or even placing a new fixture on the table.

In addition, the Poseidon 5 axis machining center's work tables are a specially fabricated version in aluminum with a grid work of holes placed uniformly across the surface of the tables to allow for accurate, easy location of the fixtures. At the front of the APC tables is a bank of vacuum connections so that the fixtures requiring vacuum can be connected to it.

Poseidon makes the blade spinner component

The Poseidon vertical machining center also makes short work of the remaining structural components for wind power systems. In the end, this means that the production of new molds or models or revisions to existing ones, is part of a predictable chain of processes with CMS' "know-how" and Poseidon's wide range of capabilities. In this picture, shown on the left, is the mold for a spinner, the central connection point of the blades, which Poseidon has made, and on the right the completed spinner with blades connected is shown.