WEINIG MACHINERY FAQs: Running at higher speeds on Powermat moulders
- PWT
- Jan 21
- 3 min read
Higher feed speeds through the moulder are always desirable, provided the surface finish doesn’t deteriorate and the setup process doesn’t outweigh the extra productivity achieved
Q: Can I run at higher feed speeds on a Powermat moulder?
A: Yes. The Powermat 1500 can operate at feed speeds of up to 40m/min, but this would typically result in a single-knife finish, meaning the surface quality would be lower than the standard finish achieved at around 20m/min. However, with the ‘Excellent’ precision tooling system, you can maintain improved finish quality at higher speeds. This tooling system offers exceptional edge-to-edge tip concentricity, delivering performance comparable to that of jointed tools.
Q: Which Powermat model can increase production while maintaining high finish quality at enhanced speeds?
A: In order to achieve this, you’d need to move up to the Powermat 3000. This model supports cutterblock jointing, whether it’s a straight knife planer block or a profiled serrated block; this allows consistent high-quality finishes to be achieved, even in the case of elevated feed speeds.
Q: What is jointing?
A: Jointing involves using an abrasive jointing stone to bring all knives on the cutterhead to the exact same cutting circle, within a tolerance of 3-5 microns. This ensures that every knife cuts at the same depth, resulting in a smoother finish – even at high speeds.
Q: Can I joint both straight & profile cutterheads & knives?
A: Yes. This is possible, but each cutterhead must be equipped with the appropriate automatic straight knife jointer or automatic profile jointer, depending on the application. Note: The first bottom spindle is limited to a planer head only and can’t be profiled.
Q: How can I produce profiled jointing stones?
A: Traditionally, these are created in situ on the machine, but this consumes valuable production time. Weinig recommends using one of its Jointer Presetting Stands, which allows you to ‘chip in’ and profile the jointing stones accurately in the toolroom – keeping your moulder in full production.
Q: What kind of feed speeds can I achieve on the Powermat 3000?
A: The Powermat 3000 offers options to run at 60, 80, 100, or 120m/min. However, at these higher speeds, some level of infeed and outfeed mechanisation is typically required, as the speeds are generally too fast for manual feeding.
Q: Can I still use the Powermat 3000 as a ‘traditional’ single-point finish machine?
A: Yes. Thanks to variable spindle speeds of 4,000-12,000rpm, controlled by the machine’s electronic inverters, the P3000 can be used in the traditional single-knife-point configuration. This gives you the flexibility to efficiently produce both short and long production runs.
Q: Is it possible to still use my existing PowerLock tooling?
A: Yes, existing PowerLock tooling can be used; however, standard PowerLock heads are typically 2-knife cutterheads, which aren’t optimal for high-speed production while maintaining a quality finish. Weinig offers 4-, 6-, or 8-knife PowerLock cutterheads, which are better suited to high-speed operation.
As a rule of thumb: 1 knife = 10-12m/min of feed speed when used in a jointed cutterhead.
Q: I have an existing Hydromat machine that produces wide products with 50mm bore hydro cutterheads – can this system still be used?
A: Yes. The Powermat 3000 is highly flexible and can be configured to accommodate 50mm horizontal spindles with state-of-the-art outboard support bearings and jointers – fully compatible with existing tooling. The vertical spindles can be either fast-change PowerLock jointed spindles or conventional 50mm jointed spindles, depending on setup.
FURTHER INFORMATION
Michael Weinig (UK) Limited
T: 01235 557 600
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