PRODUCTION - PPS GROUP Detva

From creating technical drawings to painting

Learn about the production process

From the initial idea and customer request to product finalization and assembly. In the PPS Group’s production process, modern, efficient processes, digitalisation and automation are applied in all steps. However, the main asset in our machine shops remains the experience and skilled hands of our qualified employees. We produce large products in small batches, for which it is not always worthwhile to set up robotic lines.

CREATION OF TECHNICAL DRAWINGS

Our designers and technical staff are able to provide partners with technical support services such as: drawing up 3D models, drawing up design documentation (technical drawings), drawing up accompanying documentation or a spare parts catalogue. Drawings and models are processed in AutoCAD and Autodesk Inventor.

MATERIAL PREPARATION

Material preparation

Based on the supplied technical documentation, we are able process the required type of material by cutting, sawing and burning.
For burning, oxy-acetylene (CombiCut 15001.55 GbkGGG and Picorex) and plasma burning machines are used.

Plasma machines	Number of burners	Number of tables	Table dimensions (mm)	Max. sheet thickness (mm)
OMNIMAT 5000	1 – beveled	1	13000 x 3000	80
SPLR 12001.25 PrP	1 – straight 1 – beveled	1	12000 x 2500	38
MG 12001.25 PB*	1	1	12000 x 2500	50

*Model MG 12001.25 – MG PB is equipped with a vertical burner for burning sheets up to a thickness of 50 mm and a mechanical drilling head for drilling holes up to 29 mm.

Oxygen – acetylene machines	Number of burners	Number of tables	Table dimensions (mm)	Max. sheet thickness (mm)
CombiCut 15001.55GbkGGGG	4 – striaght 1 – beveled	1	5500 x 150000	200
Pikorex (burning with template)	4	1	2000 x 2500	100

Shears	Max. sheet thickness (mm)	Max. board width (mm)
NTA 3150/10A	10	3000
CNTA 2000/6.3	6	2000

FORMING

Forming

Press brakes (TRUBEND 800, CTO 400A, LODD 315, SAFAN H-Breke 320, LO 50. ) are able to create pressures from 50 to 800 t, with a maximum length of the material to be pressed of 6000 mm, bending radius up to 200 mm. There are also sheet metal straighteners (UBR 18×200, XRM 2000×12, XRM 2000/6,3), roll bender (HR4W3840 a XZMP 2000×12), tube benders (XOTH 40, B 60).

LODD 315 Press brake

Forming equipment	Table dimensions (mm)	Clamping (mm)
Press brake 800 t (TruBend)	6050 x 250	6 osí
Press brake hydr. 400 t (CTO 400 A)	5000 x 300
Press brake H – Breke 320 (Safan)	4100 x 250	635
LODD 315 Press brake	4000 x 200	250
Hydraulic straightening press HPR 800	1600 x 2700	750
Hydraulic straightening press 400 t CDN 400B	6000 x 3100
Press brake 50 t (LODD50)	2500 x 200

WELDING

Welding

Manual welding is carried out by highly qualified personnel using MIG/MAG, TIG, CMT welding equipment. For submerged arc welding we use GOLEM 1200 welding machine. Welding especially of rotary assemblies and booms is carried out with IGM and OJ 10 welding robots. Welded materials: Grades S235 to S960. Special steel types (thickness 1 to 150 mm). PPS Group a.s. holds welding certificates.

Welding equipment	Current (A)	Protective atmosphere
Welding sources – MIG / MAG	250	82 % Ar, 18 % CO₂
Welding sources – MIG / MAG	220	82 % Ar, 18 % CO₂
Welding sources – MIG / MAG pulse	up to 400	82 % Ar, 18 % CO₂
Welding sources – CMT	up to 270	97,5 % Ar, 1,8 % CO₂
Welding sources – TIG	up to 315	100 % Ar
Submerged arc welding	up to 1200	flux
Welding robot	up to 400
Welding positioners	1000 x 640 mm	Load capacity up to 10 t

MECHANICAL MACHINING

Mechanical machining

Mechanical machining of details and smaller assemblies is carried out using lathes, drills, milling machines and grinders. For the machining of larger welded structures, the company is equipped with modern NC and CNC centres.

NC / CNC centers	Workpiece size	Table size
SHW – UFZ – duo	15000 x 1200 x 2500	16000 x 1500
2 x FFDQ 125 – duo	13000 x 1000 x 2000	14000 x 1250
FUQ 150	4500 x 1500 x 2500	2 – 3000 x 2000
FUQ 125	4000 x 1500 x 2000	2 – 2000 x 2000
WRD 150 Q (with turntable)	15 000 x 1800 x 4000	10000 x 3000 / 2500 x 3000
SORULACE FX 10 000 (with turntable)	10 000 x 1600 x 4800	7000 x 3500 / 2500 x 3500

Lathes	Running diameter	Tip distance
Center lathes	400 / 1000	800 / 2000
	Workpiece diameter	Max. workpiece length
SKIQ8 vertical lathe	800	630
Carousel lathe SK16	1620	800
SPT 32NC semi-automatic lathe	320	800

Drills	Workpiece size (mm)	Table size (mm)
Radial drill	25 – 100	850 x 780 – 2000 x 3000
Coordinate drilling machines	50 – 100	500 x 830 – 1000 x 1600
Horizontal boring machines	63 – 100	320 x 320 – 1000 x 1120
	130 – 160	1800 x 1600 – 4000 x 2500

Milling machines	Clamping area (mm)	Movement x, y, z (mm)
Milling center – FFQ 100A OR / AG	6000 x 1000	6200 x 1500 x 1400
Milling center – FSQ 100OR / A3	3000 x 1000	3000 x 1000 x 1600
Horizontal milling machines – WFQ 80 NC	850 x 1600	1600 x 980 x 950
Table type milling machine – FSQ 80-GM / A2	2000 x 800	2000 x 900 x 800
Table type milling machine – FCQV 63	630 x 2200	1500 x 630 x 630
Portal milling machines	1250 x 3500	3200

SURFACE TREATMENT

Surface treatment

We have the technology of sandblasting and degreasing by high pressure spraying with passivating agent before surface finishing and painting.

Depending on the parameters of individual products and customer requirements, wet painting is carried out, mainly with 2K paints:

In a chamber painting line with tunnel surface pre-treatment, on a circular conveyor, in a tact manner.
In a painting and drying box equipped with a track with trolleys, with pre-treatment by high-pressure spraying with passivating agent.
In a multi-mode paint booth equipped with a track with trolleys, with pre-treatment by high-pressure spraying with a passivating agent.

Sandblasting

PPS Group a.s. can offer complex surface treatment of products by sandblasting and painting processes. The company has a robotized sandblasting workplace consisting of a HOLLAND MINERAAL sandblasting chamber and a BLASTMAN sandblasting robot. At an operating pressure of 8 bar. and a 19 mm nozzle used, the sandblasting output is approx. 225 m2/h. The sandblasting process can be pre-programmed or programmed by the robot for manual sandblasting (the robot stores the manual sandblasting process in memory). We also use the workstation for manual sandblasting without the sandblasting robot.

Painting Line

The pre-treatment of the surface of the parts (degreasing + iron phosphating, rinsing and drying) is carried out in the tunnel line in a shower way using the Henkel products. Subsequent painting and drying of the base and top coat is carried out in separate painting and drying boxes. The base paint is applied with TRITON 308 low-pressure HVLP equipment, the topcoat is also applied with 2K WAGNER TWIN CONTROL 35-70 high-pressure equipment. The tact of the line is determined by the painting time and lasts about 10 – 20 min, on 43 hinges. The maximum dimensions of painted products are 4 x 1.8 x 1.35 m with a weight of up to 2 tons.

Separate Painting and Drying Box

Surface pre-treatment (degreasing + iron phosphating) is carried out with the high-pressure equipment RB-30E using the Henkel products. Painting of the base colour is carried out with medium pressure spraying equipment KREMLIN 20.25, topcoat with high pressure equipment 2K WAGNER TWIN CONTROL 35-70. The maximum dimensions of the products are 14 x 4 x 2.5 m weight up to 10 t.

Multi-Mode Paint Booth

Surface pre-treatment (degreasing + iron phosphating) is carried out with the high-pressure equipment RB-30E using the Henkel products. The fully automated BLOWTHERM T1 multi-mode paint booth ensures the entire painting and drying process. The paint booth is 16 x 5 x 5 m after modification and the transport of the parts is carried out by rail trolleys. The painting of the base colour is carried out with a KREMLIN 20.25 medium pressure sprayer, the top-coat colour with a 2K WAGNER TWIN CONTROL 35 – 70 high pressure sprayer.

ASSEMBLY

The assembly process in the company represents the final cumulative operations of joining parts and components up to the final product in a certain technically expedient sequence. The assembly process is currently dominated by manual operations and integrates all aspects of quality assurance from previous processes. The assembly process takes place in dedicated production areas that are exclusively dedicated to the assembly process.