Production rate grows at Ideal Boilers

Hull-based Ideal Boilers has increased its rate of production for domestic boiler chassis ever since a fully automated and highly efficient process designed by AP&T was implemented in 2018.

Ideal Boilers’ new production line for manufacturing boiler chassis; automated by AP&T.

Over 400,000 boilers leave the factory in Hull every year for households and commercial properties all over the UK. In order to meet growing demand for the company’s products, Ideal Boilers decided to investigate the possibilities for increased automation and streamlined production. A technology partner was sought that could take on full responsibility and supply a turnkey solution for the fully automated manufacturing
of boiler enclosure parts.
After a careful selection process, Ideal Boilers chose AP&T to be its partner. “With the customer’s two new link-motion mechanical presses as the starting point, we designed a fully automated tandem line with short set-up times and the potential for fast tool changes,” says AP&T account manager Christian Wright. “The rate of production has at least doubled compared with previously, when the parts were handled manually. Since it needs to be possible for up to 10 different products to be manufactured during the course of a working day – some formed in both presses, others only in one – achieving an optimised and flexible process was challenging.”
AP&T’s front/back transfer plays a major role in the line, which went into production in November 2018. This stable and flexible solution takes care of high-speed feeding into and out of the press, and enables fast tool changes.
“The professionalism, technical expertise and support shown by AP&T from the outset of the project have been second to none,” says Joanne Lilley, Ideal Boilers’ engineering innovation manager. “I would have no hesitation in choosing AP&T again for any future projects.”
For further information www.aptgroup.com

Remote CNC training from Mazak

Yamazaki Mazak has expanded its CNC training programme to include remote sessions at customer sites, enabling both new and existing users to unlock the benefits of Mazatrol Smooth CNC technology while social distancing remains in place.

The remote training programme involves Mazak delivering two full-size CNC control panel simulators and accompanying training material to a customer’s site, and then running a series of live interactive tutorials over the following days via Microsoft Teams. The simulators are then collected, cleaned and delivered to the next booking.
For further information programtraining@mazak.co.uk

Health and safety award for Protolabs

Protolabs has secured a global accolade for demonstrating excellence in health and safety.

The company received a RoSPA Gold Health & Safety Award for ensuring its staff, customers, contractors and any visitors to its manufacturing facility in Shropshire remain safe. “Great pride is taken in achieving excellence in the workplace, whether that is being at the forefront of innovation or creating the safest possible working environment for our employees,” states general manager Lee Ball.
The RoSPA Awards scheme is the longest running of its kind in the UK and receives entries from organisations around the world, making it one of the most sought-after global accolades in health and safety. Andrew Green, facilities manager at Protolabs, says: “As an organisation we always seek to do the right thing by our employees and all visitors to our facilities, which makes this award even more special. It reinforces our commitment to excellent standards.”
For further information www.protolabs.co.uk

Blum touch probes at WFL

The MillTurn series of machines manufactured in Austria by WFL are used around the world to produce complex parts to high tolerances.

These components include compressor rotors, for which the company has developed a highly productive method for automated complete machining. A key component of this solution is the TC63-Digilog probe from Blum-Novotest, which is used to scan workpiece contours in a matter of seconds without the need to unclamp the workpiece from the machine.
The compressor rotor is made of GG60 grey cast iron, measuring around 400 mm long with an outer diameter of roughly 160 mm. By using special forming cutters, the rotor is turned and milled on an M40 MillTurn machine down to gauge-block standard in grinding quality. The machine does this automatically in a 24/7 operation, resulting in significantly shorter machining times.
Until now, grinding was required during the rotor manufacturing process because the necessary accuracy and surface quality could not be achieved by milling.
“Although the new process does not allow us to dispense with grinding in all applications, it is however sufficient that our procedure substantially reduces the amount grinding necessary,” explains WFL product manager Manfred Baumgartner.
During the finishing process, the workpiece is initially prefabricated to an excess of two-tenths of a millimetre. This contour is measured on the machine using the digital and analogue TC63-Digilog touch probe. Engineers can scan the entire circumference of the milled profile without unclamping the workpiece from the machine. In this way, the component’s geometrical accuracy and concentricity is determined “in double-quick time”.
From the resulting contour – which is shown on the CNC display – an algorithm calculates the optimum corrections for every tool engagement.
For further information www.blum-novotest.com

Roth starts four-year AZL partnership

Roth Composite Machinery has started its four-year partnership with the cross-industry AZL network of more than 80 companies.

The manufacturer of filament winding machines will actively participate in the AZL ‘Composite Pipes & Vessels’ working group and contribute its system expertise to a joint study on winding technologies for composite pressure tanks. Andreas Reimann, managing director of Roth Composite Machinery, says: “AZL membership has many benefits. For instance, it helps us get in touch with users, interested parties and partners, and provides ideas for the development of new solutions.”
For further information www.azl-lightweight-production.com