Provalve-1000 – a precision machine designed for processing cylinder heads mainly of medium and small sizes and with any angular valve inclinations, but can also be used for heavy cylinder heads. It is a modification of the Provalve-800 machine by increasing the longitudinal movement of the working spindle to fully accommodate the most popular range of cylinder heads. Additionally, to achieve the highest precision, especially on thin pilots, the machine’s design is equipped with a built-in spindle position sensor with readings displayed on a touchscreen.
Currently, it is not only one of the most powerful universal machines among all machines of this type, performing precise mechanical machining of valve seats from the smallest to the largest diameter, and one of the most precise and fast machines of this type, but also one of the most affordable.
In other words, the machine is completely unmatched by competitors both in terms of maximum “quality/price” ratio and simply price availability, where it cannot be competed with even by many Chinese machines.
This has been achieved through the use of the latest design and production technologies, thanks to which the machine has gained the most advanced technological solutions allowing for the most efficient machining of valve seats and valve guide sleeves of all types of cylinder heads.
The MAIN ADVANTAGE of the machine is its control. The machine is equipped with a fully automatic centering system with touchscreen operation, which not only increases the precision of seat machining and significantly shortens the machining time. Just aim the pilot to the guide sleeve and press only 1 button on the screen – the rest (centering and spindle rotation start) the machine will do by itself and simply give you the opportunity to machine the seat by turning the steering wheel.
Such simple control cannot be found in any similar, much more expensive machines – both with manual control and CNC! And it does not require serious training and high operator qualifications!
This type of machine uses a polygonal cutter that processes all valve seat facets at once with the required width and angular precision (any knife profile can be used), and the installed vacuum testing system allows checking the quality of the work immediately after machining.
The basic technical solutions applied in the machine’s design are protected by patents, including Turkish patent No. 2019-GE-228828 dated 23-05-2019 “Machine control system for valve seat and guide machining” and Turkish patent No. 2019-GE-228876 dated 23-05-2019 “Valve seat and guide machining system”. These patents establish the manufacturer’s priority – Serdarlar Makine company, in the applied roller chain clamping system and automatic centering system.
Since 2020, the Provalve-1000 type machine has been produced in Turkey at the Serdarlar Makine factory only in one modification:
- Provalve-1000S – with a welded steel frame, touchscreen control, and a 10-inch screen, with an extended distance of up to 1000 mm between the outer seats of the cylinder heads.
- Note: This model machine is equipped with a spindle tilt sensor displaying its position on the screen in two planes (see video). This allows checking and adjusting 3 parameters within 1 second: 1) spindle balance, 2) guide bushing axis position, 3) automatic centering quality. This means that the operator on the Provalve machine is constantly monitoring the process – unlike operators of other machines who work in darkness!
Distinctive features of the Provalve-1000 machine:
- Universal, reliable, and safe machine with very high precision and machining speed.
- Rigid, stable, and precise construction, welded frame made of specially aged steel.
- Highest precision for all types of valve seats of all types of cylinder heads, from motorcycles to the heaviest industrial engines – depth of rework after full reinstallation of the cylinder head on the pre-worked seat – no more than 0.02 mm (verified at AB-Inżyniering).
- Allows mechanical machining of valve guides from 3.5 mm and seats with diameters from 16 to 120 mm.
- Precise centering system based on spherical and flat air cushions with longitudinal and transverse movement (unique in this class of machines with 4 air cushions).
- During centering, 3 cushions work – the table cushion with two spindle cushions, while the work cushion is used only for initial adjustment and does not participate in the centering process. This is a fundamental difference between the machine and SERDI-type analogs, which center only on two spindle cushions.
- Four air cushions: first – on the upper frame, on the spindle saddle (2 axes, longitudinal stroke 350 mm), second – on the spindle (spherical cushion with angle up to 10°), third – on the spindle (flat cushion with displacement in two axes of 10 mm), fourth – on the table, on the clamp of the lower part of the frame (2 axes, longitudinal stroke 630 mm, which ensures maximum spacing between the extreme valves in the cylinder head up to 1000 mm during machining without moving the cylinder head).
- Automatic tool centering system after pressing 1 button with CNC, automatic start, stop, and screen control (lacking in competitive machines).
- Reliable patented holder of the machine’s work spindle with two double pneumatic lifters.
- Spindle motor with electronic control system, variable speed, and digital display – ensures exceptional smoothness and power (not used in competitor machines).
- Quick mounting and dismounting system of the tapered tool holder ensures reliable mounting in the spindle and completely eliminates (unlike competitors) any damage.
- Universal clamping device with a 130° angle for all types of cylinder head blocks and clamping device for flat head blocks.
- Full-value table of the machine on an air cushion with longitudinal movement of 630 mm and transverse movement of 200 mm (the only machine in this class with such a table), mounting on the lower part of the frame using vacuum and parallel lifters ensures processing of cylinder heads without the need for repositioning with a maximum distance between end valves up to 1000 mm.
- The flat air cushion of the table participates in precise centering, increasing processing precision and reducing spindle load (not used in competitor machines).
- Folded leather protectors on the upper frame (absent in competitors) eliminate wear for the entire period of machine use.
- Electronic spindle movement limiter with adjustment for periodically repeating tasks.
- 10″ touch screen with touch control, cylinder head data library, and database recording of all operations.
- Built-in spindle tilt sensor with display on the touch screen (not used in competitive machines) enables precise balancing of the spindle during setup and precise adjustment of the cylinder head position, ensuring vertical spindle position for maximum machining precision.
- Capability to update data and control program via USB port.
- Integrated lighting with neon light on the machine base and LED lamp for local illumination of the spindle’s work area.
- Separate vacuum pump (not used in competitive machines) eliminates the influence of air flow on the operation of vacuum clamps and vacuum tester. Unlike vacuum testers operating on the principle of air expulsion under pressure, the machine’s vacuum tester allows for double quality control of saddle processing – based on maximum thinning and time of its decrease with the vacuum pump off.
- Vacuum tester, air filter with oiler, tool grinder with metal insert, and tool case are integrated into the machine’s design.
- High-quality painting in customer-selected colors (standard colors – red RAL 3000 and gray RAL 7011).
MACHINE DESIGN PROVALVE-1000S
Leg, made of high-quality steel and subjected to aging process, ensures high rigidity, stability, and precision of the machine (upper part of the legs is made of cast iron). Vacuum pumps, mounted in the lower part of the legs, provide vacuum clamping of the table and leak tester. The air filter is standardly equipped with an oiler that delivers a very small amount of oil to the machine’s pneumatic system.
Air cushion table can move both transversely and longitudinally, as well as provide vacuum clamping. Standard clamping device, rotating 130° in both directions, is designed for mounting any cylinder heads. Chrome-plated spindle, mounted in adjustable cast iron bearings of the spindle’s work spindle, is practically wear-resistant.
Upper leg protectors significantly increase the comfort of using the machine and ensure its exceptional durability even in dusty environments.
10″ Touchscreen Control Pilot transforms the machine into a CNC lathe with automatic spindle centering and stopping after processing. It also features a database storage function (with update capability) for seat sizes and tools for their processing for multiple engine models.
Spindle tilt sensor allows continuous monitoring of the spindle position and its deviation from vertical at all stages of work — from machine setup and spindle balancing to adjusting the cylinder head position in the holder to ensure precise vertical alignment of the guide sleeve axis.
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 head aim to ensure high precision with minimal mechanical processing time.
Electrical cabinet of the machine is equipped with components produced exclusively by European companies.
Clamps for flat block heads are supplied as standard equipment for the machine, along with pairs of parallel clamps of different heights.
Mounting and dismounting system for tapered tool holder has not only been designed for quick operation but also eliminates any damage to the tool holder.
Tool table has 3 drawers, allowing storage of all necessary tools directly at the operator’s fingertips.
Tool sharpening device is included in the standard equipment of the machine.
