THIS WEEK’S HIGHLIGHTS

Ergonomic bicycle assembly boosts productivity

At Rose Bikes in Bocholt, 120 different bicycle and e-bike models weighing between 5 and 28 kg are ergonomically manufactured on six flow lines with the help of flexible Bike Promobil assembly carts produced by Roemheld. The result of a joint development project between the two German companies, the cart is now available worldwide, including in the UKand Ireland through Roemheld UK.

A shortage of potential employees in the Bocholt area, near the Dutch border, prompted family-run Rose to look for a production solution to meet increasing demand for its products. Instead of producing on a conveyor belt, as is the case with other bicycle manufacturers, Rose chose the flow line option when it opened its new factory in 2020.

Stefan Strauss, production manager at Rose, says: “The conveyor belt is too inflexible and tends to stress employees. Flow line production is much more operator friendly, so it’s easier to find new staff and train them. Work should be fun. We don’t have anyone watching with a stopwatch and staff take turns at different stations to maintain their interest.”

Strauss originally wanted to design and build an assembly aid himself, but did not have enough time. So in 2020, Roemheld offered an early version of the cart, but it was too big, heavy, inflexible and expensive. A development partnership took shape to address these issues. One elegant idea was to hold the bike not by gripping on the frame but by placing an insert into the seat tube. Adapter sleeves accommodate different tube diameters on the various bike models, making the clamping process universal across the whole range. Rose Bikes now has 130 Bike Promobil assembly carts from Roemheld.
For further information www.roemheld.co.uk

Sales manager appointment

Machine tool supplier TW Ward CNC Machinery (Ward CNC) has appointed Kasra Mehraky as its sales manager for the Midlands and southwest regions.With over 12 years of experience in the CNC machine tool industry, Mehraky brings with him a proven track record in a variety of market sectors, including automotive, aerospace, energy and medical. He started his career with CNC machine design and manufacturing and, over the years, has moved towards consultancy and sales. He will now promote Ward CNC’s wide portfolio of machines,including the Hyundai-Wia, Hartford, Soraluce, Takisawa and Hankook brands.
For further information www.wardcnc.com

MACH Machine Tools unveils knee-mill series

MACH Machine Tools, part of the Vigilance Group and a supplier of CNC andmanual machines, is introducing a range of flexible, high-productivity CNC knee mills, comprising the MACH MDS 700-4T and MACH MDS 900-4T models. Both are equipped with the three-axis DynaPath WinDelta control and feature integrated, four-station automatic tool changers positioned around their directly driven BT40 (5000 rpm) spindles. The machines come with large worktables (up to 1470x 320mm) that support loads up to 220kg.

The DynaPath control, available on all new CNC lathes, toolroom mills and machining centres from MACH Machine Tools, is one of the most widely used control systems in the world.Used extensively in the US and Far East for over 50 years, MACH Machine Tools says that the control is flexible, versatile and easy-to-use – providing customers with simple-to-understand navigation and operation screens, and accommodating ISO and conversational programming on the same platform.

With online CAD editing capabilities, semi-auto functions and DRO operation, as well as the ability to run programs of unlimited size, top-of-the-line dynamic motion control and the system’s revolutionary 24/7 remote diagnostic control – the company says that it is clear and understandable why the DynaPath control is becoming the preferred option for experienced and aspiring manufacturers.

Says Dave Andrew, managing director of the Vigilance Group:“Knee-mill technology has come on leaps and bounds over the past few years and we are at the head of these developments.Our MDS 700-4T and MDS 900-4T machines, equipped with the DynaPath control system and integrated tool changers, demonstrate that toolroom mills that deliver increased and improved productivity, flexibility and process efficiencies.”
For further information www.machmt.co.uk

GM CNC unveils heavy-duty machining centre

According to GM CNC,unparalleled stability and rigidity are the foundation blocks of the new VictorVcenter G-series range, which offers high material removal rates for applications where manufacturers are processing particularly challenging materials.

The three-axis G series is available in a trio of sizes to meet diverse demands. Unlike its competitors in the mid-sized VMC market segment, the G-series incorporates a meehanite casting with a wide base A-frame design, a wide span column, four boxways and screw removers with a wide boxway.

Victor’s smaller G105 provides X, Y and Z-axis travel of 1050 x 600 x 600mm,stretching to a spacious 1650 x 850 x 900mm on the largest G165. This freedom of movement is matched by accommodating bed sizes of 1100 x 600mm (G105), 1400 x 700mm (G135) and 1700 x 800mm (G165). Furthermore, the robust nature of the range permits the loading of components up to 1200, 2200 and 2500kg respectively.

Common features on all three machines include a powerful gearhead spindle design that generates a power output of 18.5 kW with a torque level of 498Nm. Developed, manufactured and built in-house by Victor, the 6000rpm gearhead design spindle retains maximum torque levels throughout the speed range. Thisfactor makes the Vcenter series a good choice for machining hard materials and exotic alloys with high material removal rates. In addition, the G-series incorporates a Big-Plus BBT-50 spindle taper that guarantees dual face and taper spindle contact.

The Victor Vcenter has an automatic tool change unit with 24-tool capacity and the option for 32 or 40 tool positions; all positions can accommodate tools up to 15kg.
For further information www.gm-cnc.com

Subcontractor gets into gear with Quaser machine

Leicestershire-based Sovereign Gears has recently invested in a Quaser MF400UH five-axis machining centre that follows on from three Nakamura turning centres also purchased from the Engineering Technology Group (ETG).

Director Ryan Spring says: “The majority of our work is 1- and 2-off bespoke gears, as well as jigs and kits for holding, assembling and working with the gears. Unfortunately, with so many complex forms, most of our milling work requires two, three or four set-ups, and this can take a lot of time and slow down our throughput. We bought the Quaser MF400UH with Open Mind’shyperMILL CAM software, also supplied via ETG to reduce our set-ups. The Quaser is our first five-axis machine, but we’re already seeing huge benefits.”

Previously, set-up time were frequently in the order of 4-5 hours, but the Quaser has instantly eliminated 75% of this time, and with only a single set-up required for five-sided machining.The precision of each component is subsequently improved.

“As a small business, it’s imperative that we maximise the productivity of both our machine tools and our staff,” says Spring.“By having the Quaser machine and reducing our set-ups, we’re freeing-up the capacity of two employees. Instead of spending excessive hours repeatedly setting up three-axis machines, staff can be allocated to other tasks.”

He adds: “Since having the Quaser, we’ve improved our ability to machine complex forms and this has ultimately won us new business that previously, we would have turned away. The ability to increase the type of work that we can machine, such as round gear teeth, challenging chamfers, forms and keyways has enabled us to increase our customer base and our offering to those customers.”
For further information www.engtechgroup.com