In modern machining centres, inductive sensors are the components of choice for monitoring the motor spindle clamping process. Integrated into the spindle, they must be exceptionally small and offer high repeatability to ensure smooth tool changing at all times.

Baumer offers a portfolio of miniature sensors for the intelligent design of effective spindle solutions. Products can either involve a classic concept with three switching sensors, or a smart design with one measurement sensor.

Tool change in fully automated machining centres, from removal until insertion of the new tool in the spindle, takes less than a second. To achieve maximum system effectiveness, this process must function with ultimate reliability. The error-free functioning of the smallest inductive sensors plays a major role in ensuring this attribute. For the machine to function error-free, the control requires the following key information regarding the status of the collet chuck: open and no tool clasped; closed and no tool clasped; or closed and tool clasped. The answer to this challenge are inductive sensors.

In drive and clamping solutions, the sensor technology integrates into the motor spindle. Given the confined space, sensors must be as small as possible, yet very powerful. One example is the IFRM 03 inductive proximity sensor, which has a diameter of only 3 mm. This product is available in various lengths starting at a mere 12 mm. Yet its miniature housing contains the complete evaluation electronics that are responsible for high repeatability switching points, as well as precise analogue measurement values. In addition, these industrial-grade sensors are robust, EMC-stable and comply with protection class IP67. The sensors remain unaffected by the heat, oil and vibrations that normally occur in machine tools.

For further information
www.baumer.com

Following the recent installation of a DMU 85 MonoBlock five-axis machining centre at the manufacturing facility of Cambridge University’s Whittle Laboratory, the search began for a flexible, comprehensive work-holding system. Given the important projects undertaken by the busy department, the proposed work holding needed to exhibit robust, high-precision characteristics and support rapid changeovers.

After considering several alternatives, the answer arrived in the form of Lang Technik’s Quick Point, a durable, baseplate-centred system that acts as an accurate interface between a machine tool’s table and work-holding devices. To enable Quick Point to accommodate and mount the facility’s diverse work-holding applications, the Whittle Laboratory purchased a further range of work-holding devices from Lang Technik UK, including a stamping unit, Makro-Grip five-axis vices, Avanti base jaws and soft top jaws.

Dr James Taylor, compressor research fellow at the Whittle Laboratory, which specialises in turbomachinery research, says: “In addition to the Quick Point and associated clamping devices satisfying our efficiency and precision criteria, as Lang Technik’s solution cost less than certain other less technically capable systems, our purchasing decision was relatively easy.

“Given the generous 1000 mm diameter of our new machine tool’s table, we have now located Quick-Point baseplates across the whole of the available area. Each of the baseplates is fitted with Lang Technik clamping devices. These set-ups allow us to quickly change between, for instance, vice-type machining and larger fixtures that hold the roots of our different blade designs. It helps that, in addition to accommodating our new work holding, the flexible Quick-Point system is also able to securely hold our existing work-holding devices. The speed and simplicity of Lang Technik’s Quick Point and clamping devices means that we have now achieved our aims of significantly reducing time lost between machining jobs and increasing our productive cycle times.”

For further information
www.lang-technik.co.uk

A member of the Russell Group, the University of York has more than 30 academic departments, among them the Department of Chemistry. The Department of Chemistry’s research groups cover a wide variety of disciplines, including atmospheric chemistry, renewable technologies and both medical and neuroimaging, all of which are supported by the extensive capabilities of a multi-disciplinary mechanical workshop.

Senior technician Mark Roper says the flexibility of the workshop’s machine tools is vital to its effective operation. Therefore, when the need arises to purchase new equipment, he looks for cost-effective products that add value and increase the workshop’s capabilities.

This policy is reflected in the recent purchase of a pL Lehmann CNC rotary table now fitted to the workshop’s DMG Mori CMX 600V three-axis VMC. The pL Lehmann TF-507510 was chosen as it provides the required levels of precision, ease of use and flexibility. In addition, the design and lower profile of the TF-507510 ensures minimum intrusion into a machine’s working envelope. Therefore, when compared with conventional, bulky rotary tables, the use of the compact TF-507510 results in much greater space being made available for spindle and tool movement.

Since entering operation, the pL Lehmann CNC rotary table has significantly increased the effectiveness of the workshop’s VMC by enabling it to perform efficient 3+2 axis machining.

“Fitting a pL Lehmann CNC rotary table to our existing three-axis VMC has proven a practical way add to achieve five-sided machining in a single set-up and eliminate steps in our processes,” says Roper. “Furthermore, the rigidity of the TF-507510 and its high clamping forces allows high cutting forces to be applied and precision workpieces to be produced.”

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

Vehicle component manufacturer ElringKlinger, headquartered in Dettingen an der Erms, Germany, includes high-performance, lightweight plastic products such as oil pans and cam covers in its product portfolio for the global automotive industry.

Tobias Gerst, production engineer responsible for capital equipment procurement and process planning says: “Over the past few years we’ve grown steadily and are running out of space for our production equipment, so we’re sometimes faced with very cramped conditions.”

Space is particularly limited where two automated injection moulding machines operate over three shifts. The machines are located in an enclosure and mould exchange is only possible by entering a narrow, low door. These machines, positioned at an angle of about 120° to each other, require a mould change every 8-9 days. As there is no overhead crane in the factory, it is impossible to load the machines from above. Instead, until recently, operators used one of a number of standard transport carts – a challenging and physically exhausting task.

All that changed with the arrival of a compact transport cart supplied by Roemheld. The RWA 1600 is characterised by its small size, an electro-hydraulic lifting platform and a shuttle table equipped with hydraulically actuated ball bars. In addition, Roemheld can customise the carts to meet specific requirements.

With ball bars set into the support surface of the table, it is easy to move the dies manually in any direction. A special safety mechanism ensures that, during mould transportation, the ball inserts lower into the table surface so the die cannot move.
As standard, Roemheld offers three versions of the 1600 kg capacity cart with either four, six or eight ball bars. After detailed consultation, however, Gerst asked ElringKlinger to produce a special version with nine bars.

For further information
www.roemheld.co.uk

A UK engineering specialist has completed its largest-ever rapid tooling project as demand for shorter lead times intensifies. MetLase, which is a joint venture between Rolls-Royce and Unipart, has designed and manufactured a stainless-steel tool measuring 4 m in diameter and capable of holding a component 2 m tall.

The company met the challenge of the major aerospace customer head-on, with manufacturing sign-off and delivery completed in just one month; 150 days quicker than the client would have previously expected. It is just one in a list of notable successes from the Yorkshire-based firm, which harnesses the design skills of a 25-strong engineering team and innovative joining solutions that replace traditional welding process.

“Typical conventional tooling approaches often take a massive block of material and then machine away the unrequired bits to form the tool,” says Richard Gould, business development manager at MetLase. “We take a different stance, basically laser cutting sheet metal, usually stainless steel or titanium, into lots of different elements. These are then joined to form the tool using our own manufacturing technique, removing the need to weld them together and endure the distortion that usually comes with this process.”

He continues: “Everything is controlled ‘in-house’ at MetLase. We’re always adding to our standardised feature library and parametric modelling system that allows us to instantly access formulas for creating tools for specific applications. All of this means we can work with customers to reduce lead times to weeks if not days, ensuring the client has more time for iterating their component design before signing off the tooling. As well as the time saving, our service can also help mitigate massive financial costs associated with last minute changes.”

For further information
www.metlase.com