MECAL GIANOS

General

The Mecal Gianos elevates the high-speed performance of the Falcon platform into a premier Dual-Zone Aluminium Profile Machining Centre engineered for maximum throughput. It features a single high-performance spindle that services two independent, rotating work-holding beams (A-axis). This dual-zone architecture enables two powerful production modes:

Pendulum Working: The machining head works in one zone while the operator safely loads and unloads the other. This creates a non-stop production cycle that virtually eliminates downtime. Each beam can hold two smaller parts (four total), dramatically increasing batch throughput.

Tandem Working: The two work-holding beams synchronize to function as a single, extended machine bed, providing the capacity to process oversized profiles.

Clamping

The Mecal Gianos can be equipped with self-motorized MMI clamps or head-driven DPM system. The clamps are moved to calculated positions automatically, ensuring security during operations. Exclusive to the MMI system, the MAM function allows for seamless clamp relocation mid-cycle, drastically reducing downtime and maximizing continuous production.

Programming

Programming is handled through the intuitive Mecal CAD/CAM3D interface. The controller’s key feature is its intelligent zone optimization. When multiple parts are loaded, the system analyzes all required operations and reorders them across both zones to drastically reduce tool changes, saving valuable time on every cycle. An optional STEP/IGES driver CADLink is available for seamless integration with third-party 3D design files.

Features

• Single or dual piece pendulum working capability (total of 4 working fields)
• 4-axis servo control with absolute encoders – No axis referencing required.
• Ultra-high X axis rapid speed: 150 m/s
• Choice of automatic Clamp positioning systems DPM head-driven or MMI self-motorized
• MAM automatic clamp repositioning within the cycle (exclusive to MMI system)
• Servo-driven rotating beam (A-axis) with integrated clamps for multi-angle machining.
• Precision clamp positioning on linear guide rails ensures accurate and secure holding.
• Supports end-notching operations on either end of the profile with a dedicated disc cutter.
• Pneumatic flipping stops ensure consistent positioning and fast setup.
• Central tool changer holds up to 11 tools; expandable with optional magazines.
• Minimum Quantity Lubrication (MQL) provides clean, efficient tool cooling.
• Automatic central lubrication for all guideways and ball screws reduces maintenance.
• Pre-configured for chip trays or conveyor to simplify chip removal.

Technical Data

• X axis rapid speed: 150 m/min
• X axis acceleration: 3.8 m/s^2
• Max. Total Working Length: 7,223 mm (23.7 ft), including end milling
• Max. Working Length per Zone: 3,408 mm (11.18 ft), including end milling
• Spindle Power: 8.5kW
• Spindle Speed: 24000 rpm
• Tool Holding System: HSK 63F
• Tool Magazine Capacity: 10 tool
• Standard Clamp Width: 250 mm (10”)
• Optional Clamp Width: 300 mm (12")
• Standard Number of Clamps: 8
• A-Axis (Beam Rotation): ±125° rotation around the X-axis
• A1-Axis (Beam 2 Rotation): ±125° rotation around the X-axis
• Control Interface: Windows 10 based PC with 18.5” touch screen

Standard Equipment

• Electrospindle: air cooled, HSK 63F, 24000 rpm, 8.5 kW
• Magazine with 11 tools capacity
• 8 x Pneumatic clamps
• 4 x Reference stops
• Windows 10 based PC
• CAD/CAM 3D Graphic software with office licence

Optionals

• Upgrade to 8.5kW spindle with encoder for rigid tapping
• Additional MMI clamp, max 12
• Additional DPM clamps, max 12
• Additional tool magazine, 3 seats on the RH
• Additional tool magazine, 3 seats on the LH
• Tool length measuring probe
• Work-piece touch probe
• Clamp capacity expansion kit
• Chip conveyor
• Inclined chip conveyor
• Chip bins
• Steel processing kit
• Sound insulation kit
• Bar code reader
• Integration with third party software
• CADLink 3D file convertor
• Various aggregates for milling, cutting or tapping
• Tailor-made tool kit