THIS WEEK’S HIGHLIGHTS

Audi Toolmaking steps on the gas with WorkNC

Vero Software has developed a new WorkNC high-feed rate strategy together with the machining specialists at Audi Toolmaking. The outcome: Audi has reduced processing times in various pre-finishing pressing tools by up to 30% while tool service life has tripled.

Responsibility for optimising the toolmaking in terms of CAD and CAM technology at the Ingolstadt plant of Audi AG is Markus Brunner. Brunner is primarily occupied with increasing processing quality and throughput times through the use of modern, CAM-programmed machining technologies, thus reducing processing costs. His partner in programming software is Vero Software, with its WorkNC CAM system, which Audi Toolmaking has been using for many years now.
Vero is constantly refining WorkNC software in order to make milling work even more efficiently. For instance, the current release includes a new high-feed strategy which was proposed by the toolmakers at Audi and created in a close and partner-like co-operative effort.
The new high-feed strategy factors-in deviations in milling tool geometries with irregular cutters. WorkNC thus prevents undefined allowances from appearing on the workpiece. Brunner is enthusiastic about the result: “This new strategy enables us to use milling tools of any contour, even ones with cutters which deviate from a regular geometry, such as a sphere or torus. As a result, we can even use milling tools which were specifically designed for a defined application case. Moreover, by using WorkNC’s high-feed strategy and the tools to match, we have reduced processing time in pre-finishing work by up to 30%.”
For further information www.worknc.com

HMS technology underpins connected machines

Paper-slitting machines from American machine builder JSI are well connected indeed. By using technology from HMS Industrial Networks, and system design by Millennium Controls, JSI can remotely access and control machines via the internet and enable wired and wireless communication between different machine parts.

To access the machine remotely, JSI and Millennium Controls installed an eWON Cosy from HMS – a remote router which allows users to log in securely via the internet to perform machine monitoring or even programming and maintenance. This means that operators can change blades from a safe distance inside a plant or indeed from anywhere in the world.
The eWON Cosy is connected to the machine’s PLC (a Rockwell ControlLogix L7); in turn, the router communicates with the cloud-based eWON Talk2M service where users can log in to access their control system.
With many moving parts in a machine, cabling can be difficult and cumbersome. However, by mounting an Anybus Wireless Bolt on the paper-slitting machine, JSI can offer wireless communication between the PLC cabinet and different parts of the machine.
An Allen Bradley PLC controlling the machine communicates using EtherNet/IP, the preferred network of Rockwell Automation-based systems. The PLC communicates seamlessly with most other systems and components in the machine, but JSI wanted to use a stacklight to show the current status of the machine, and this stacklight used Modbus-TCP communication. To enable the stacklight to communicate on EtherNet/IP, Millennium Controls suggested HMS’s EtherNet/IP Linking Device, which acts as a translator between the stacklight and the PLC, enabling them to communicate.
For further information www.hms-networks.com

Door firm invests in Salvagnini technology

Assa Abloy Security Doors, a UK division of Assa Abloy, a global specialist in door opening solutions, has invested in a number of new technologies at its Lisburn manufacturing plant in Northern Ireland. Two new Salvagnini systems – an L1X-30 fibre-laser system and a P4lean-3216 panel bender – are helping to enhance the site’s manufacturing capabilities by improving lead times, increasing productivity and reducing environmental impact.

The fibre-laser system – which was installed last month – combines high-speed sheet metal processing with precise cut quality, while the new panel bender will enable the company’s SMARTform technology to fold doors more accurately and quickly. In addition, MAC 2.0 software ensures folding results remain at a consistently high standard.
The panel bender will be able to process 90% of the total door range at Assa Abloy Security Doors.
Having been awarded the ISO 14001 accreditation for environmental management in 2017, the new investments further contribute to this objective. For instance, the consumption of electricity and oil is reduced when using the Salvagnini machines, resulting in lower running costs.
Neil Chambers, production manager at Assa Abloy Security Doors, says: “The new systems have allowed us to streamline production by improving areas of our manufacturing and removing some unwanted processes that were labour intensive and costly. This move reflects our commitment to improving operational efficiencies while investing in sustainable technology. In the near future, we believe these new technologies will positively impact on lead times, product design and overall product quality.”
For further information www.salvagninigroup.com

Aston Martin production returns to Newport Pagnell

Another landmark in Aston Martin’s ‘Second Century Plan’ was achieved last month with production officially returning to the company’s historic Newport Pagnell site. It marks a significant moment in which history has come full circle, with a special run of 25 DB4 GT Continuation cars being built at same site as the original DB4 GTs were made almost 60 years ago. Each car will take approximately 4500 man hours to build.

Since moving to its purpose-built headquarters and production facility at Gaydon in 2003, Aston Martin’s Newport Pagnell premises has been home to Aston Martin Works – heart of the marque’s heritage sales, service, spares and restoration operation. Production of the Mk1 Vanquish ceased in 2007, but since that time countless classic Aston Martins have been restored to their former glory by the Works team.
For further information www.astonmartinworks.com

Large capacity VTLs from Broadbent Stanley

Broadbent Stanley has announced a strategic agency agreement with Radar Industrial, a Taiwan-based manufacturer of CNC VTLs. The agreement will see Broadbent Stanley actively marketing and selling the Radar range in many markets, including the UK, Ireland, Egypt, Africa and the Middle East.

Radar VTLs are available in three model designations: the RAL-12, RAL-16 and RAL-20. The machines offer maximum turning diameters ranging from 1500 to 2400 mm, and turning heights up to 1600 mm – with a maximum workpiece weight of 13,000 kg on the largest machine. All three models come with the Fanuc 0i-TF CNC. As standard, Radar VTLs are equipped with a 12-position tool changer, which can be increased to 18 on the optional M-specification machines, with nine of those positions being capable of handling driven tooling powered by a 15 kW motor (with up to 2400 rpm available for the live tooling).
For further information www.broadbentstanley.co.uk