Precision and flexibility for complex engineering

More processing possibilities for ŽOS Zvolen sro with flexible MG series

Precision and flexibility for complex engineering

ŽOS Zvolen has been placing modernized locomotives and wagons on rails in Central Europe for decades - the cutting is done by MicroStep technology

Published 21.11.2016 | Erich Wörishofer

Company profile:

ŽOS Zvolen sroŠtúrova ul. C 24Zvolen 960 01Slovakia

ŽOS Zvolen, founded over 140 years ago and based in central Slovakia, is the largest and most important company in the maintenance and modernization of motorized locomotives and railroad carriages.

3D processing of flat material with the R5 plasma rotator  
Thanks to the endlessly rotating R5 plasma rotator, contours on flat materials can even be processed in 3D. Simple V- and X- seams as well as complex Y- and K- seams can be applied. For example, bevels up to 50° are possible for weld edge preparation.

Machine profile:

MG series
  • Working area 12.000 x 2.500 mm
  • R5 rotator for weld preparation up to 50° with auto-calibration
    feature (ACTG®)
  • Drilling up to Ø 40 mm and tapping up to M33
  • Inkjet marking

For more than 140 years, ŽOS Zvolen has been an expert in the maintenance and modernization of railway vehicles and in this function it is in demand far beyond the borders of Slovakia. In order to serve the various customer needs and to be able to repair the different technologies, the company relies on precise and extremely flexible machines. After a long selection process, the company decided in the field of cutting technology to use a multifunctional CNC machine of the MG series from MicroStep for the versatile processing of large-sized plates.

At ŽOS Zvolen, a company based in central Slovakia, everything revolves around the railroad. This is because the stock company is the largest and most important company in the maintenance and modernization of motorized locomotives and railroad carriages in Slovakia. The repair of railway vehicles has been a tradition at ŽOS Zvolen for more than 140 years – the company takes care of many components from the drive to the outer skin of the vehicles. Experience and quality are appreciated: Competence is in demand beyond the borders of Slovakia – because the portfolio and special customer requirements for various maintenance works of different types and years of construction require a wide range of know-how and engineering skills.

High demands on machinery to implement the most diverse customer requirements

Accordingly, the company places high demands on the technologies used in production in terms of precision, speed and above all flexibility. Specifications with the most demanding requirements as well as an extensive look at the most diverse manufacturers are essential components of the company policy when equipping the machinery. In this selection process, MicroStep was able to prevail with its premium series. Because since 2015, an MG plasma cutting machine with an extraordinary working surface and versatile processing options has been among the technologies used.

Long sought and found: CNC cutting solution for 3D processing of large-format plates

Because, after an intensive search, ŽOS Zvolen relied on the experience of MicroStep in the development of CNC cutting machines with flexible technology for the application of numerous machining options. Thus, the company decided to purchase an MG 12001.25 PrkMB. The MG series is MicroStep's all-rounder and was designed to combine maximum flexibility and efficiency in one type of machine. The configuration, as used by the specialist for rail vehicles, enables multifunctional 3D processing of flat material on a working area of 12,000 x 2,500 mm.

Chamfers up to 50° with the MicroStep R5 rotator for weld edge preparation

Within the processing spectrum on the area of 12,000 x 2,500 mm, the Slovak company has the following technologies at its disposal: the MicroStep R5 rotator is an endlessly rotating beveling tool, which enables the application of chamfers up to 50° to the sheet metal. This is mainly elementary in the preparation of welding seams and avoids annoying material handling within several processing stations. The plasma source is a powerful HiFocus 440i from the German plasma technology manufacturer Kjellberg Finsterwalde.

Fully automatic drilling support for various cutting tasks

With the 26 kW drilling unit, the CNC machine can also be used to drill holes, countersinks and threads into the workpieces. The fully automatic drilling support allows drilling up to 40 mm diameter and threads up to M33. With two automatic eight-fold tool changers for a total of 16 cutting tools, the processing time of complex drilling tasks is reduced to a minimum.

An implemented inkjet marking unit is used as an effective solution for marking the components and rounds off the multifunctional processing capabilities of the CNC plasma cutting system. The ACTG® calibration unit is used for exact results. The automatic and patented system developed by MicroStep measures deviations of the tools in the hundredths range and corrects them independently with the highest precision.



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