Integration of bending and robotics

In 2015, Wesbart decided to carry out a full review of all products and manufacturing processes, which involved looking at every aspect of manufacturing to help improve productivity and reduce costs.

One of the main processes which required investment was folding. All aluminium and stainless steel parts were folded at Wesbart using a manual system with an operator. Due to an increase in orders it was necessary to use subcontractors to meet demand.

“Our production runs can range from 150 parts to more than 5000,” says sales executive David Patey. “We carried out some testing of various automation options and found the parts would need to be fed into the cell on a conveyor system. As a result, we contacted a locally based robot integration company [ICS Robotics and Automation] to work with Bystronic and develop a suitable system. We chose to use Kuka robots and the Bystronic Xpert 40 press brake due to their small footprint.”
ICS designed a bespoke space-saving set up using three Kuka robots, one operating each press brake with another feeding components from the conveyors. A camera system was included to identify the parts and confirm their correct placement on the conveyor.

The system arrived in January 2021 and has already shown a great deal of potential. According to Wesbart, the Bystronic press brakes are incredibly quick and reliable, while the user interface is very easy to operate, which helps expedite robot programming for the company’s components.

“With the investment made in the bending cell we hope to remain a market leader based on the quality, price and lead time of our products,” concludes Patey. “We also hope it will allow us to enter new markets.”

For further information
www.bystronic.co.uk

New alternative lender launches

Blazehill Capital has launched as a new alternative lender that provides credit and working capital funding to mid-market manufacturers requiring additional financial support which they cannot get from traditional providers. The company typically provides secured lending ranging from £5m to £30m per transaction, delivering fast and flexible credit solutions to companies with non-standard lending requirements that are often complex and time critical. Blazehill’s ambition is to build a lending book of over £1bn in five years.

The team focuses on supporting management teams through tough trading periods, providing them with the necessary capital and financial breathing space to deliver on a turnaround plan. Blazehill Capital has the backing of a number of high-profile investors, including major financial institution WAFRA Capital Partners, the global credit investment firm with $5.1bn in assets under management and specialisms in asset-based finance.

For further information www.blazehill.com

DMC to pioneer data platform

The Digital Manufacturing Centre (DMC) in Silverstone will be the first business to officially adopt Renishaw’s new manufacturing connectivity and data platform, Renishaw Central, across its complete additive and subtractive manufacturing operations. Ongoing collaboration between the two companies has evolved from Renishaw initially supplying the DMC with additive manufacturing (AM) equipment, followed by several of its metrology solutions, to the implementation of this digital platform.

Driving the future of AM by realising a fully connected process chain, the DMC is leveraging actionable data to deliver a step-change in manufacturing capability. Renishaw Central will play a crucial role in this ambition and enable the DMC to embrace Industry 4.0 practices and principles. Not only will Renishaw Central provide end-to-end manufacturing data capture, it will allow DMC engineers to further refine part design and processes by effectively implementing capabilities that include predictive analytics and AI.

For further information
www.digitalmanufacturingcentre.co.uk

UK car production soars

UK car production rose 46.6% in March, the first increase after 18 months of decline, with 115,498 cars manufactured, according to the latest figures released by the Society of Motor Manufacturers and Traders (SMMT). March output for the domestic market rose 19.4% to 20,269 units with exports also increasing, up 54.1% to 95,229 units. More than eight-in-10 (82.5%) cars were sent overseas in March. The EU remained by far the number one market for UK-made cars, with more than half (51.9%) of exports heading across the Channel.

UK commercial vehicle (CV) production also increased in March, by 16.9%, as 6166 units left factory gates, thus indicating the CV sector’s first month of growth since September 2020. In addition, March UK engine production climbed 31.7% compared with the same month last year. Engine output for domestic and overseas markets increased 50.4% and 19.9% respectively.

For further information www.smmt.co.uk

Machining centres drive savings at foundry

Two Starrag Heckert machining centres are enabling an aluminium foundry in Italy to finish-machine cast components for the automotive industry. The two machines – a five-axis Heckert X40 and a four-axis Heckert H40 – are also helping Lombardy-based Industria Metalli to effectively become a system supplier of components that, because of the reliability and speed of the Heckerts, are now significantly more cost-competitive than those offered by companies without in-house machining.

Industria Metalli specialises in vehicle components, from supports and brackets through to housings, generating 40% of turnover from the automotive sector. Each year it produces over five million cast aluminium parts using 8000 tonnes of secondary aluminium for 160 customers around the world.

Until the installation of the Heckert machines, the company outsourced all of its machining. However, subcontracting was increasingly causing logistical concerns, as well as cost and quality issues. The turning point came with the arrival of a new project manager who had worked as a machining specialist in the automotive industry. He recommended purchasing Heckert machines to assist the establishment of an in-house machining facility.

Following installation, Industria Metalli began its in-house machining by processing simple housings for oil filters. “I’m optimistic that we’ll soon be able to finish more products using the Heckert machining centres and that we’ll also receive orders for new components,” states managing director Fausto Becchetti.

“By establishing a mechanical manufacturing facility, our opportunities to progress to tier one, to become a system supplier, have increased significantly,” he continues. “Our products are now significantly more competitive in comparison to those from many of our competitors which do not have in-house machining. The two Heckert machining centres represent the first milestone in our journey.”

For further information
www.starrag.com