UCIMU reports excellent 2021

Last year was extremely positive for the Italian industry of machine tools, robotics and automation, which reported double-digit increases for all key economic indicators. This trend should continue throughout 2022, the year when ground lost in 2020 should be recovered. In 2021, production reached €6,325 million, marking a 22.1% upturn compared with the previous year. This outcome was due to the excellent trend of deliveries from Italian manufacturers to the domestic market, which increased by 27.8% to €2,965 million, as well as to the positive performance of exports, achieving €3,360 million (up 17.4%).

For further information
www.ucimu.it

Software inspects gears automatically

CMM manufacturer LK Metrology has introduced a third release of its CAMIO 2021 programming and measurement software featuring numerous improvements. The most significant is the inclusion of a module that automates the inspection of spur and helical involute gears.
CAMIO Gears makes it possible to begin measuring the specific geometry of gears quickly by utilising the core capabilities of CAMIO software to generate straightforward inspection programs, advanced gear reports and automated probe calibration routines.

For each gear type, the software has a unique set of definitions, evaluation algorithms and reporting graphics packaged into one add-on module, making it easy for users to bring a new capability to their existing CMM. The module supports alignment of the gear axis during measurement using any of the three CMM axes and traditional touch-trigger probes or advanced scanning probes.

LK has incorporated several other improvements into CAMIO 2021 R3, the availability of which was announced at the end of November. For instance, Smart 3-2-1 datum alignment is new functionality that intelligently selects the datum axis and origin constraints, as well as the most suitable datum features using best-practice techniques. Should the user change the alignment properties manually, the selections automatically update.

A further improvement is the Explorer Tree Datum Definition, which allows the more efficient definition of datum features directly from the feature explorer, with the option of specifying the datum label. In addition, the Report Table Feature Order provides new options for controlling the order in which features are reported in graphical tables, either alphabetically, by program output or in a user-defined order.
As another example, users may now define teach-path coordinates and directions using the CAD model.

For further information
www.lkmetrology.com

4K resolution digital microscope

The new Makrolite 4K digital microscope from Vision Engineering provides high image quality and wide dynamic range, making it is suitable for a broad spectrum of complex and high-contrast applications. According to Vision Engineering, the Makrolite 4K provides more fine detail with greater detail shadow and highlight areas. As a result, the microscope can handle challenging inspection routines, including reflective subjects such as solder joints, subjects in shadow, or subjects with low contrast, like rubber and plastic.

Makrolite 4K is said to be flexible and easy to use, providing high-definition video images with up to 330x magnification. The microscope delivers both versatility and high performance in applications such as production, lab research, R&D, micro assembly, quality control, inbound/outbound product checking, dissection and rework.

Available in two versions, the console configuration provides direct HDMI connection to the monitor for live display with full control of zoom and all camera settings. Connecting Makrolite 4K to a PC with Vision Engineering’s dimensioning software, ViPlus, extends its capabilities to include image capture, annotation, on-screen measurement, live overlays, data/image report generation and a range of image processing tools.
Additionally, the Makrolite 4K solution includes a wide range of stands and objectives, making it a flexible solution equipped to deal with a broad range of demanding inspection tasks.

Paul Newbatt, Vision Engineering’s group sales and marketing director, says: “Makrolite 4K represents a step forward for Vision Engineering in terms of inspection microscope image resolution. It retains the core Vision Engineering values of superb image quality combined with ease of use, but adds 4K resolution, a choice of console or PC versions, and range of five stands, to deliver a really flexible inspection solution”.

For further information
www.visioneng.com

MTC helps FFI achieve green hydrogen target

The UK-based Manufacturing Technology Centre (MTC) has underlined its net zero credentials by supporting Australian giant Fortescue Future Industries (FFI) in its goal to produce 15 million tonnes of green hydrogen a year by 2030. Huw Sullivan, hydrogen leader at the MTC, says: “Supporting the delivery of net zero, including green hydrogen, is core to our vision for future manufacturing and creating clean growth jobs. Through our Liverpool, Midlands and southeast UK facilities we are engaging to support the next generation of green manufacturing technologies and stimulate investment in the UK supply chain.”

For further information www.the-mtc.org

Investment strengthens design-to-delivery offer from Unifabs

Nuneaton-based Unifabs has installed a brand new Amada Regius high-speed CNC fibre laser profiling centre with load/unload automation and storage. The company, which is targeting 25% growth in 2022, says the machine has already improved laser cutting speeds by 50% for certain parts. To further improve its ‘design to delivery’ offer for customers, the company has also placed an order for a new Amada HRB-ATC, the first mid-range press brake in Amada’s portfolio to feature automatic tool-change capability.

Founded in 2007, Unifabs has grown into a £12m turnover business with 125 people. Supplying precision sheet-metal parts to a customer base of blue-chip manufacturing companies across a host of industries.

“Our goal is to be much more than just a supplier of sheet metal fabrications and parts,” says managing director Tom James. “We want to be a manufacturing partner to our customers, supplying a start to finish service. Whether we’re supplying sheet metal components just in time to a manufacturing line, or controlling the entire production process on a contract manufacturing basis, we operate as an extension of our customers’ business.”

Unifabs has seen growth of around 65% over the past two years and today operates from a single site with five factories that total 52,000 ft2 of manufacturing space.

“We don’t specialise in one particular sector, but strong-performing industries right now include HVAC, catering equipment and construction,” says James. “To ensure timely deliveries to our customers we continuously invest in the latest manufacturing technologies.”

A case in point centres on the company’s laser cutting capacity, which was recently struggling to keep pace with rising demand.

“Even though we have an Amada FOL-AJ 4 kW fibre laser with AS LUL loading system and an Amada EML-3610NT punch-laser combination with MP loading system, we were still outsourcing a lot of laser cutting,” explains James.

To help improve lead times for its customers and regain control of parts, Unifabs decided to invest in another laser cutter.

“We looked at different models, but along with the increased processing speed we really liked the automated set-up features on the Amada Regius, which we knew would help to reduce set-up/inspection time and maximise productivity,” he says.

Automatic inspection on the Regius utilises technology such as the Amada i-Nozzle Checker to assess nozzle damage and circularity. If the nozzle requires changing (against a predetermined set of parameters), this will happen automatically via the machine’s 16-station nozzle changer, negating the need for subjective operator judgement. A further function of the i-Nozzle Checker is automatic alignment of the nozzle centre if/when required.

Installed in November 2021, the Amada Regius at Unifabs is primarily processing mild steel, galvanised steel and zintec from 1 to 8 mm thick. The machine features an Amada ASLUL-3015 for the automatic loading and unloading of sheets and the storage of raw material, ensuring uninterrupted production runs and optimal machine utilisation. Typical batch sizes are in the region of 50 to 200. At present the company is running a double shift during the week, plus a weekend shift.

“The machine is very easy to use,” says James. “It has several process monitoring systems that do much of the work for operators.”
Regius features Amada’s new i-Process Monitoring system, which checks the wavelength of reflected light in real time to provide a reliable indication of good or poor cuts. Automatic head collision recovery is a further function of i-Process Monitoring. Machines without this function simply stop and issue an alarm, wasting valuable time.

“The Regius is a 6 kW laser, whereas our other Amada laser capacity is 4 kW,” says James. “Combined with the more intelligent head movement, we find that any parts over 4 mm thick are around 50% quicker to cut, shortening lead times for customers without any compromise in quality. It’s a great step forward for Unifabs and our partners. The Regius is also more efficient and uses a lot less power than our Amada FOL laser cutter, such is the advance in technology.”

The high-specification Regius CNC fibre laser profiling centre is not only the fastest in Amada’s portfolio, but the first to integrate a number of key technologies: linear drives in all axes; the company’s all-new laser integration system; and variable beam control technology.
Beyond laser cutting, Unifabs offers extensive sheet metal fabrication capabilities that include design, CNC punching, CNC bending, welding, powder coating and final assembly.

Automated bending is a core business function, which is why Unifabs has placed an order for a new Amada HRB-ATC. Adding to the company’s existing seven Amada CNC press brakes (HFE and HFP models), the HRB-ATC is the first at the company with automatic tool change capability.

“We manufacture a lot of samples, prototypes and small batch runs to help get components ready for serial production,” explains James. “We have 10 people in our CAD team, so a lot of our work comes from the product development side of our business. However, these parts often have long set-up times, so we’re really hoping that the new press brake’s ATC capability will have a big impact on throughput in this area. We’ll program a prototype part offline using Amada software, send it to the new HRB-ATC and hopefully be folding metal within a few minutes.”

Amada HRB-ATC features a full size ATC, offering exactly the same number of tool storage racks as the company’s high-end HG-ATC press brake. The machine comes with a package of Amada tools based on an assessment of the customer’s manufacturing requirements. Importantly, the HRB-ATC is completely compatible with Amada AFH standard tool sets. As a result, any existing customer using these tools can load them manually to the new machine if desired.

“The new Amada investments support our growth strategy and mission to continue as a trusted contract manufacturing partner to our customers,” says James. “While our customer service and communications set us apart from competitors, it’s our investment in new technology that can impact factors such as lead time, providing a direct benefit for clients.”

Of course, there are numerous industry challenges currently threatening to quell any potential gains, including labour shortages, but Unifabs has plans in place to overcome this issue.

“The retention of staff is challenging with so many companies seeking new employees,” says James. “However, we’re now a real Living Wage accredited manufacturer, so we pay above the minimum. Furthermore, from January we’ll be launching our Unifabs Academy in partnership with North Warwickshire and South Leicestershire College, with 10 youngsters starting a two-year bespoke apprenticeship to help support our growth trajectory.”

He concludes: “Alongside a number of good prospects for 2022, we’ll keep striving to maintain great relationships with our existing customers. We’re targeting £15m turnover in 2022, which will represent 25% growth.”

For further information
www.amada.eu