Case Study: Automation and Precision in the Mining Sector with IBARMIA and Metso Outotec

With an extensive product portfolio ranging from industrial valves and controls to mining filtration equipment, Metso Outotec is a world leader in total solutions and services for the aggregates, mineral processing and metal refining industries. In terms of pressure filter manufacturing, the multinational has the facility in Lappeenranta in Finland, built in 2015. This Dewatering Technology Center, one of Metso's largest filter equipment manufacturing facilities, has just unveiled a new IBARMIA machining center intended for the fast and flexible production of sealing rings for the various pressure filters used in mining and other industries.

THE ZVH 55/L6000 EXTREME_
This machining center with 6000 mm longitudinal travel is the heart of an automated production system tailored to Metso Outotec's requirements. Designed and manufactured in close collaboration with the customer, it is a model that dispenses with the standard fixed table to integrate a 4100 mm long trunnion tooling as a fifth rotary axis, a key element in this customized development.
The trunnion is an ideal solution when machining long workpieces where longitudinal travel is a priority. This tooling pivots around an A-axis, in this case by means of two motorized rotary tables located at each end. The Metso Outotec trunnion system has 4 working faces, three of which integrate a clamping system designed ad hoc by means of a series of separately controlled hydraulic clamps, allowing the production of up to 30 different references in stainless steel profiles. The fourth side, with its classic T-slots, in turn offers the possibility of machining fully customized parts. The solution therefore endows the assembly with unparalleled flexibility, optimizing all the benefits of this machining center whose generous X-traverse makes it possible to handle workpieces of very different lengths.

Precision in Manufacturing Complex Components

Mining components, such as sealing rings, require high levels of precision. The IBARMIA machining center guarantees micrometric accuracy in the manufacturing of these components, ensuring high-quality production for each piece.

Precision Features:

- Advanced CNC system for micrometric precision

- Tooling adapted to complex geometries

- Consistent quality across a wide range of profiles

Automation Driving Productivity

A key aspect of this project is automation, which has transformed Metso Outotec’s machining process. Integrated with the IBARMIA machining center, automation allows for the efficient handling of up to 30 different sealing ring profiles, significantly reducing downtime and boosting production capacity. The installation is completed by a robot arm in charge of feeding parts to the machine. This robotic automation, capable of handling up to 400 kg in weight, is designed to handle a large number of references, in line with the production flexibility of the ZVH 55/L6000. Using machine vision and sensor technology, the robot positions, straightens or rotates the parts to be machined with a wide operating range.
The entire system is PLC-controlled and the unit is managed from the operator's HMI interface, from where the entire production flow is controlled: a work queue is formed with the different parts produced, allowing real-time monitoring of production progress and system status.

Key Benefits:

- Reduced manual intervention

- Faster production cycles

- Ability to manage multiple profiles effortlessly

Enhancing Safety through Automation

The use of automation at Metso’s plant not only boosts productivity but also reduces the risks associated with manual handling of large components. The IBARMIA machining center, combined with automated systems, ensures that operators are kept away from dangerous tasks. Special attention has also been paid to ergonomics and operator safety. The machining center is cast in a 300 mm hollow space, which makes manual operation of this large machine much easier. At the same time, the location of all control panels is designed according to the situations of use and the safety circuits of all devices are integrated into a single unit.

Safety Improvements:

- Reduced manual handling of heavy parts

- Automated systems that take over high-risk tasks

- Continuous monitoring for a safer working environment

Tailored Solutions for Metso Outotec’s Needs

One of IBARMIA’s strengths is its ability to adapt its machining centers to the specific needs of each client. In Metso Outotec’s case, the ZVH 55/L6000 EXTREME center was customized to integrate seamlessly with their existing automated systems, resulting in an efficient and flexible solution.

Customization Highlights:

- Full adaptation to existing production processes

- Seamless integration with Metso Outotec’s automation systems

- Collaboration with local partners for successful implementation

In the words of Antti Ylä-Outinen, Filter Manufacturing Development Manager, "The aim of the project was to find an overall solution that would increase our productivity and safety at work. Thanks to the full cooperation between all parties involved in the project; MTC Flextek as the overall solution provider and IBARMIA as the machining center manufacturer, we got the solution we wanted. The cooperation during the project was very close and both the schedule and the budget were met. Indeed, the implementation has been so smooth that we were able to start production immediately after the acceptance test.".

Conclusion

The IBARMIA ZVH 55/L6000 EXTREME machining center, combined with advanced automation, has enabled Metso Outotec to significantly improve productivity and safety in the production of sealing rings for the mining sector. If you’re looking to enhance your machining operations, IBARMIA has the perfect solution for you.