Making AIDA lighter

In March 2007 “AIDAdiva“ at an imposing length of 252 metres left as the first ship of a series of club cruisers of the ocean carrier AIDA-Cruises the roofed construction dock I of the Meyer docks in Papenburg going for the fitting-out quay. In distant Bavarian Stephanskirchen the four young founders of lightweight solutions e.K., all students of Fachhochschule Rosenheim, department of wood technology also watched it going to sea. That was as the luxury liner that can carry 2,500 passengers in 1025 cabin might in future also carry products by lightweight solutions.

Composite material lisocore®.

At present “AIDAdiva“ is till a bit overweighed by approx. 250 tons. However, that might change in future due to the patented light-weight concept “lisocore^®“, an ultra-light composite material. It consists of natural materials and acrylate and is pressed with a weight of 200 tons and will save up to 60-70 % of weight in comparison to conventional solutions. The processing of the complicated moulds required for the production of light-weight sheets is done by a lightweight solutions developed CNC machine, with drives that operate using polyurethane timing belts SYNCHROFLEX^® GEN III by Mulco.

When asked why they took on the development for the processing of the mould themselves, the young wood technology experts replied soberly that “there had not been any suitable machines for such a production process" on the market.

CNC machining centres from lightweight solutions e.k., Stephanskirchen.

The only suitable drive for this development “had been the polyurethane timing belt technology”, since it provided “all required characteristics with respect to dynamics and being free of maintenance”. The lightweight solutions developed CNC processing machine, which is used to turn extremely complicated moulds made of wood, PVC, aluminium or steel for the presses and it provides X, Y and Z axes, which are driven by SYNCHROFLEX timing belts 32 AT5 / 600 GEN III at a width of 32 mm (Z axis for vertical drive) and 50mm width (X and Y axes).

Controls all CNC axes: SYNCHROFLEX® GEN III polyurethane timing belts.

For the young developers it was clear from the beginning that polyurethane timing belts should be used. Such dynamic drives have to run precisely and free of maintenance, it has to be position precisely and has to be resistant against mechanical and chemical influences and temperature deviations. The high-performance timing belt SYNCHROFLEX GEN III by Mulco fulfilled these specifications.

lightweight solutions is supported by Bernhard Fischer of Roth GmbH & Co. KG, the Nuremburg Mulco partner. Talking about choosing SYNCHROFLEX GEN III in the drive of this machined he adds: “The unusual combination of high-strength steel cord tie beams in bifilar arrangement and abrasion resistance polyurethane guarantees high timing belt strength, an optimal straight run and high performance.

The drive of the CNC machine was developed online using the always-available “belt-pilot“. This around the clock free-of -charge available support on the Mulco website offers designers access to the entire Mulco product range, CAD download and a calculation programme. “Working with Mulco belt-pilot made our life much easier in the design of the drive“, says Michael Schäpers. Apart from the calculation of the number of teeth required for the belts used all other required components, the width of the belt and the washer diameter could be determined.

Michael Schäpers (lightweight solutions), Josef Sturm (Roth) and Bernhard Fischer (Roth).

Even in the controls of the machine the young developers used innovative concepts. TwinCAT CNC, a software solution for PCs, controls the milling machine. This control enables the operation of the facility as a high-end system for complex moving and cinematic specifications. The PC based environment enables the processing data quantities and the direct operation of the facility from the design department.

“Light-weight materials made of natural materials will be the future” explains Dipl.-Ing. (FH) Michael Schäpers, the 29 year old owner of the Bavarian company. The material does not just have a market in ship-building, but also automobile and caravan construction, well even in construction technology. The background of environmental protection would play an increasing role in the comparison to chemical additives of moulds, panelling or covers.

Hanover, September 2007
Mulco-Europe EWIV