March 2011 Product Spotlight
A new generation of high-speed motor drives for its programmable dot peen and scribe marking machines has been introduced by Borries Marking Systems. These drives replace the costlier, more complex servo drive systems, which were the existing high-speed alternative for marking situations.
The new markers utilize an enhanced, high-speed stepper motor drive system, which cuts cycle time in half—or more. The drives, developed in response to automotive industry demands for faster production rates (with lower machine cycle times), are exemplified by automotive stamping plants, where marking is done at a rate of 12 characters—at a height of 5 mm—in three seconds.
In addition to the new systems, which reduce cycle times and increase throughput, Borries also offers retrofit packages for existing machines.
Higher speed drives can be installed in these units either in the field—as retrofit kits—or at the Borries factory. This provides users a low-cost solution for increasing marking speeds without the expense of purchasing a completely new machine.
The high-speed drives are capable of being translated into various marking technologies: Scribe Marking, which is suited to almost any three-dimensional, deformable configuration and provides an easily-readable continuous-line mark; Stylus Marking, which uses a fast-vibrating needle technology, producing a minimal force on any three-dimensional material; Dot Matrix Marking, which is similar to the two technologies mentioned above, but produces a visible dotted appearance; and DataMatrix Marking, which produces camera-legible 2D codes (ECC 200 standard) with the same type of tool as the dot matrix.
These high-speed drives are available for the full line of Borries programmable dot peen and scribe machines, including the simplest integrated date stampers to the more complex VIN marking systems.
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Borries
Renishaw's new PH20 probe head will demonstrate at the AeroDef show its unique "head touch" capability for high-speed point capture with minimal CMM movement. With its fast, infinite positioning capability, it increases touch-trigger CMM inspection throughput up to three times.
Designed for use with the industry-standard TP20 touch-trigger probe, the new PH20 head brings 5-axis inspection capability to smaller CMMs for the first time by optimizing the working volume of the measurement platform. The PH20 is available for new CMMs, as well as retrofit machines using shank or quill mounting. It can use most existing inspection programs for indexing heads without modification, and requires no compressed air.
"REVO® 5-axis scanning measurement set the benchmark for performance on larger CMMs, but the PH20 is equally significant because it makes 5-axis inspection practical and accessible for almost all CMMS," said Denis Zayia, Renishaw National Sales Manager. "Unlike conventional touch-trigger measurement which relies on speeding up the movement of the CMM's 3 axes to measure quickly, PH20 uses head motion to minimize CMM movement – and the associated dynamic errors – at higher measurement speeds. It also enhances inspection efficiency with adaptive positioning to accommodate part misalignment and provide optimal feature access."
The PH20 probe head offers additional time savings with synchronized motion of the head and CMM between measurements. Its unique rapid "inferred calibration" technique determines head orientation and probe position in a single operation, allowing subsequent measurements at any head angle.
PH20 incorporates the TP20 touch-trigger probe, affording access to a range of proven probe modules and wide selection of trigger forces, directional sensing options and extensions to meet application requirements. Current users of TP20 systems can upgrade to the PH20 and utilize all existing modules, with the exception of the extended-force module.
The PH20 system uses a Renishaw UCC controller, which provides connection to existing metrology and application software through the established I++ protocol. As a retrofit package, the PH20 comes with the controller and Renishaw's MODUS™ metrology software for a fully integrated solution.
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Renishaw
MAG IAS, LLC's new HyperMach® H-series profiler sets the industry standard for high output machining of large monolithic aluminum or titanium aerospace parts. H-series horizontal machining centers offer a wide choice of spindle speeds and torques to match material requirements for high-speed machining of aluminum, high-torque titanium cutting with the HyperMach GTi, or the wide-range capabilities of the HyperMach Ti, with increased stiffness and a high-torque motorized spindle for applications that require machining both aluminum and titanium.
The 5-axis HyperMach H-Series turns the typical profiler concept on its side in a fixed-column, traveling table arrangement available in 2 m x 4, 5, 6, 7 or 8 m. A moving column configuration is available to handle single or nested parts up to 2 m x 20 m. All HyperMach H-series machines are available with optional 3 m wide pallets, increasing the Y-axis travel to 3200 mm (126 in) for range to machine larger parts such as wing ribs, spars, bulkheads and fuselage frames.
For machining aluminum, the H-series features a standard high-speed 30,000 rpm/60 kW/29 Nm spindle. An optional 20,000 rpm/85 kW/85 Nm spindle is also available. The GTi model uses an HSK100A 6000 rpm/52 kW/854 Nm high-torque geared spindle to machine titanium and other hard metals, while the new HyperMach Ti wide-range model handles applications that require machining both aluminum and titanium with a hearty 12,000 rpm/60 kW/250 Nm spindle. The Ti delivers a combination of moderate speed and increased power to enhance cutting performance to machine a broader range of materials for manufacturing flexibility.
All HyperMach H-Series machines feature a patented full-portal, open-center design, allowing chips to fall through to a high-volume conveyor to avoid chip re-cutting and the need for a blow-off attendant, further improving productivity by reducing labor and parasitic time to keep the machine clean. Programmable, variable high-pressure through-spindle and external coolant system is a standard feature on the GTi version. Pallet load can be from the right or left side, and the chip conveyor can be configured to discharge in either direction. Installation is on a flat floor, which reduces the cost and time required for installation by avoiding the need for pits and expensive multi-step foundations. This makes future reconfiguration of the plant layout easy. Combined with MAG’s CINCRON® cell automation modules, the H-series design allows virtually an infinite number of material handling and cell configurations for extremely flexible multi-machine and multi-pallet part manufacturing.
The HyperMach machine design is covered by four patents, including one for the rigid four-point lockup between the column and table base, which provides consistent stiffness and improved accuracy throughout the work zone. A second patent covers the "flight deck" ergonomics of the operator station. Its layout permits visual monitoring of the machine's HMI, the work zone, the tool change process, tool in the ready position, the tool magazine itself, and utilities panel, as well as immediate physical access to the work zone. A third patent covers maintenance and reliability issues – motors and drives are on the exterior of the machine, away from workzone contamination, and critical drive components, such as ways, bearings, ballscrews, and feedback scales, can be accessed and serviced from the exterior of the machine. A fourth patent covers the pallet handling system, which allows a pallet to be loaded from either or both sides of the machine without any modification to the system, permitting a wide variety of work handling configurations without modification to the machine.
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MAG
United Grinding Technologies (UGT) announces the new Studer S41 CNC universal cylindrical grinder, featuring outstanding technology and cost-effectiveness. The machine grinds with superior precision and at extreme metal removal rates. In addition, the longitudinal and cross slide, as well as the swivel axis for the wheelhead, feature electric direct drives, which move to the working position swiftly and precisely.
Extremely Rigid Machine Bed and Maintenance-Free Guide System
The Granitan® S103 machine bed provides a very solid, rigid and thermally stable machine ideal for absorbing the high forces that occur during grinding with high metal removal rates.
Its remarkable thermal behavior allows the machine to operate with consistently high precision even with changing ambient temperatures. Its high rigidity and excellent damping provide the basic prerequisites for outstanding surface quality of ground parts and long grinding wheel lifetimes.
The new StuderGuide® guideway system ensures high precision of the longitudinal and cross slides when both stationary and during movement. The StuderGuide® system uses the advantages of hydrostatic and hydrodynamic guide systems and avoids the slip-stick effect or floating of the slide. Also contributing to the machine's high precision is the fact that the solid gray cast iron longitudinal and cross slides rest completely on the guideways over the entire travel. With this maintenance-free guide system, Studer guarantees a straightness of < 0.0001” over a measured length of 37.4”.
Electric Direct Drives Increase Speed and Precision
The longitudinal slide (Z-axis) has a ground work table which carries the workhead and tailstock as well as additional accessories and devices. Longitudinal and cross slides are moved by linear direct drives and, with up to 66 ft per minute, achieve four times higher travel speeds and axis system resolutions of ten nanometers. This enables high-precision and highly efficient grinding, as well as making a huge contribution to reducing auxiliary times.
The swivel movement of the turret wheelhead (B-axis) is also powered by a direct drive. It swivels the turret wheelhead around three times faster and positions the new grinding wheels in a much shorter time with a positioning resolution of 0.00005 deg. The positioning is therefore twice as precise as with the predecessor machine. The elimination of the Hirth gear, which fixed the wheelhead in position on the predecessor machine, also contributes to faster positioning.
Machine Variants Expand Market Potential for Users
The S41 also has a number of advantageous characteristics which enable the user to cover an extended workpiece range, and thus a broader market range. This includes greater heights of centers and distances between centers, allowing workpieces with weights of up to 551 lb. to be machined.
Up to four external grinding wheels or three internal grinding spindles enable over 30 grinding head combinations. The grinding wheels are now driven by motor spindles rather than belt drives; the machine can be equipped with motor spindles for high speed grinding (HSG); internal grinding spindles with speeds from 6000 to 120,000 rpm can be used; and automatic balancing systems and frequency converters for each external grinding spindle allow grinding processes to be matched to the respective conditions of use. Wheelhead variants are also available with a vertical spindle for grinding keyways or with a traverse grinding axis for traverse grinding of internal tapers.
Simple Operation and Integration Into Complete Manufacturing Processes
Fatigue-free working and straightforward machine operation are important components for consistently high quality. For this reason, optimized ergonomics were one of the developers' priorities. For instance, hoses and cables have largely disappeared from the work area of the machine. Grinding wheel change is performed with a single Allen wrench, and a special small crane is integrated into the machine, so that heavier grinding wheels do not have to be lifted manually.
The Fanuc 31i-A machine control with integrated PC operates with the StuderGRIND software specially developed for the grinding processes, and the StuderWIN operator interface. A 15” touch screen and ergonomically arranged controls are available and an additional manual control unit facilitates setup of the grinding processes. A free-standing operating panel with adjustable height is also available.
UGT and Studer recognize that the efficient grinding of workpieces requires process-optimized solutions. For this reason, the S41 includes an integrated quality control system based on continuous measurement, re-measurement, recording and correction. In addition, grinding of workpieces with modular peripheral equipment such as loading/unloading systems can be seamlessly integrated into the complete production process. The automation systems of the peripheral equipment communicate with the S41 by means of standard interfaces, so that even complex handling tasks can be carried out.
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United Grinding
ZPS America LLC, Indianapolis, IN, announces its newest cam-driven 8-spindle automatic lathe with 32 or 42 mm bar capacity. The rigid, European-built machine is designed for continuous or series production of precision turned parts. Solid base casting ensures maximum rigidity and stability.
ZPS' line of cam-driven multispindles, can accomplish a wide variety of precision metalcutting operations very quickly, consistently, and accurately. The machine includes eight frontal slides with up to 110 working strokes, and eight cross slides plus four compound slides with clamping, and bar stop in the 8th station. An independent cam controls each slide. Stroke is adjustable on the rocker arm of the corresponding drive. Machines in the range are provided with different spindle speed ranges, depending on material type and size.
The ZPS machines are designed for precision, safety, and long, reliable operation. Four safety clutches prevent the slides from overloading. Spindle drum locking is accomplished by a triad of rims with spur gearing. A bar stock guide is standard, and the machine can also include automatic bar loaders and bar magazines for long, unattended operation.
Spindles are driven by SIMODRIVE Siemens variable speed motors and the machines are controlled through a Siemens S7.
To accomplish nearly any operation, the machines can be provided with a wide range of optional equipment, including NC drive of the pick-up spindle, bar stock feeding and clamping in the fourth station, attachments for high-speed drilling, reaming, tapping and broaching, and multi-spindle drilling heads on the frontal slides.
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ZPS
Cable carrier expert, igus®, has launched Guidelok Slimline (SL), a system designed to safely guide cables at heights up to 262 feet.
Guidelok SL is designed for vertical cable carrier applications operating on storage-and-retrieval units in high-bay warehouses, as well as elevators and material-handling equipment. Compact and easy to install, even when being retrofitted into an existing system, it allows safe energy and data supply in warehouses, deep-freeze storage units, crane systems, or power stations.
Vertical cable carrier applications are reaching higher heights and faster speeds and accelerations than ever before. In such applications, it is possible for a cable carrier supplying power and data to swing out of its normal area of operation. If it then collides with a metal beam or pallets, cable carrier and cable damage can occur.
Normally a hanging cable carrier is guided vertically in an enclosed trough system. With Guidelok SL, these types of trough systems can be eliminated and costs reduced by about 80 percent as a result. The cable carrier is also easier to maintain, because it is not in a continuous trough. Guidelok SL locks the cable carrier into position using a unique design.
The cable carrier travels freely and safely between small sections of easy-to-install steel trough. These units feature two large control buttons which are pushed back, as the radius of the cable carrier passes between them, and then move back into position where they hold the hanging length in place. This not only provides operational safety, but also reduces noise due to the smooth, controlled motion.
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igus