Client and Industry Overview
The client operates in the railway manufacturing industry, specializing in the production of rail wagons. The client’s newly designed CNC milling station plays a crucial role in the production process. The station involves two sequential stages: the first is preparing the roof of the wagon for processing (transport, fixing, and positioning), while the second involves material processing through a CNC milling machine.
CNC Milling Machine Overview
A CNC (Computer Numerical Control) milling machine is a high-precision industrial machine used to process large materials such as steel. The specific machine used by the client measured 80 meters long and 8 meters wide. Due to its size and complexity, the machine operates on two milling tables, with milling portals mounted on rails to move along the workpiece.
Key components include:
- Machine Frame: A heavy-duty steel structure designed to withstand the intense loads during machining.
- Work Table: A robust, flat surface for securing large steel parts for processing.
- Milling Head: The mechanism that holds the cutting tools and moves along multiple axes for three-dimensional machining.
- Drives and Guides: Electric motor-based systems that control the precise movements of the milling head and work table.
- Cooling and Lubrication Systems: Critical for managing the heat generated during machining.
- Chip and Dust Extraction Systems: Essential for maintaining cleanliness and safety during operation.
The Challenge
The production hall housed multiple workstations, and the milling machine was a significant source of noise pollution, causing discomfort for workers. The client had a specific request of an assumed noise reduction by 21 dB or achieving an average level of 80 dB around the enclosure at a distance of 1 m in relation to 8 hours of equivalent noise exposure time, with the element being processed in a part closed by a roof.dB in the production environment.
Our Solution
We designed an acoustic enclosure specifically for the CNC milling machine. The structure was an 87-meter-long, 10-meter-wide, and 7-meter-high steel enclosure, covered with acoustic panels designed to absorb and minimize sound. The enclosure included two sliding roofs, with dimensions of 31 meters in length and 5 meters in width, to allow easy access for loading and unloading materials while maintaining sound isolation.
Key features of the solution:
- Sliding Roof: Mounted on the ceiling to facilitate access to the machine without compromising the acoustic insulation.
- Interface and Insulating Partition: Installed between the two workstations to provide additional soundproofing between different stages of the production process.
- Acoustic Panels: These panels were specially engineered to absorb sound and reduce noise pollution within the workspace.
Project Execution
- Design Work
Collaboration with the client began with conceptual discussions and establishing design guidelines, such as the position of doors, gate height, and object locations. Calculations were made regarding the quality and strength of the steel to ensure durability and stability of the enclosure. The client also provided us with a 3D model of the CNC machine to assist with the design process.
- Production Work
After receiving approval for the design concept, a team of designers worked to bring the project to life, incorporating all necessary elements to ensure the enclosure met both structural and acoustic standards.
- Assembly
Assembly began with installing the fastening elements, followed by the roof structure and the sliding roof mechanism. Cladding was then installed along with lighting, emergency exits, and control stations. The assembly phase posed a significant challenge, as we had to coordinate with multiple entities, including the machine supplier and the infrastructure provider. Additionally, strict rules were imposed by the machine supplier regarding assembly, especially around the milling table, which had to be done in conditions of stable air temperature to ensure precision.
- Final Measurement
Upon completion, we conducted noise measurements in the production hall and compared the results with the initial noise levels provided by the client.
Results
Our solution achieved a significant reduction in noise levels, lowering the noise emission. It fell below the 21 dB target and it provided a noticeable improvement in the working conditions at the production hall, reducing the noise pollution and enhancing comfort for workers.
Summary
This case study highlights our ability to deliver large-scale acoustic protection solutions in industrial environments. Despite the complexity of the project and the strict requirements of the client and machine supplier, our team successfully designed, produced, and installed a custom acoustic enclosure. The project showcased our expertise in engineering, problem-solving, and collaboration across multiple stakeholders, resulting in a quieter, more comfortable production environment.
