EDITORIAL ROUNDUP

CME robot cell increases productivity

When CME Ltd received a request to develop a fully automated solution for a pneumatic valve assembly, a six-axis robot was at the heart of its innovative system. The robot performs a series of different pick and place, orientation, transfer and assembly operations in combination with several dedicated workstations and peripheral technologies, increasing output and productivity.

In simple terms, the application requires the assembly of a pneumatic valve body that comprises of several individual parts, including a coil, circlip, label and adhesive. The robot collects parts from a series of magazine drawer systems that both present the individual components and store the fully assembled items. The system can automatically assemble 600 parts in an eight-hour shift.

Historically, the assembly of these valve bodies took place manually, with an operator requiring 90 seconds to complete the various tasks for a single valve assembly. There were several objectives targeted as part of the transition from manual to fully automated assembly, such as eliminating repetitive manual tasks, reducing the time needed for assembly and subsequently increasing productivity while reducing manufacturing costs. The automation of the different assembly operations also makes it possible to introduce additional quality checks that improve quality and yield.

Cell capacity is 300 assemblies before the system requires re-priming with fresh components. The total run-time to empty, without stoppages, is approximately 4 hours with an average cycle time of 48 seconds. This represents a saving of over 45% on the original manual cycle time of 90 seconds. The system achieves all of the initial objectives, while a further benefit is its potential for re-tooling to produce other part variants in future.
For further information www.cme-ltd.com

Driven to succeed, with help from Ceratizit

In under seven years, Driven Engineering has grown from a one-man operation with just a second-hand three-axis machining centre into a thriving subcontract manufacturing business on the back of founder Ray Harris’s commitment to invest in the company’s future.

The type of components machined by Driven Engineering lend themselves to vices, rather than fixtures, which is where Ceratizit UK & Ireland plays its part. In addition to providing cutting tools, Ceratizit has also been instrumental in kitting out the pallets with its latest ZSG4 vice system. The ZSG 4 vice has several benefits, but key to Driven Engineering is the ability to grip billets on just 3 mm of material.

“Using such a small amount of material for gripping allows us to program the part using the bottom of the billet as the datum, while we also get great access to five sides of the part,” says Harris. “In addition, the vices deliver consistent grip and accuracy, making them ideal for unmanned machining.”

In total Ceratizit has supplied Driven Engineering with 75 ZSG 4 centric vices, in a combination of 125 and 80 mm widths. Each vice is capable of applying up to 35 kN of gripping force, which allows the minimum grip depth of 3 mm. A further advantage is the lack of any requirement for billet preparation prior to gripping, which Ceratizit says is unlike other systems on the market. Their suitability for pallet-based machining is enhanced by their compatibility with PNG, MNG and Lang zero-point clamping systems.

Further support is provided by the Ceratizit tool-vending system that Driven Engineering has installed, which helps to maintain production with 24-7 tooling availability.
For further information www.ceratizit.com

Simplifying gripper configuration and integration

The task of configuring bespoke vacuum gripper systems that will meet the specific requirements of individual applications has never been easier thanks to the comprehensive digital configuration services now available from Schmalz. This range of digital services helps end users, machine builders and system integrators to achieve quick configuration of products such as Schmalz SLG lightweight gripping systems for individual applications. Tools such as filters, configurators, ordering aids and apps simplify the process – regardless of the stage of the project, whether it’s product design, procurement or operation.

A simple and highly intuitive six-stage process guides users through steps such as: selecting the workpiece; defining the application; selecting the type, number, size and positions of vacuum cups; and finally choosing a vacuum generator and robot mounting flange. The proposed SLG lightweight gripper then generates automatically and is shown in 3D on the basis of users input and responses to this series of intuitive choices.

At the end of the process, a summary of all of the information used to specify the gripper is available for download, together with valuable information for the end user or machine builder covering gripper dimensions, weights, air flow and gripping force.

Additional digital services available from Schmalz make it possible to simulate your handling process with a digital twin of the products selected, and test the function of the system long before it is actually built. For example, it is even possible to obtain information about the behaviour of a suction pad in its operational state. There are also a series of software and function modules that help integrate Schmalz products even more quickly into the end user’s process and control system.
For further information www.schmalz.com

MACHINING IN THE SUB 5 MICRON RANGE

Focusing on the production of components for machine tools, as well as main spindles, SPL Präzisionsfertigung GmbH in Germany demands the utmost in precision. For this reason, the company invests in boring and tooling technology from Big Kaiser, which is available in the UK from cutting tool specialist Industrial Tooling Corporation (ITC).

Andreas Pilz, the managing director of SPL Präzisionsfertigung GmbH, which was founded in 2007, says: “We started with just 14 workers and today we employ 30 highly skilled employees. We produce all manner of parts for turning, milling and grinding spindles, as well as special spindles and test-bench spindles.”

The production of main spindles requires the utmost precision, accuracy and care, so from the very beginning, SPL has regularly invested significant resources into employee training and state-of-the-art technology. In 2019, the company took the decision to build a brand new, air-conditioned production hall, purchasing a high-precision machining centre from Hermle together with all the necessary tools and accessories. This investment enabled SPL to stay on top of precision manufacturing, enabling the production of spindle housings, which are now an essential segment in its product portfolio.

For the task of finish-machining prismatic parts or spindle housings, SPL has also purchased a Hermle C62U five-axis machining centre.

“We made the decision to invest in a state-of-the-art machine and I remember writing to various manufacturers, but Hermle was the only supplier not discouraged by our demanding specifications and strict accuracy requirements,” explains Pilz. “This cutting-edge five-axis milling machine meets the most stringent demands in terms of machine kinematics and positioning accuracies, which are necessary for production in the ≤0.005 mm range.”

SPL utilises fine boring heads from Big Kaiser to ensure that the bearing bores in the spindle housings also meet the company’s precision tolerances.

“It was while machining a test workpiece at the headquarters of the machine manufacturer Hermle in Gosheim that we first saw the fine boring heads from Big Kaiser in action,” says Pilz. “The quality of the bores was second to none and convinced us from the very outset that Big Kaiser was the optimal choice. We would not only be purchasing a high-precision tool, but also gaining access to expert technical support and assistance from Jochen Renz, technical manager of customer service at Big Daishowa, the sister company of Big Kaiser in Germany. This was extremely important for us, particularly concerning our strict parameters such as rotational speeds, cutting and feed rates.”

SPL relies heavily on the digital EWE fine-boring heads from Big Kaiser.

“The industrial components that SPL produces are very expensive,” points out Enrico Müller, application engineer at Big Daishowa. “So it makes sense to rely on the proven quality provided by Big Kaiser’s digital fine-boring heads. We would use them regardless, even if only to eliminate reading errors in the very tight tolerance ranges under which we operate,”

Adds Pilz: “Another advantage of digital fine-boring heads is their ultra-fine handling accuracy. High-precision machining requires the utmost care and cleanliness. When manufacturing in the micron range, the machine, as well as the tool, must also ideally be in the micron range. In our situation it’s a clear-cut case with no room for compromises.”

Big Kaiser has a modular system that covers all diameters and lengths. Fine-boring heads can be adapted in a modular fashion to diameters and boring depths with various adaptations. The HSK-A 100 tool interface and the solid extensions provide high stability, even at great depths. Due to the system’s vertical tool infeed design, errors caused by tool deflection are prevented and the achieved cylindrical shape of the bores is less than or equal to 0.005mm.

The EWE fine-boring heads feature a high-precision insert-holder diameter adjustment. Since SPL spindle diameters range from 60 to 400 mm diameter, with bore lengths up to 800 mm, the company uses bridge tools from the 318 series. The 318 series is suitable for various applications such as roughing, finishing, tenoning and face grooving. It is based on aluminium bridges of varying lengths that can be combined with a variety of aluminium and steel components for roughing and finishing configurations. The tool components are plugged on to the bridges at specific points and bolted in place. As a point of note, the precise positioning of the components on the bridges, together with setting scales for the fine-boring heads, allows for fast and easy diameter setting.

SPL also uses Big Kaiser spindle tools for roughing operations on an MTE milling machine. However, in this application, two cutting edges are utilised on the tool, not just one as is the case with finishing.

“Mr Müller, who has worked together with us on the project from the very beginning, came up with the great idea, right on-site, that we could try roughing using a two-flute cutter on our MTE,” explains Pilz. “As a result, our machining speed is now five times greater than before with the milling tool. This is important, we’re talking about an 80% time improvement, not to mention a better surface finish and reduced costs.”

Now, 15 fine-boring heads from Big Kaiser are in use at SPL, for the fine boring of bearing bores and roughing during re-boring.

“We could not be more satisfied with the results,” concludes Pilz. “The tools, the service as well as the advice are all top-notch, there is simply no other way to put it. Our industry places the highest possible demands on us in terms of precision, accuracy and quality. Nevertheless, with the tools from Big Kaiser, coupled with their consulting competence and on-site support, success is practically guaranteed. In this case, we’re also a little proud that we’ve earned our place in the ≤ 5 µm range.”
For further information www.itc-ltd.co.uk

New sales and marketing director at RPI

RPI, a provider of rotary measurement and angular positioning devices, has promoted Jim Palmer to sales and marketing director. Palmer is an RPI stalwart with over 20 years’ experience in the business. He joined the company as an engineer before becoming sales manager, where he increased sales by over 60% in the past five years, thanks in large part to his extensive network of contacts. More recently he secured orders within a fortnight of Control 2022, the international trade fair for quality assurance, the fastest this feat has ever been achieved.
For further information www.rpiuk.com