Componentes de pórtico de granito/mármol: Solución de soporte estructural central y guía para equipos de precisión a gran escala

Descripción general de la solución

Designed specifically for gantry-type equipment (gantry machining centers, large coordinate measuring machines, laser cutting equipment, wind turbine blade machining tools), these granite/marble gantry components focus on “large-size precision retention, high load-bearing deformation resistance, and full-scenario anti-interference”. They address three key pain points of traditional metal gantry components: “easy deformation with large spans, strong vibration transmission, and precision impact from thermal deformation”.

Leveraging the ultra-low thermal expansion coefficient, high rigidity, and excellent vibration damping properties of high-density natural stone, they provide stable structural support and guidance references for large-scale equipment with spans of 2-15m. They ensure the equipment operates with a precision of ≤ 0.005mm per meter and a long-term precision attenuation rate of ≤ 0.1% per year, adapting to the machining and inspection needs of ultra-large parts such as aerospace large components, wind turbine blades, and high-speed rail car bodies. These components help enterprises improve the manufacturing precision of large products by over 30% and extend the equipment maintenance cycle by 2 times.

Sistema de funciones principales

1. Large-Size High-Precision Support and Guidance

• Ultra-Span Precision Control: High-density Jinan Green Granite (quartz content ≥ 65%, density ≥ 2.7g/cm³) or high-purity marble (density ≥ 2.75g/cm³) is selected and processed through the “CNC rough milling – multi-pass fine grinding – precision lapping” process. This achieves a straightness of ≤ 0.003mm per 1000mm and parallelism of ≤ 0.005mm per 2000mm for gantry beams/columns. A single beam can have a maximum span of 8m, and the maximum spliced span reaches 15m, with a step error of ≤ 0.002mm at the splicing joint. This avoids the “mid-span sagging” deformation of metal components with large spans, ensuring uniform precision across the full stroke of the equipment.
• High Load-Bearing Stability: Gantry columns adopt an “integral casting + thickened wall” design (wall thickness: 80-200mm) with a compressive strength of ≥ 180MPa. A single column can bear a load of 50-200 tons. The connection surface between the beam and column uses a “high-precision spigot positioning + bolt fastening” structure. Under long-term loads from components such as slides, spindles, and tool magazines (≤ 30 tons), the deformation is ≤ 0.001mm per meter, ensuring stable guidance precision.
• High-Precision Guidance Integration: V-shaped, rectangular, or dovetail-shaped guide grooves are precision-machined on the beam/guide surfaces, with a groove width tolerance of ±0.005mm and a groove surface roughness of Ra ≤ 0.02μm. When matched with granite guide sliders, the slide movement precision reaches ≤ 0.002mm per 1000mm—40% higher than that of metal guides—without the wear gap issue of metal guides.

2. Full-Scenario Anti-Interference and Stability Guarantee

• Ultra-Low Thermal Deformation Suppression: The thermal expansion coefficient of granite is as low as (5-7)×10⁻⁶ per ℃, and that of marble is (6-9)×10⁻⁶ per ℃—far lower than cast iron (11×10⁻⁶ per ℃) and steel (13×10⁻⁶ per ℃). Under workshop temperature fluctuations of -5℃~40℃, the length variation of a 10m-span beam is ≤ 0.05mm, avoiding guidance deviation caused by thermal deformation. This is particularly suitable for temperature-sensitive scenarios such as large-scale laser cutting and precision machining.
• Efficient Vibration Attenuation: The internal damping coefficient of natural stone is 4-6 times that of cast iron, with a vibration attenuation rate of ≥ 85%. It can absorb high-frequency vibrations (50-2000Hz) generated during the operation of gantry equipment (e.g., high-speed spindle rotation, heavy cutting). Elastic vibration-damping gaskets (vibration damping efficiency ≥ 60%) are installed at the connection between the beam and column to further isolate equipment vibration transmission and reduce the impact of vibration on machining surface quality (e.g., roughness, geometric tolerance).
• Corrosion Resistance and Wear Durability: The surface undergoes “phosphating + nano-ceramic coating” treatment (coating thickness: 5-12μm), withstanding industrial reagents such as cutting fluids, lubricating oils, and rust inhibitors—eliminating rust and oxidation issues of metal components. The surface hardness of the guide groove reaches HS75-80 (for granite), and its wear resistance is 2.5 times that of metal guides. After long-term use (≥ 100,000 slide movements), the wear of the guide surface is ≤ 0.001mm, requiring no frequent regrinding.

3. Integration and Adaptation for Large-Scale Equipment

• Collaborative Installation of Multiple Components: Gantry columns reserve mounting holes (φ16-φ30mm, hole position tolerance ±0.01mm) and positioning pin holes (tolerance H7) for spindle boxes and slide drive systems. Beams reserve mounting grooves (width: 20-50mm) for grating scales and cable chains, adapting to the direct installation of precision components such as servo motors and ball screws—reducing precision loss caused by intermediate connectors.
• Adaptation Optimization for Large-Size Workpieces: The inner side of the gantry frame adopts an “arc transition + no protruding structure” design to avoid interfering with the clamping and movement of large workpieces (e.g., wind turbine blades, high-speed rail car bodies). A customized integrated gantry structure with a “workpiece support table” is available, with a support table flatness of ≤ 0.005mm per 2000mm, meeting the overall machining and inspection needs of ultra-large workpieces.
• Cable and Pipeline Integration: Concealed cable channels (aperture: 30-80mm) and cooling water circuits (aperture: 15-25mm) are opened inside the beam, adapting to power cables, signal cables, and spindle cooling pipelines required for slide movement. This avoids cable dragging affecting slide movement precision while keeping the equipment appearance neat.

Composición del sistema principal

Casos típicos de aplicación industrial

1. 10m Gantry Machining Center: A heavy industry enterprise used it for machining wind turbine main shafts (length 8m, diameter 1.2m) — Jinan Green Granite gantry components (10m-span beam, spliced structure) were adopted. The beam straightness is ≤ 0.005mm per 10,000mm, and the vibration amplitude during spindle cutting was reduced from 0.015mm to 0.003mm. The roundness error of the wind turbine main shaft was reduced from ±0.02mm to ±0.005mm, and the machining yield was increased by 35%.
2. Large Coordinate Measuring Machine: An aviation enterprise used it for geometric tolerance inspection of aircraft wings (length 12m) — customized marble gantry components (12m-span beam, 4m-high columns) were adopted. The guidance precision is ≤ 0.002mm per 1000mm, and the inspection repeatability error was reduced from ±0.01mm to ±0.003mm. The inspection efficiency was increased by 50%, avoiding inspection deviations caused by metal gantry vibration.
3. Laser Cutting Equipment: A sheet metal enterprise used it for laser cutting of large stainless steel plates (size 6×2m) — a granite gantry beam (6m span) was adopted. The thermal deformation is ≤ 0.03mm per 6000mm, and the laser cutting precision was improved from ±0.05mm to ±0.015mm. The cutting surface roughness Ra was reduced from 3.2μm to 1.6μm, eliminating the need for secondary grinding.

Ventajas competitivas principales

• Large-Size Precision Barrier: With a maximum single-segment span of 8m and a maximum spliced span of 15m, its precision retention capability far exceeds that of metal gantries (metal gantries have a deformation of ≥ 0.1mm at 10m span, while granite has only ≤ 0.05mm). It is the only feasible structural solution for ultra-large precision equipment.
• Strong Long-Term Stability: After 24-36 months of natural aging treatment, over 99% of internal stress is eliminated. The precision retention period reaches 5-8 years (only 2-3 years for metal gantries), reducing equipment downtime for frequent calibration and saving enterprises over 300 hours of operation and maintenance losses annually.
• Lower Comprehensive Cost: Although the initial purchase cost is 20%-30% higher than that of metal gantries, there are no maintenance costs for rust prevention and regrinding required for metal components. With a service life extended by 2 times, the total lifecycle cost is over 50% lower than that of metal gantries.
• More Flexible Adaptability: Customization of special-shaped cross-sections (e.g., trapezoidal, I-shaped), multi-station mounting surfaces, and special guide grooves is supported, adapting to different types of gantry equipment (machining, inspection, cutting). Unlike metal gantries that rely on complex welding, it shortens the equipment R&D cycle.

Full-Dimensional Customization Services

Dimension and Structure Customization

• Span Customization: 2-8m for single-segment, 8-15m for spliced structures, with beam span designed based on the maximum machining/inspection size of the equipment;
• Cross-Section Customization: Cross-sections such as rectangular, trapezoidal, and I-shaped, with cross-sectional sizes ranging from 200×300mm to 600×800mm, and wall thickness adjusted as needed from 80-200mm;
• Special Structures: Custom integrated gantry frames with workpiece support tables, multiple sets of guide grooves, and integrated cable channels.

Precision and Function Customization

• Precision Grades: Grade 00 (straightness ≤ 0.003mm per meter), Grade 0 (≤ 0.005mm per meter), and Grade 1 (≤ 0.01mm per meter) are available. Grade 00/0 is selected for machining equipment, and Grade 00 for measuring equipment;
• Function Enhancement: Nano-level polishing of guide groove surfaces (Ra ≤ 0.01μm), surface anti-static treatment (surface resistance 10⁶-10⁹Ω), and integrated cooling water circuits to adapt to special application scenarios.

Installation and After-Sales Customization

• Installation and Commissioning: On-site splicing services (splicing precision ≤ 0.002mm), horizontal calibration (precision ≤ 0.001mm per meter), and collaborative commissioning with equipment components are provided;
• After-Sales Guarantee: 3-year free warranty, lifelong precision calibration and maintenance, with customizable “semi-annual inspection + biennial in-depth maintenance” plans;
• Technical Support: Provide gantry structural mechanical simulation and precision optimization suggestions to assist customers in completing the overall equipment solution design.