Rotary table keeps Exactaform at ‘cutting edge’

In order to remain at the ‘cutting edge’ of tooling manufacture and help keep pace with growing demand for its output, employees at Coventry-based Exactaform continually search for advanced production equipment that will further improve capabilities. The latest addition to the company’s machining aids is a rotary table purchased from Swiss manufacturer PL Lehmann.

Research and development director Martyn Biddle says: “To further develop our capabilities in the important area of tooling trials we recently searched for a large, heavy-duty CNC rotary table that would provide the high-precision, five-axis machining that we need, and that could be retrofitted to our DMG Mori DMC 1450 machining centre. After carefully assessing alternative products from several manufacturers, we came to the conclusion that the T1-520530 TOP3 from PL Lehmann best matched our needs.

“Following trouble-free fitting into our machining centre and integration with its Siemens controller, our new rotary table soon began to deliver the levels of performance we were promised,” he continues. “The 5th axis provided by our PL Lehmann rotary table, and its impressive speed and precision, are now making significant contributions to our tooling machining trials.”

The T1-520530 TOP3 model, as installed on Exactaform’s DMG Mori DMC 1450, is PL Lehmann’s largest available CNC, 5th-axis rotary table, and is able to accommodate workpieces of up to 600 mm diameter and weighing up to 200 kg. Despite the rotary table’s capacity, its design means that it occupies a relatively small space within the machine tool. Given the demanding machining applications it undertakes, the rotary table boasts high clamping forces of 2000 Nm rotating/7000 Nm tilting. Aiding machining efficiency, the T1-520530 TOP3 provides 50 rpm rotating and 25 rpm tilting speeds.

For further information
www.lehmann-rotary-tables.com

PSL Datatrack aids road to accreditation

Mildenhall-based subcontractor CTPE is on the road to acquiring ISO9001 accreditation and has made some significant recent investments to achieve this target. Its manufacturing services now include five-axis machining and multi-pallet lights-out production as part of a complete supply-chain solution. The company has also streamlined the administration of its manufacturing processes by taking on a PSL Datatrack production control system. When it comes to acquiring and retaining ISO9001, CTPE is discovering that the traceability afforded by PSL Datatrack makes the process much slicker.

For further information www.psldatatrack.com

COMMITMENT TO CONTINUOUS IMPROVEMENT DRIVES MACHINE INVESTMENT

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has recently supplied DRB Group, a supplier of innovative and integrated turnkey and process improvement solutions based in Deeside, with three new, high-productivity machine tools. The machines, comprising two Fanuc-controlled multi-tasking lathes with integrated Y axes and driven tools, and a large-capacity, Fanuc-controlled five-axis machining centre, were delivered and installed at DRB Group’s 100,000 sq ft machine shop facility in late 2021.

DRB Group is a family-owned business established in 1976 with a focus on the repair, maintenance and supply of industrial electric motors, generators and mechanical transmission systems. The company has, over the past 46 years, undergone a metamorphosis and today provides a growing number of UK-based processing and manufacturing customers operating in highly regulated and demanding sectors with a range of integrated and standalone services and solutions. DRB Group serves industries that include rail, pharmaceutical, food and beverage, medical, energy, and waste management, to name but a few.

The company’s services can include everything from the supply of high-quality machined components and assemblies, critical asset condition monitoring, the maintenance and repair of customer plant and equipment, through to the design, development, manufacture and installation of, what can often be, complex turnkey solutions that can include new plant, equipment and processes.

With a dedicated project management team working alongside highly experienced design, applications and production engineers, DRB Group is a proven and successful single-source solutions provider with particular skills and competencies in mechanical, electrical, hydraulic and pneumatic systems.

As part of its regularly updated strategic company-wide continuous improvement programme, DRB Group makes significant investment, year-on-year, in improving its people, plant and equipment, and its processes and systems. This commitment to continuous improvement has, over recent years, seen the company increase its headcount, implement an in-house apprenticeship training programme, create dedicated areas for assembly, inspection and testing, and develop its in-house manufacturing capabilities that centre on machining and fabrication.

Explains Matt Bennett, CEO, DRB Group: “The investment in the three new Doosan machines was made to increase our machining capacity and improve our capabilities. Despite the outbreak of the pandemic, demand for our turnkey and process improvement solutions – many of which require the machining of bespoke components – and for our high-quality batch machining services, were on the increase. This situation was putting pressure on our existing in-house machining resources.”

He continues: “In order to avoid production bottlenecks occurring in the future, and ensure that lead times were not compromised, we made the decision to invest in multi-tasking machine tools.”

The three new Doosan machines acquired by DRB Group are all multi-axis, multi-tasking machines. Multi-tasking machines deliver significant productivity, operational efficiency and quality benefits to manufacturers. These include: reduced part set-up and cycle times; lower fixture costs; increased part accuracies and repeatabilities (because parts do not require transferring from one machine to another for completion); the elimination of production bottlenecks; and the ability to meet tight lead times and customer delivery schedules.

Says Bennett: “We made the strategic decision not just to increase our machining capacity, but to increase our capabilities. That’s why we now have lathes with Y axes, C axes, driven tools and tailstocks, and why we have a large-capacity, ultra-versatile, simultaneous five-axis machining centre.”

DRB Group, having audited its current machining resources and analysed where existing and future ‘pinch points’ were, and were likely to be, approached the market to discuss its plans and requirements with a handpicked number of machine tool suppliers. Mills CNC was one of those suppliers.

“We did our homework and knew that Doosan machine tools, and Mills CNC, had good reputations in the market,” says Bennett.
From talking over its plans with Mills CNC’s sales and applications engineers, it was agreed that a three machine tool package comprising two multi-tasking lathes and a large-capacity five-axis machine would meet DRB Group’s immediate and future machining requirements.

Recalls Bennett: “The Doosan/Mills CNC package had a number of advantages. As well as the machines ticking all the right boxes with regard to their technical specifications, they were also in stock and could be delivered and installed quickly. The comprehensive, integrated and single-source services provided by Mills – like its independent machine tool financing operation and its well-resourced and responsive aftersales support services – all had a positive impact on our decision making.”

DRB Group’s three new machines were installed at the company’s 6.5-acre facility in December 2021 and, since then, according to the company “haven’t missed a beat.” The two Puma lathes have been operating around the clock machining precision parts for two customers, while the VCF 850LSR has been used, among many other heavy-duty jobs, to machine large gearbox casings.

Concludes Bennett: “The new machines we now have at our disposal provide a strong foundation for future business growth.”

For further information
www.millscnc.co.uk

Over 100 new jobs at Aston Martin

Aston Martin is to create more than 100 jobs at its St Athan site in Wales, following the launch of its new DBX707 luxury SUV. The DBX707 will enter full production later this quarter at the manufacturer’s plant in South Glamorgan, with more than 100 new skilled automotive technicians required to support it. Applications are open now via Manpower recruitment.

Tobias Moers, CEO of Aston Martin Lagonda says: “As we ramp-up production of the DBX707, we’re delighted to have the opportunity to increase our team at St Athan and create more employment opportunities for the local community. Our DBX SUV is the first Welsh-built production car for nearly 50 years and these new positions are an opportunity to join a team delivering our incredible new DBX707 derivative that is setting new benchmarks for performance in the luxury segment.”

For further information www.manpower.co.uk

Robots to help assemble Scania batteries

ABB has entered into an agreement with Scania to provide a range of robotic solutions for the auto giant’s new automated battery assembly plant in Sweden, which be fully operational by 2023. The plant will assemble battery modules from cells supplied by Northvolt’s battery factory in Skellefteå, with the completed packs delivered directly to the vehicle assembly hall. Multiple ABB robots will be involved in the assembly process, including IRB 390, 4600 and 6700 models.

This agreement will mark the first time ABB’s IRB 390 robot will find use in a battery production facility. Originally designed for the packing industry, the robot can mount contact plates in batteries at a rate of one plate every second, 24 hours a day. ABB’s RobotStudio simulation and programming software will enable full verification of the production line prior to deployment, which will significantly shorten lead times and support the quality process.

For further information www.abb.com