Provalve-4.0 type valve seat machining workstation

Distinctive features of the Provalve-4.0 table:

• Universal, reliable, and safe machine with very high precision and processing speed.
• Allows for mechanical processing of valve guides with diameters from 3.5 mm and seats with diameters from 16 to 120 mm.
• Exceptionally rigid, stable, and precise construction, with a cast iron frame with a monolithic housing (models 1600SE and 1600SL) or welded steel frame, subjected to aging to eliminate deformations (model 1600S).
• Highest precision for all types of seats of all types of cylinder heads, from motorcycles to the heaviest industrial engines – the depth of reprocessing after full reconfiguration of the cylinder head to a previously prepared seat – no more than 0.02 mm (verified at AB-Inżyniering).
• Servo spindle motor with electronic control system, with variable speed and digital display – ensures exceptional smoothness and power (not used in competitor machines).
• Quick mounting and dismounting system of the conical tool holder ensures reliable mounting of the holder and completely eliminates (unlike competitors) any damage during disassembly.
• Precise centering system based on spherical and flat air cushions with longitudinal and transverse movement.
• Four air cushions: first – on the upper beam on the spindle axis (2 axes, longitudinal stroke 850 mm), second – on the spindle spherical cushion with an inclination angle of up to 10°, third – on the spindle flat cushion with longitudinal movement on 2 axes by 10 mm, fourth – on the table on the lower part of the beam (2 axes, longitudinal stroke 760 mm).
• During centering, 3 cushions are used – the table cushion with two spindle cushions, while the working cushion is only used for initial setup and does not participate in the centering process. This is a significant difference compared to SERDI-type machines, where centering is provided by only two spindle cushions.
• Automatic tool centering system activates sequentially upon pressing 1 button, turning on and off the air cushions in a specified order upon CNC command, initiating automatic start, stopping the spindle, and providing screen control (manufacturer’s know-how, lacking in competing machines).
• Reliable patented clamping of the spindle working cushion by two double pneumatic cushions.
• Universal tool clamping device with a 130° tilt angle for all types of cylinder head blocks and a clamping device for flat head blocks.
• True table on an air cushion machine with a transverse movement of 200 mm and longitudinal movement of 760 mm, clamping on the lower beam of the table using vacuum and parallel cushions ensures cylinder head machining without the need for reassembly, enabling a maximum distance between end valves of up to 1610 mm.
• Flat table air cushion participates in precise centering, increases machining precision, and reduces spindle load (not used in competing machines).
• Protective accordion covers for the upper beam (not used in competing machines) eliminate wear throughout the machine’s lifespan.
• Electronic spindle stroke limiter with adjustment for cyclically repeating tasks.
• 12″ Touchscreen with touch support, featuring a library of data for cylinder heads and recording the database of all works.
• Spindle Position Sensor displaying deviation from vertical in X and Y axes on the touchscreen (absent in competitive machines) enables precise spindle balancing (position control) during machine setup and monitors the position of the guide bushing hole vertically both before and after automatic centering.
• Built-in Printer (not found in competitive machines) allows for immediate printing of vacuum test results after seat machining and attaching the printout to the job order for objective quality control.
• Possibility of updating data and control program both via the Internet and through the USB port.
• Integrated Lighting with neon light on the machine beam and LED lamp for local illumination of the spindle work area.
• Separate Vacuum Pump (not used in competitive machines) eliminates the influence of air supply on the operation of vacuum clamps and vacuum tester – this means 2 separate vacuum pumps for clamps and vacuum tester for greater precision. Unlike a vacuum tester, which operates by blowing air under pressure, the machine’s vacuum tester allows for double quality control of seat machining – maximum pressure reduction and time for pressure drop with the vacuum pump turned off.
• Vacuum tester, air filter with lubricator, carbide knife grinder, and tool box are integrated into the machine design.
• High-quality painting in customer-selected colors (standard colors – red RAL 3000 and gray RAL 7011).

Position assembly Provalve-4.0

The highest stability and precision of the machine are ensured by a fully cast iron frame made of alloyed cast iron, which has the highest rigidity. Such a frame, made according to this technology, is practically inaccessible to most competitors. Its application in the machine’s construction guarantees that with precise leveling, no precision features of the machine will change over decades of uninterrupted operation. Vacuum pumps, located at the bottom of the frame, provide vacuum to the table clamps and leak tester. The air filter is equipped with a grease nipple for delivering very small doses of oil to the machine’s pneumatic system.

The air cushion table provides both transverse and longitudinal movement of the table, as well as vacuum clamps. The standard tool clamping device, rotatable 360°, is designed for mounting any cylinder head attachments. The chromed spindle, mounted in adjustable cast iron spindle sleeves, is practically wear-resistant.

Protected covers on the top of the frame significantly increase the convenience of operating the valve seat machining machine and ensure its exceptional durability even in dusty environments.

Control of the machine is performed using a touchscreen control panel, which transforms the machine into a CNC machine with automatic tool centering and stopping after processing. It also has a database storage function (with update capability) for seat and tool sizes for machining them for multiple engine models.

The spindle position indicator along the X and Y axes, displayed on the touchscreen, enables precise control and adjustment of spindle balance during machine configuration, as well as checking the correct positioning of the cylinder head relative to the valve guide hole in terms of verticality during centering. These features, absent in competing machines, are an extremely important part of seat machining precision and quality.

The patented spindle clamping chain system, servo motor for spindle drive, precise vertical spindle balancing system, flat and spherical spindle air cushions – all these devices, mounted in the working spindle, aim to ensure high precision with minimal mechanical processing time.

The electrical installation of the machine is equipped with components produced only by European companies.

Clamps for flat block heads are standard equipment for the machine, supplied with pairs of parallel clamps of varying heights.

Cone tool holder assembly and disassembly system is not only designed for quick operation but also eliminates any damage to the holder.

Tool table has 3 drawers, allowing for storage of all necessary tools directly at the operator’s fingertips.

Tool sharpening device is standard equipment of the machine.