Sil-Pro has announced the appointment of Kevin Carver to the position of president. He succeeds his father, Lee Carver, who will continue on with company in a realigned role as part of the company's strategic management transition process. Lee Carver, one of the founders of Sil-Pro in 1998, announced the management changes and said that his son's appointment will provide continuity to Sil-Pro's rapid growth as a leading supplier of precision silicone components and assemblies to the medical device community.
Lee Carver said as part of the management transition, he will continue on with the company and focus primarily on Sil-Pro's customer and supplier relationship programs while turning over company-wide management to his son.
'With over four very successful years in his previous position at Sil-Pro as vice president, Kevin is ideally qualified to move into the position of president,' stated Lee Carver.
'He served the company well as vice president and was responsible for strengthening Sil-Pro's management team.
He guided the growth of the company's highly automated molding, part slitting and removal, and electronic vision inspection process capabilities.
He played an integral role in the tripling of Sil-Pro's sales volume and expansion of our customer base to include dozens of the world's leading medical device manufacturers.' Sil-Pro currently has over 100 employees with annual sales exceeding 8 million dollars.
The company is highly specialized in its field with ISO 9001:2000 certification providing CAD product development and class 10,000 cleanroom molding.
This includes fully automated molding cells and complete assembly services.
Included in Sil-Pro's capabilities are liquid silicone molding, gum stock molding, and bonding silicone parts to plastics, metal and other silicone parts using medical grade adhesives.
Sil-Pro's bonding and assembly capabilities include robotic equipment and part specific fixturing to aid in the manufacturing process.
Prior to joining Sil-Pro, Kevin Carver was founder and president of Acrylium, a successful contract fabricating manufacturer, which he sold in order to join Sil-Pro.
Thursday, February 15, 2007
Composites components for Airbus A400M
An expert, international team has designed, prototyped, and successfully tested a composite fuel tank access cover (FTAC) for the new Airbus A400M military aircraft.
The various members of the team have brought to the project, skills in composites components design, materials technology, process tooling and composites manufacture, to ensure that the innovative finished product totally complies with the Airbus specification, especially in terms of its light weight, its damage resistance and cost-effectiveness. Brookhouse has itself worked closely with Airbus and bae systems for many years on projects from the Canberra bomber to the JSF and on various aircraft within the Airbus series.
However, in order to win the contract for the design and manufacture of the Fuel Tank Access Cover for the next generation of composite wings for the A400M, the Darwen company brought together a team comprising Sener, a Spanish company, who have an expertise in aeronautical design composites structures, Cytec, a US-based carbon fibre company, and Degussa, who manufacture a leading brand of core material for composite structures.
This team then designed, built and tested prototype models prior to the contract award to demonstrate that they had in principle a design that that could fulfil the stringent A400M design requirements.
All pre-production tooling required to support this task was manufactured by Brookhouse Tooling.
The qualification programme is now well advanced with the delivery of the production Fuel Tank Accces Covers scheduled to be in the last quarter of this year, in line with the schedule requirements.
The effective handling and efficient completion of this exciting project is a demonstration of Brookhouse's ability to offer a comprehensive, design/ make packaged composite product.
Acting as overall project manager, Brookhouse can supply aerospace companies with the capability to take responsibility and assume the risk for complete packages of composites development and manufacture work.
Working with global partners, it can develop the materials and techniques to design, manufacture and test prototype composite components and it can then design and manufacture the required production tooling before producing the finished components in-house.
As a result, Brookhouse is ideally placed to help aircraft manufacturers meet the challenges and opportunities afforded by composites components and structures.
The various members of the team have brought to the project, skills in composites components design, materials technology, process tooling and composites manufacture, to ensure that the innovative finished product totally complies with the Airbus specification, especially in terms of its light weight, its damage resistance and cost-effectiveness. Brookhouse has itself worked closely with Airbus and bae systems for many years on projects from the Canberra bomber to the JSF and on various aircraft within the Airbus series.
However, in order to win the contract for the design and manufacture of the Fuel Tank Access Cover for the next generation of composite wings for the A400M, the Darwen company brought together a team comprising Sener, a Spanish company, who have an expertise in aeronautical design composites structures, Cytec, a US-based carbon fibre company, and Degussa, who manufacture a leading brand of core material for composite structures.
This team then designed, built and tested prototype models prior to the contract award to demonstrate that they had in principle a design that that could fulfil the stringent A400M design requirements.
All pre-production tooling required to support this task was manufactured by Brookhouse Tooling.
The qualification programme is now well advanced with the delivery of the production Fuel Tank Accces Covers scheduled to be in the last quarter of this year, in line with the schedule requirements.
The effective handling and efficient completion of this exciting project is a demonstration of Brookhouse's ability to offer a comprehensive, design/ make packaged composite product.
Acting as overall project manager, Brookhouse can supply aerospace companies with the capability to take responsibility and assume the risk for complete packages of composites development and manufacture work.
Working with global partners, it can develop the materials and techniques to design, manufacture and test prototype composite components and it can then design and manufacture the required production tooling before producing the finished components in-house.
As a result, Brookhouse is ideally placed to help aircraft manufacturers meet the challenges and opportunities afforded by composites components and structures.
Design capability expanded at contractor
Brookhouse has significantly increased its in-house design capacity with the addition of four more Catia seats at its Darwen manufacturing site. The extra design capability has been created to help the company meet increasing demands from the aerospace sector for composites mould tooling. In terms of volume, Brookhouse is Europe's leading independent supplier of mould tooling and its totally self-sufficient, multi-disciplined design department offers extensive experience and expertise in the production of 2D and 3D computer-aided designs using advanced software packages.
It has particular experience in the application of Catia, the preferred aerospace software, and the new seats comprise two Catia V4.2.4 and two Catia 5.14 seats, increasing the number of in-house Catia seats to twelve.
In addition, the company can call on more than 30 Catia contract design engineers, working off site.
The design department uses the latest Sun operating systems with a Fast Transfer Protocol server and high quality translation software packages.
It can also send and receive data by CD, tape and e-mail and has the ability to transfer data internally via electronic links to shop-floor machining centres.
The increase in design capacity continues a programme of focused capital investment, covering all aspects of Brookhouse's business from design and production of tooling to manufacture, assembly and finishing of composite components.
It also complements the significant investments that the company has made in quality, people and process technology which will help Brookhouse to maintain its dedicated concentration on its core aerospace business to provide its customers with innovative and cost-efficient solutions to composites problems.
It has particular experience in the application of Catia, the preferred aerospace software, and the new seats comprise two Catia V4.2.4 and two Catia 5.14 seats, increasing the number of in-house Catia seats to twelve.
In addition, the company can call on more than 30 Catia contract design engineers, working off site.
The design department uses the latest Sun operating systems with a Fast Transfer Protocol server and high quality translation software packages.
It can also send and receive data by CD, tape and e-mail and has the ability to transfer data internally via electronic links to shop-floor machining centres.
The increase in design capacity continues a programme of focused capital investment, covering all aspects of Brookhouse's business from design and production of tooling to manufacture, assembly and finishing of composite components.
It also complements the significant investments that the company has made in quality, people and process technology which will help Brookhouse to maintain its dedicated concentration on its core aerospace business to provide its customers with innovative and cost-efficient solutions to composites problems.
5-axis CNC routing and trimming machine
A new 5-axis CNC routing and trimming machine has been installed at Brookhouse to further improve the UK's largest independent composites assembly company's finishing expertise and capabilities.
The installation is one of a series of programmed capital investments to help Brookhouse meet the increasing global trend towards composite components and structures in the aerospace sector. The new CMS Ares Machining Centre will be used primarily for work on flying composite components, which have formerly been routed and trimmed by hand, using hard-edged jigs and fixtures.
It features two trimming tables, so that one table can be loaded while the other is in operation.
An 8-station tool rack, mounted on the carriage of the X-axis allows multiple operations and a 400MHz microprocessor can control up to 4 simultaneous processes and 8 axes, with dynamic pre-calculation of movement and controlled acceleration/deceleration to ensure very high quality finishing.
Other recent investments in Brookhouse's composites finishing facilities have included the introduction of an additional paint shop, while there has been comprehensive refurbishment of its extensive cleanroom capacity.
The company has also added a sixth, high specification autoclave to its already comprehensive autoclave capacity.
Brookhouse's tooling resources have been enhanced with two more CNC machining centres and further Catia seats.
The company recently gained Nadcap approval and is continually extending the scope and capability of its 'captive laboratory' status to new and existing customers.
In addition to its conventional composites manufacturing and repair expertise, Brookhouse is also developing 'out-of-autoclave' technologies for the aerospace sector.
These can often be applied to provide cost effective solutions to composites problems.
Brookhouse is totally focused on the aerospace sector.
It offers design and manufacturing for composites tooling, a facility for the repair of composite components and a capability for design, prototyping, manufacture, testing and finishing of complete composite components.
As a result, Brookhouse can offer its worldwide aerospace customers a global facility to take responsibility for complete packages of composites' development and manufacture projects.
The installation is one of a series of programmed capital investments to help Brookhouse meet the increasing global trend towards composite components and structures in the aerospace sector. The new CMS Ares Machining Centre will be used primarily for work on flying composite components, which have formerly been routed and trimmed by hand, using hard-edged jigs and fixtures.
It features two trimming tables, so that one table can be loaded while the other is in operation.
An 8-station tool rack, mounted on the carriage of the X-axis allows multiple operations and a 400MHz microprocessor can control up to 4 simultaneous processes and 8 axes, with dynamic pre-calculation of movement and controlled acceleration/deceleration to ensure very high quality finishing.
Other recent investments in Brookhouse's composites finishing facilities have included the introduction of an additional paint shop, while there has been comprehensive refurbishment of its extensive cleanroom capacity.
The company has also added a sixth, high specification autoclave to its already comprehensive autoclave capacity.
Brookhouse's tooling resources have been enhanced with two more CNC machining centres and further Catia seats.
The company recently gained Nadcap approval and is continually extending the scope and capability of its 'captive laboratory' status to new and existing customers.
In addition to its conventional composites manufacturing and repair expertise, Brookhouse is also developing 'out-of-autoclave' technologies for the aerospace sector.
These can often be applied to provide cost effective solutions to composites problems.
Brookhouse is totally focused on the aerospace sector.
It offers design and manufacturing for composites tooling, a facility for the repair of composite components and a capability for design, prototyping, manufacture, testing and finishing of complete composite components.
As a result, Brookhouse can offer its worldwide aerospace customers a global facility to take responsibility for complete packages of composites' development and manufacture projects.
Mould tools and mouldings for medical equipment
The console housing and service trolley mould tools and mouldings for PlasmaJet, a new neutral plasma coagulator being developed by Plasma Surgical, are being manufactured by Midas Pattern.
The console housing and service trolley (front panel) mould tools and mouldings for PlasmaJet, a revolutionary new neutral plasma coagulator being developed by Plasma Surgical, are being manufactured by Midas Pattern following a competitive tender process. PlasmaJet consists of an electronic console mounted on a portable, floor standing service trolley that also houses the argon tank. Central to the success of PlasmaJet as a manufacturing project were the two largest mouldings - the console housing and service trolley front panel.
The appointed moulding company tasked with producing these parts had to fulfil many prerequisites, including: the ability to work closely with the client and its design agency; meet strict deadlines; manufacture tooling and moulded components of the highest quality; and, importantly, provide the most competitive quotation.
Midas Pattern Company won the contract based on its ability to match these requirements.
To help accelerate the development of its products, Plasma Surgical retains Greaves Best Design as its technical adviser.
Based at Lockerley in Hampshire, Greaves Best is a product and engineering design company that has been involved with PlasmaJet from the outset.
'Initially we produced 3D CAD models,' explains company partner Mike Best.
'Then we produced what we thought was the largest single piece SLA model in the UK at that time.
A set of rubber tools followed, which we shot with PU and produced six prototypes sets so we could prove-out the process.
Once we had done this we needed the input of a PU moulder to move the development to the next stage: the manufacture of production mould tools and the moulding of an initial 50 sets of parts.' Greaves Best has known of Midas Pattern Company since the mid 1990s and had no hesitation in including the Bedford company in a shortlist of companies invited to tender.
All Midas Pattern Company PU mouldings are manufactured using the company's own, specifically developed 'metallised' resin injection moulding (MRIM) process.
A metal-filled composite resin mould tool is manufactured directly from a CNC machined master model or pattern: this technique ensures the most complex of forms can be produced accurately and very quickly.
Complex forms can be generated using various coring, side action, and even multi part mould tool techniques.
Square faces, undercuts, metal inserts, bushes and features that would normally require machining can all be cast into Midas Pattern Company mouldings.
ISO9001:2000 accredited Midas Pattern Company believes that the highest quality rigid polyurethane mouldings can only be produced from tooling of equal quality.
By manufacturing accurate, hard wearing tooling Midas Pattern Company can offer ongoing repeatability without mould tool deterioration.
In fact the company guarantees its MRIM tooling for the life of the product.
Since being commissioned by Greaves Best to produce PlasmaJet mouldings, Midas Pattern Company has completed the tooling manufacture and to date has delivered further sets of parts - on time.
'Midas Pattern Company has always delivered on time,' confirms Mr Best.
'As a company I find them very responsive and I enjoy dealing them.' 'PlasmaJet has massive potential,' concludes Mr Best, 'but this potential could not be realised without the valuable input of Plasma Surgical's partner suppliers.
Midas Pattern Company have fulfilled our expectations and helped ensure this product is set to have a massive impact on the medical industry.
The technology deployed by Midas Pattern Company and the whole hearted support of the company's engineers have been of enormous benefit to Plasma Surgical.'
The console housing and service trolley (front panel) mould tools and mouldings for PlasmaJet, a revolutionary new neutral plasma coagulator being developed by Plasma Surgical, are being manufactured by Midas Pattern following a competitive tender process. PlasmaJet consists of an electronic console mounted on a portable, floor standing service trolley that also houses the argon tank. Central to the success of PlasmaJet as a manufacturing project were the two largest mouldings - the console housing and service trolley front panel.
The appointed moulding company tasked with producing these parts had to fulfil many prerequisites, including: the ability to work closely with the client and its design agency; meet strict deadlines; manufacture tooling and moulded components of the highest quality; and, importantly, provide the most competitive quotation.
Midas Pattern Company won the contract based on its ability to match these requirements.
To help accelerate the development of its products, Plasma Surgical retains Greaves Best Design as its technical adviser.
Based at Lockerley in Hampshire, Greaves Best is a product and engineering design company that has been involved with PlasmaJet from the outset.
'Initially we produced 3D CAD models,' explains company partner Mike Best.
'Then we produced what we thought was the largest single piece SLA model in the UK at that time.
A set of rubber tools followed, which we shot with PU and produced six prototypes sets so we could prove-out the process.
Once we had done this we needed the input of a PU moulder to move the development to the next stage: the manufacture of production mould tools and the moulding of an initial 50 sets of parts.' Greaves Best has known of Midas Pattern Company since the mid 1990s and had no hesitation in including the Bedford company in a shortlist of companies invited to tender.
All Midas Pattern Company PU mouldings are manufactured using the company's own, specifically developed 'metallised' resin injection moulding (MRIM) process.
A metal-filled composite resin mould tool is manufactured directly from a CNC machined master model or pattern: this technique ensures the most complex of forms can be produced accurately and very quickly.
Complex forms can be generated using various coring, side action, and even multi part mould tool techniques.
Square faces, undercuts, metal inserts, bushes and features that would normally require machining can all be cast into Midas Pattern Company mouldings.
ISO9001:2000 accredited Midas Pattern Company believes that the highest quality rigid polyurethane mouldings can only be produced from tooling of equal quality.
By manufacturing accurate, hard wearing tooling Midas Pattern Company can offer ongoing repeatability without mould tool deterioration.
In fact the company guarantees its MRIM tooling for the life of the product.
Since being commissioned by Greaves Best to produce PlasmaJet mouldings, Midas Pattern Company has completed the tooling manufacture and to date has delivered further sets of parts - on time.
'Midas Pattern Company has always delivered on time,' confirms Mr Best.
'As a company I find them very responsive and I enjoy dealing them.' 'PlasmaJet has massive potential,' concludes Mr Best, 'but this potential could not be realised without the valuable input of Plasma Surgical's partner suppliers.
Midas Pattern Company have fulfilled our expectations and helped ensure this product is set to have a massive impact on the medical industry.
The technology deployed by Midas Pattern Company and the whole hearted support of the company's engineers have been of enormous benefit to Plasma Surgical.'
Saturday, February 10, 2007
Real-time 'point-cloud' inspection to be shown
A novel measurement system allows real-time, point cloud inspection of parts allows faster, more detailed inspection against CAD models by using a laser to collect large amounts of data.
Delcam will join forces with Cimcore and Perceptron to show a unique system allowing real-time, point cloud inspection of parts at the Russian Automotive Industry Forum to be held in Moscow from 13th -15th March 2006. The combination of Delcam's PowerINSPECT inspection software, the Cimcore inspection arm and the Perceptron laser head allows faster, more detailed inspection against CAD models by using a laser to collect the data. The use of a laser for inspection allows rapid collection of huge amounts of data and so is ideal for larger components and the associated tooling.
It also avoids any contact with the part that might cause marking of sensitive surfaces.
Using PowerINSPECT to analyse data produced from a Perceptron head fitted to a Cimcore arm gives the additional ability to undertake detailed real-time inspection, for example on a production line, so that any errors can be spotted more quickly and corrected at lower cost.
The main application of this approach is expected to be in the inspection of large sheet metal components, such as automotive bodywork.
These parts need to be produced to a high level of accuracy, particularly the external panels that must have a high quality finish.
It is also essential to ensure that they fit together successfully - an especially important factor when using robots for assembly and welding operations.
The combined Delcam/Cimcore/Perceptron solution is capable of collecting more than 20,000 points/s.
It allows far more detailed inspection of both geometric and surface features than would be practical with a physical probe.
Fitting the laser to a portable and flexible inspection arm ensures that data can be collected from all areas of the component in a single operation.
PowerINSPECT offers rapid methods for easy analysis of this large volume of data.
A filter can be applied to the points so that only those out of tolerance are displayed on the screen or included in the report.
Alternatively, the PowerINSPECT coloured dots, which indicate whether the point is in tolerance, above tolerance or below tolerance, can be used to produce what is effectively an instant colour map of the accuracy of the component.
The larger volume of data, together with the speed and ease of interpretation of the results, means that any trends in the measurements can be identified much earlier, possibly even before the parts have moved out of tolerance.
Any problem components can be removed from the line before any further work is completed on them.
Subtle defects across the whole of the part, such as a twist or warp in the surface, can be identified more easily with point cloud data than is possible with a series of discrete measurements.
Similarly, any drift in accuracy, for example as a result of worn tooling, can be identified before large numbers of defective items have been produced.
All data collected can be used for more detailed off-line analysis and reporting with PowerINSPECT's wide range of editing options.
Delcam will join forces with Cimcore and Perceptron to show a unique system allowing real-time, point cloud inspection of parts at the Russian Automotive Industry Forum to be held in Moscow from 13th -15th March 2006. The combination of Delcam's PowerINSPECT inspection software, the Cimcore inspection arm and the Perceptron laser head allows faster, more detailed inspection against CAD models by using a laser to collect the data. The use of a laser for inspection allows rapid collection of huge amounts of data and so is ideal for larger components and the associated tooling.
It also avoids any contact with the part that might cause marking of sensitive surfaces.
Using PowerINSPECT to analyse data produced from a Perceptron head fitted to a Cimcore arm gives the additional ability to undertake detailed real-time inspection, for example on a production line, so that any errors can be spotted more quickly and corrected at lower cost.
The main application of this approach is expected to be in the inspection of large sheet metal components, such as automotive bodywork.
These parts need to be produced to a high level of accuracy, particularly the external panels that must have a high quality finish.
It is also essential to ensure that they fit together successfully - an especially important factor when using robots for assembly and welding operations.
The combined Delcam/Cimcore/Perceptron solution is capable of collecting more than 20,000 points/s.
It allows far more detailed inspection of both geometric and surface features than would be practical with a physical probe.
Fitting the laser to a portable and flexible inspection arm ensures that data can be collected from all areas of the component in a single operation.
PowerINSPECT offers rapid methods for easy analysis of this large volume of data.
A filter can be applied to the points so that only those out of tolerance are displayed on the screen or included in the report.
Alternatively, the PowerINSPECT coloured dots, which indicate whether the point is in tolerance, above tolerance or below tolerance, can be used to produce what is effectively an instant colour map of the accuracy of the component.
The larger volume of data, together with the speed and ease of interpretation of the results, means that any trends in the measurements can be identified much earlier, possibly even before the parts have moved out of tolerance.
Any problem components can be removed from the line before any further work is completed on them.
Subtle defects across the whole of the part, such as a twist or warp in the surface, can be identified more easily with point cloud data than is possible with a series of discrete measurements.
Similarly, any drift in accuracy, for example as a result of worn tooling, can be identified before large numbers of defective items have been produced.
All data collected can be used for more detailed off-line analysis and reporting with PowerINSPECT's wide range of editing options.
660nm laser diode module is very stable
A 660nm laser diode module with a very high, very stable output power of 70mW and adjustable AR coated glass optics is designed for machine vision applications.
UK optoelectronics device manufacturer and laser diode specialist, Photonic Products, has launched a new 660nm laser diode module with a very high, very stable output power of 70mW and adjustable AR coated glass optics. The 660nm Photon Laser Module, PM806G-GR, incorporates an Opnext HL6548FG high power laser diode (100mW absolute maximum optical output power), with internal monitor photodiode in a 9mm package. An internal monitor photodiode is a unique feature for a laser diode of this power and wavelength which enables the output power of the laser diode module to be accurately stabilised over its operating temperature range of -10 deg C to +50 deg C.
Designed for applications such as machine vision, graphic displays, medical imaging, inspection systems and industrial alignment and positioning, the 660nm laser diode module produces an elliptical output beam of 3.5 x 1.5mm with an output power of 70mW.
Operating voltage is from 3V to 6V DC with a typical operating current of 150mA.
Beam divergence is <0.6 x 0.3mrad and operating temperature range is -10 deg C to +50 deg C.
The module consists of an aluminium housing, laser diode, drive circuit and collimating lens and is stable and reliable.
All Photon Modules can be supplied in various colours, (red, green, blue, black, violet), to assist in wavelength or power identification.
The PMF version modules have a 25mm mounting flange.
Electrical connections are made via external flying leads.
The lens may be adjusted to produce either a collimated beam or focused spot.
The standard lens may be replaced by other optical systems such as line and cross generators.
The Photon range of elliptical beam laser diode modules has been designed as a complete laser diode solution for OEM use.
* About Photonic Products - Photonic Products was established in 1995 and has offices in the UK, USA and Germany.
It is an ISO9001:2000 certified manufacturer of electro-optical sub-assemblies and innovative optoelectronic components based on semiconductor laser diode technology and also a specialist distributor of high performance industrial laser diodes, LEDs and precision optical lenses.
UK optoelectronics device manufacturer and laser diode specialist, Photonic Products, has launched a new 660nm laser diode module with a very high, very stable output power of 70mW and adjustable AR coated glass optics. The 660nm Photon Laser Module, PM806G-GR, incorporates an Opnext HL6548FG high power laser diode (100mW absolute maximum optical output power), with internal monitor photodiode in a 9mm package. An internal monitor photodiode is a unique feature for a laser diode of this power and wavelength which enables the output power of the laser diode module to be accurately stabilised over its operating temperature range of -10 deg C to +50 deg C.
Designed for applications such as machine vision, graphic displays, medical imaging, inspection systems and industrial alignment and positioning, the 660nm laser diode module produces an elliptical output beam of 3.5 x 1.5mm with an output power of 70mW.
Operating voltage is from 3V to 6V DC with a typical operating current of 150mA.
Beam divergence is <0.6 x 0.3mrad and operating temperature range is -10 deg C to +50 deg C.
The module consists of an aluminium housing, laser diode, drive circuit and collimating lens and is stable and reliable.
All Photon Modules can be supplied in various colours, (red, green, blue, black, violet), to assist in wavelength or power identification.
The PMF version modules have a 25mm mounting flange.
Electrical connections are made via external flying leads.
The lens may be adjusted to produce either a collimated beam or focused spot.
The standard lens may be replaced by other optical systems such as line and cross generators.
The Photon range of elliptical beam laser diode modules has been designed as a complete laser diode solution for OEM use.
* About Photonic Products - Photonic Products was established in 1995 and has offices in the UK, USA and Germany.
It is an ISO9001:2000 certified manufacturer of electro-optical sub-assemblies and innovative optoelectronic components based on semiconductor laser diode technology and also a specialist distributor of high performance industrial laser diodes, LEDs and precision optical lenses.
Laser calibration reduces costs, ups accuracy
Laser calibration reduces costs and gives four-fold accuracy improvement for CNC water-jet cutting machine manufacturer, which is experiencing rapid sales growth.
Czech manufacturer PTV, based in Prague, Czech Republic, has experienced a very rapid increase in sales of its CNC water-jet cutting machines. To help manage this growth, the company uses Renishaw's ML10 laser interferometer measurement system and QC10 ballbar, which has reduced manufacturing costs and increased machine accuracy by a factor of four. Precision water cutting has a huge number of applications, and particular advantages over traditional CNC machine tools in processing high specification metals, composites and other media.
Thin, flexible or sensitive materials, such as rubber, plastics and even paper, are especially difficult to 'machine' using traditional methods.
In these cases water cutting offers many of the advantages of laser cutting machines, but at a lower cost.
In the cutting process, the water is compressed to a pressure of over 4000 bar, then directed through specially designed nozzles.
For certain materials and for high-speed grinding, water is mixed with natural garnet abrasive prior to cutting.
PTV manufactures one design of machine, but is able to vary the X and Y dimensions over a large range, according to customer needs.
In effect, every machine is customised - PTV engineers can easily adapt machine components to different requirements, both in initial construction in Prague, and during installation at a customer's site.
* Alignment problems - the PTV machine was designed in 2002, originally with a magnetic linear encoder system and a MEFI CNC control.
Initially there were problems with maintaining the precise separation required between encoder and readhead, particularly over distances greater than 6m.
There were also dynamic problems in achieving the required machine accuracy, due to the lightweight aluminium structures for the X-axis and Y-axis.
PTV therefore sought advice from MEFI, who suggested using a laser interferometer to identify the causes of these inaccuracies.
* Renishaw's solution - PTV searched the Internet and, from a short list of possible systems, reviewed Renishaw's ML10 laser interferometer measurement system.
Explained Jan Kunert, CNC engineer, 'We visited one of our customers, where a Renishaw engineer demonstrated the ML10 system to us'.
'We realised that not only could we use it to identify the dynamic errors, but we could also use it to map errors during machine production'.
'We were only looking for someone to do a one-off study of our machines, as a sub-contract service, but very quickly knew that we had to have a system ourselves'.
'In fact, the system we bought is now used so extensively, both in the factory and during on-site installation, that we intend to buy another.' * Linear accuracy improved from 0.2mm to 0.05mm/m - PTV removed the magnetic linear encoders from the original design, instead taking positional feedback from the rotary encoders integrated onto the drive motors.
These encoders had always been there, but had been thought to provide inaccurate feedback, due to the variable distance and the resulting effects from the twisting of the ball-screw.
This is where the Renishaw ML10 laser interferometer measurement system and Laser10 software proves its worth.
The system's laser optics are mounted onto the structure of the finished machine and readings taken at every 20mm of axis movement.
This is compared to the value provided by the machine's rotary encoder, which is at least always repeatable, to generate a compensation value for that specific position.
The positioning uncertainty on the original design could be up to 0.2mm/m.
Kunert now knows that accuracy is always better than 0.05mm/m and provides customers with a certificate from Renishaw's Laser10 software to prove it.
* Proving quality through international standards - the ML10 laser interferometer measurement system is a reference standard on which PTV relies, using the highly stable wavelength of laser light, to provide performance verification to ISO 230-6 and traceability of the measurements in line with their ISO9001 certified systems.
PTV sees both these factors as crucial in winning new customers, especially in markets where it is unknown.
* Combining Renishaw solutions for maximum efficiency - in addition to the compensation provided by the ML10 laser interferometer for linear positioning, there are a series of other machine characteristics which PTV checks and adjusts through the use of a ten-minute test with a Renishaw QC10 ballbar.
During the test the water cutting machine is instructed to describe a circular path in the X-Y axis, with the QC10 ballbar coupled to the machine on special magnetic mounts.
Any variation from the normal test circle radius is picked up by the ballbar's highly sensitive transducer and data fed back to a PC running Renishaw's Ballbar5 analysis software.
This immediately provides exact error values for 21 different machine characteristics.
* Considerable time-saving - PTV finds that backlash and scale mismatch are two major sources of error, but provided with the exact values from the QC10 ballbar, the engineers can now adjust them immediately.
Jan Kunert estimates that the company used to spend half a day on a machine attempting to find and remove errors.
Now it can be done in 30-40 minutes.
Says Kunert: 'Without the Renishaw ballbar, even if we thought we knew the problem, we were not always right'.
'We often brought in service companies, for example for the motors, to find it was a waste of time'.
'We have one engineer here who is very good at guessing errors, but previously, if he was out sick, or at a customer when we had problems here, we were stuck.' * Rapid increase in business - the future is looking bright for PTV.
After long experience in this field, distributing machines from the USA, it is now selling an increasing number of its own machines.
Its largest customer, V.S.M.P.O.
in Russia, already has six machines and has ordered a special 5-axis machine, which it will use to cut titanium for military and aerospace applications.
Czech manufacturer PTV, based in Prague, Czech Republic, has experienced a very rapid increase in sales of its CNC water-jet cutting machines. To help manage this growth, the company uses Renishaw's ML10 laser interferometer measurement system and QC10 ballbar, which has reduced manufacturing costs and increased machine accuracy by a factor of four. Precision water cutting has a huge number of applications, and particular advantages over traditional CNC machine tools in processing high specification metals, composites and other media.
Thin, flexible or sensitive materials, such as rubber, plastics and even paper, are especially difficult to 'machine' using traditional methods.
In these cases water cutting offers many of the advantages of laser cutting machines, but at a lower cost.
In the cutting process, the water is compressed to a pressure of over 4000 bar, then directed through specially designed nozzles.
For certain materials and for high-speed grinding, water is mixed with natural garnet abrasive prior to cutting.
PTV manufactures one design of machine, but is able to vary the X and Y dimensions over a large range, according to customer needs.
In effect, every machine is customised - PTV engineers can easily adapt machine components to different requirements, both in initial construction in Prague, and during installation at a customer's site.
* Alignment problems - the PTV machine was designed in 2002, originally with a magnetic linear encoder system and a MEFI CNC control.
Initially there were problems with maintaining the precise separation required between encoder and readhead, particularly over distances greater than 6m.
There were also dynamic problems in achieving the required machine accuracy, due to the lightweight aluminium structures for the X-axis and Y-axis.
PTV therefore sought advice from MEFI, who suggested using a laser interferometer to identify the causes of these inaccuracies.
* Renishaw's solution - PTV searched the Internet and, from a short list of possible systems, reviewed Renishaw's ML10 laser interferometer measurement system.
Explained Jan Kunert, CNC engineer, 'We visited one of our customers, where a Renishaw engineer demonstrated the ML10 system to us'.
'We realised that not only could we use it to identify the dynamic errors, but we could also use it to map errors during machine production'.
'We were only looking for someone to do a one-off study of our machines, as a sub-contract service, but very quickly knew that we had to have a system ourselves'.
'In fact, the system we bought is now used so extensively, both in the factory and during on-site installation, that we intend to buy another.' * Linear accuracy improved from 0.2mm to 0.05mm/m - PTV removed the magnetic linear encoders from the original design, instead taking positional feedback from the rotary encoders integrated onto the drive motors.
These encoders had always been there, but had been thought to provide inaccurate feedback, due to the variable distance and the resulting effects from the twisting of the ball-screw.
This is where the Renishaw ML10 laser interferometer measurement system and Laser10 software proves its worth.
The system's laser optics are mounted onto the structure of the finished machine and readings taken at every 20mm of axis movement.
This is compared to the value provided by the machine's rotary encoder, which is at least always repeatable, to generate a compensation value for that specific position.
The positioning uncertainty on the original design could be up to 0.2mm/m.
Kunert now knows that accuracy is always better than 0.05mm/m and provides customers with a certificate from Renishaw's Laser10 software to prove it.
* Proving quality through international standards - the ML10 laser interferometer measurement system is a reference standard on which PTV relies, using the highly stable wavelength of laser light, to provide performance verification to ISO 230-6 and traceability of the measurements in line with their ISO9001 certified systems.
PTV sees both these factors as crucial in winning new customers, especially in markets where it is unknown.
* Combining Renishaw solutions for maximum efficiency - in addition to the compensation provided by the ML10 laser interferometer for linear positioning, there are a series of other machine characteristics which PTV checks and adjusts through the use of a ten-minute test with a Renishaw QC10 ballbar.
During the test the water cutting machine is instructed to describe a circular path in the X-Y axis, with the QC10 ballbar coupled to the machine on special magnetic mounts.
Any variation from the normal test circle radius is picked up by the ballbar's highly sensitive transducer and data fed back to a PC running Renishaw's Ballbar5 analysis software.
This immediately provides exact error values for 21 different machine characteristics.
* Considerable time-saving - PTV finds that backlash and scale mismatch are two major sources of error, but provided with the exact values from the QC10 ballbar, the engineers can now adjust them immediately.
Jan Kunert estimates that the company used to spend half a day on a machine attempting to find and remove errors.
Now it can be done in 30-40 minutes.
Says Kunert: 'Without the Renishaw ballbar, even if we thought we knew the problem, we were not always right'.
'We often brought in service companies, for example for the motors, to find it was a waste of time'.
'We have one engineer here who is very good at guessing errors, but previously, if he was out sick, or at a customer when we had problems here, we were stuck.' * Rapid increase in business - the future is looking bright for PTV.
After long experience in this field, distributing machines from the USA, it is now selling an increasing number of its own machines.
Its largest customer, V.S.M.P.O.
in Russia, already has six machines and has ordered a special 5-axis machine, which it will use to cut titanium for military and aerospace applications.
Interface connects laser calibration to PC
Interface is designed to connect Renishaw ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection.
Renishaw's new DX10 interface is designed to connect its market leading ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection. The DX10 is a reliable high speed communications device, transmitting data at 5kHz to Renishaw's Laser10 software and new QuickView motion analysis software. Suitable for both laptop and desktop PCs, the new DX10 interface avoids the need for PCMCIA or internal PCI interfaces, which are gradually being phased out of mainstream PCs in favour of USB connectivity.
For dual axis data capture from the ML10 laser interferometer, a user can simply use 2 DX10 interfaces which can be plugged into 2 separate USB ports or a separate hub.
Replacing Renishaw's existing PCM20 (PCMCIA) card as the standard system interface, the DX10 unit is compatible with Windows XP and service pack 1 and 2.
The new DX10 interface kit includes a 3m USB cable, DX10 driver and installation CD-ROM.
* Note - Renishaw's ML10 laser interferometer measurement system is used by some of the largest OEMs and end users in industries such as metal cutting, semiconductor processing, flat panel display production and biotechnology.
The ML10's unique properties ensure that the system provides a linear position reading resolution of just 1.24nm, a range of up to 40 m and accuracy better than 1 ppm.
This combination of resolution, accuracy and range makes the laser interferometer an ideal tool for characterising the performance of motion systems, both large and small.
Renishaw's new DX10 interface is designed to connect its market leading ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection. The DX10 is a reliable high speed communications device, transmitting data at 5kHz to Renishaw's Laser10 software and new QuickView motion analysis software. Suitable for both laptop and desktop PCs, the new DX10 interface avoids the need for PCMCIA or internal PCI interfaces, which are gradually being phased out of mainstream PCs in favour of USB connectivity.
For dual axis data capture from the ML10 laser interferometer, a user can simply use 2 DX10 interfaces which can be plugged into 2 separate USB ports or a separate hub.
Replacing Renishaw's existing PCM20 (PCMCIA) card as the standard system interface, the DX10 unit is compatible with Windows XP and service pack 1 and 2.
The new DX10 interface kit includes a 3m USB cable, DX10 driver and installation CD-ROM.
* Note - Renishaw's ML10 laser interferometer measurement system is used by some of the largest OEMs and end users in industries such as metal cutting, semiconductor processing, flat panel display production and biotechnology.
The ML10's unique properties ensure that the system provides a linear position reading resolution of just 1.24nm, a range of up to 40 m and accuracy better than 1 ppm.
This combination of resolution, accuracy and range makes the laser interferometer an ideal tool for characterising the performance of motion systems, both large and small.
Measuring dynamic movements in machinery alignment
An off-line- to -running fixture combined with a shaft alignment system makes it possible to measure dynamic movements on machines from hot to cold or vice versa.
Dynamic changes in the rotating machinery from an Off Line toRunning condition, needs more attention. There is no such thingas 'identical' machines having identical dynamicmovements. One cannot ignore the possibility of horizontalmovement, assuming growth will be symmetrical and only accountingfor the thermal effects.
Shaft alignment has mostly been carriedout in off-line operating conditions.
However, machine conditionschange from the time they are off line to running under normaloperating conditions.
Some of these changes are due to processforces (fluid pressures, airflow, etc.).
The most notable ofthese changes is the change in the temperature of the machinebearings and supports.
Dynamic changes are difficult tocalculate.
Two 'identical' machines may showdrastically different alignment changes from Off Line to Running.Great care must be taken when calculating the changes in thealignment condition of machines.
Just because two machines appearidentical and serve the same function does not ensure they willexhibit the same operational characteristics.
Several methodshave been used to measure the changes in the shaft alignment oftwo or more machines.
Although widely used, 'hot aligningmachines', only measures changes in the shaft alignment duesolely to the changes in the machines' temperature.Discharge pressure, shaft torque, multiple machines operating inparallel, electrical loading of a generator, etc., can also playan important role in the change of the alignment condition fromOff Line to Running.
The changes will mostly be seen in theHorizontal Plane, but could also affect the Vertical Alignment.
Amachine that operates exposed to large changes in temperaturecould exhibit extreme changes in its shaft alignment as thetemperature changes.
Coupled machines need to be set to coldalignment targets that will reflect the actual changes in theshaft alignment.
This will lead to lower vibration levels,increased mean time between failures, decreased maintenancecosts, and increased production.
Fixturlaser's extensiveresearch into the problems of dynamic movement has resulted in arevolutionary new alignment method.
Fixturlaser L2R off-line- to-running fixture combined with a FixturlaserShaft alignmentsystem makes it possible to measure dynamic movements on machinesfrom hot to cold or vice versa.
Changes in machinery alignmentare mirrored by changes in the alignment of the L2R brackets.
Bymeasuring and documenting the initial position of the bracketsthe actual online changes in the alignment values can be measuredwhen the machine is online under normal operating conditions.Alignment costs are small compared to production loss, shouldcritical machinery fail.
Poor alignment is one of the leadingcontributors to premature rotating machinery failure, often as aresult of too little attention being paid to dynamic movements.Fixturlaser have, through extensive tests, showed that inaddition to cold alignments, the actual dynamic movements ofmachinery need to be considered when aligning.
Dynamic changes in the rotating machinery from an Off Line toRunning condition, needs more attention. There is no such thingas 'identical' machines having identical dynamicmovements. One cannot ignore the possibility of horizontalmovement, assuming growth will be symmetrical and only accountingfor the thermal effects.
Shaft alignment has mostly been carriedout in off-line operating conditions.
However, machine conditionschange from the time they are off line to running under normaloperating conditions.
Some of these changes are due to processforces (fluid pressures, airflow, etc.).
The most notable ofthese changes is the change in the temperature of the machinebearings and supports.
Dynamic changes are difficult tocalculate.
Two 'identical' machines may showdrastically different alignment changes from Off Line to Running.Great care must be taken when calculating the changes in thealignment condition of machines.
Just because two machines appearidentical and serve the same function does not ensure they willexhibit the same operational characteristics.
Several methodshave been used to measure the changes in the shaft alignment oftwo or more machines.
Although widely used, 'hot aligningmachines', only measures changes in the shaft alignment duesolely to the changes in the machines' temperature.Discharge pressure, shaft torque, multiple machines operating inparallel, electrical loading of a generator, etc., can also playan important role in the change of the alignment condition fromOff Line to Running.
The changes will mostly be seen in theHorizontal Plane, but could also affect the Vertical Alignment.
Amachine that operates exposed to large changes in temperaturecould exhibit extreme changes in its shaft alignment as thetemperature changes.
Coupled machines need to be set to coldalignment targets that will reflect the actual changes in theshaft alignment.
This will lead to lower vibration levels,increased mean time between failures, decreased maintenancecosts, and increased production.
Fixturlaser's extensiveresearch into the problems of dynamic movement has resulted in arevolutionary new alignment method.
Fixturlaser L2R off-line- to-running fixture combined with a FixturlaserShaft alignmentsystem makes it possible to measure dynamic movements on machinesfrom hot to cold or vice versa.
Changes in machinery alignmentare mirrored by changes in the alignment of the L2R brackets.
Bymeasuring and documenting the initial position of the bracketsthe actual online changes in the alignment values can be measuredwhen the machine is online under normal operating conditions.Alignment costs are small compared to production loss, shouldcritical machinery fail.
Poor alignment is one of the leadingcontributors to premature rotating machinery failure, often as aresult of too little attention being paid to dynamic movements.Fixturlaser have, through extensive tests, showed that inaddition to cold alignments, the actual dynamic movements ofmachinery need to be considered when aligning.
One man can operate accurate alignment system
Fixturlaser AB, Molndal has developed a new and highly accuratesystem for positioning and aligning machines and production lineinstallations. The new Fixturlaser Level is a laser based'one-man-level' system, which meets high mechanical andaccuracy levelling requirements. The one-man-level makes ahelping hand redundant, since the system consists of a selflevelling, scanning laser transmitter and a high resolutionreceiver.
The laser transmitter, T310, generates a laser planewhich is level or plumb to level.
The laser plane can also belocked to specific receiver values, the receiver then controlsthe transmitter by either IR or cable communication.
This featureis very helpful in unstable environments, e.g when performingmeasurements on-board ship and on high rising constructions, suchas harbour cranes.
The Level can be operated with one or morereceivers and can be fully integrated in the Fixturlaser systemutilising the display unit as a data collector.
All units arepowered by standard batteries or AC-adapter.
The receiver can bepowered by the Display Unit when connected.
The laser transmitter, T310, generates a laser planewhich is level or plumb to level.
The laser plane can also belocked to specific receiver values, the receiver then controlsthe transmitter by either IR or cable communication.
This featureis very helpful in unstable environments, e.g when performingmeasurements on-board ship and on high rising constructions, suchas harbour cranes.
The Level can be operated with one or morereceivers and can be fully integrated in the Fixturlaser systemutilising the display unit as a data collector.
All units arepowered by standard batteries or AC-adapter.
The receiver can bepowered by the Display Unit when connected.
Laser scanner unseats templates and save money
US-based Lear Corporation has realised savings of $240,000 injust one seat manufacturing programme by replacing atemplate-based inspection system with a laser scanning one. Using3D Scanners' ModelMaker software, Lear inspects automotiveseats during design and manufacturing. Before, Lear compared asample seat with a series of contoured plastics templates whichshoed the original styling guidelines.
Typically nine templateswere needed for each seat, and the seat had to line up within 6mmunder manual 'GO, NO-GO' inspection.
Total templatecost for a seat programme with 29 seat configurations was some$104,000.
An inspection stand could cost $22,000 and fivedifferent stands would be needed.
Two sets of stands - costing$220,000 - would be needed if a seat style were produced in twodifferent factories.
Lear chose the ModelMaker system, whicheliminated the templates and the stand cost is now $15,000instead of $22,000.
The system is based on a 3D laser sensor, aposition-sensing device on which the sensor is mounted, a PC andsoftware.
The software extracts displays and manipulates thesensor data.
Lear chose the FaroArm with seven degrees of freedomto reach any point in the seat.
In operation, the sensor ispositioned to show a laser light line across the seat, and ismoved across the area to be checked and the data is displayed onthe PC screen.
Laser scanning is much faster than making templatemeasurements, so Lear now scans a number of customer-approvedseats and averages the data to set manufacturing tolerances.Scanning provides real X, Y and Z co-ordinates.
If a seat area isout of tolerance, manufacturing personnel can see exactly howmuch it is in error.
The scanning system is more accurate thanthe template system (gaps between template surfaces and seatareas would have to have been measured manually) and readilywarns of any drift away from the 'mean'.
Also thescanning system is immediately adaptable to seat modifications.
Typically nine templateswere needed for each seat, and the seat had to line up within 6mmunder manual 'GO, NO-GO' inspection.
Total templatecost for a seat programme with 29 seat configurations was some$104,000.
An inspection stand could cost $22,000 and fivedifferent stands would be needed.
Two sets of stands - costing$220,000 - would be needed if a seat style were produced in twodifferent factories.
Lear chose the ModelMaker system, whicheliminated the templates and the stand cost is now $15,000instead of $22,000.
The system is based on a 3D laser sensor, aposition-sensing device on which the sensor is mounted, a PC andsoftware.
The software extracts displays and manipulates thesensor data.
Lear chose the FaroArm with seven degrees of freedomto reach any point in the seat.
In operation, the sensor ispositioned to show a laser light line across the seat, and ismoved across the area to be checked and the data is displayed onthe PC screen.
Laser scanning is much faster than making templatemeasurements, so Lear now scans a number of customer-approvedseats and averages the data to set manufacturing tolerances.Scanning provides real X, Y and Z co-ordinates.
If a seat area isout of tolerance, manufacturing personnel can see exactly howmuch it is in error.
The scanning system is more accurate thanthe template system (gaps between template surfaces and seatareas would have to have been measured manually) and readilywarns of any drift away from the 'mean'.
Also thescanning system is immediately adaptable to seat modifications.
Laser displacement sensor measures problem surface
Laser displacement sensor measures problem surfaces MatsushitaElectric Works has enhanced its range of measurement sensors byintroducing the new SUNX HL-C1 laser measurement system. Usingcharged coupled device (CCD) based technology, the sensor is ableto quickly and precisely inspect surfaces that have historicallyposed problems for analogue based non-contact measurementequipment. Black rubber and specular objects, including glass andwafers, can now be reliably and accurately measured using the newSUNX HL-C1 laser based measurement system.
Suitable applicationsfor the HL-C1 series include measurement of the eccentricity ofsteel shafts, co-planarity of IC pins, thickness measurement ofbrake discs and tyre tread measurement.
Containing an extremelycompact controller, the unit can accept the connection of up totwo measurement sensor heads.
This allows thickness measurementto be carried out easily using built in calculation functions.The sensor heads themselves are available in two styles: one formeasurement of diffuse type surfaces, including black rubber andmachined metal; and the other for specular objects such as glassand highly reflective surfaces.
Both styles offer two measurementranges and are capable of measuring to accuracies of 1micron.Configuration of the controller can be performed using either acompact touch screen console or PC based configuration softwarevia the built in RS232C communications port.
This port can alsobe used to transmit measurement data to a third party device, orthe internal decision-making capability can be utilised andinformation accessed via digital I/O connections.
Suitable applicationsfor the HL-C1 series include measurement of the eccentricity ofsteel shafts, co-planarity of IC pins, thickness measurement ofbrake discs and tyre tread measurement.
Containing an extremelycompact controller, the unit can accept the connection of up totwo measurement sensor heads.
This allows thickness measurementto be carried out easily using built in calculation functions.The sensor heads themselves are available in two styles: one formeasurement of diffuse type surfaces, including black rubber andmachined metal; and the other for specular objects such as glassand highly reflective surfaces.
Both styles offer two measurementranges and are capable of measuring to accuracies of 1micron.Configuration of the controller can be performed using either acompact touch screen console or PC based configuration softwarevia the built in RS232C communications port.
This port can alsobe used to transmit measurement data to a third party device, orthe internal decision-making capability can be utilised andinformation accessed via digital I/O connections.
Object dimensioning as easy as scanning barcodes!
Datalogic's VS8000 is a device for object volume measurement representing a valid alternative to traditional automatic measurement systems for materials handling applications.
With Datalogic's VS8000 Dimensioning systems are becomingmore and more popular among parcel carriers and postal servicesaround the world. Goods are becoming lighter, and containers andtrucks are more often full before becoming too heavy. Volume, notweight is increasingly becoming the limiting factor.
The same istrue for warehouses where capacity is given in volume andconveyor systems are more often limited by volume rather than byweight.
In this scenario, traditional weight-based tariff systemsare no longer appropriate and carriers and postal services areincreasingly adopting volume based price tariffs.
Whereverparcels in different sizes, shapes and weight are collected,transported, stored and distributed, cost-effectiveness dependson achieving the optimal utilisation of the available space forwarehousing and of equipment for transportation.
Accuratelyestablishing the size of the various packages is always thebiggest bottleneck in parcel handling.
Datalogic's solutionis the VS8000 - a device for object volume measurementrepresenting a valid alternative to traditional automaticmeasurement systems for materials handling applications.
Based onthe mechanical and optical architecture of Datalogic'sDS8100 laser scanner, the VS8000 scans at speeds of up to 2000scans per second and covers a standard measurement area of 800mmx 800mm, providing an extremely fast and reliable dimensions andvolume estimation of objects moving along the conveyor.
The veryhigh scan speed and real time processing features allow beltspeeds of up to 5 metres per second, enabling the gap betweenparcels to be reduced to only 50mm.
The VS8000 can be rapidlyintegrated in omni-directional reading stations, with nomodifications to existing structures.
Set-up is fast and easywith the intuitive Monitor Configuration Program.
With theVS8000, Datalogic offers an excellent alternative to existingdimensioning systems.
The VS8000 is more cost-effective andeasier to use and install than traditional measurement systemsand, above all, makes new process automation and optimisationcapabilities available to all materials handling operators.
With Datalogic's VS8000 Dimensioning systems are becomingmore and more popular among parcel carriers and postal servicesaround the world. Goods are becoming lighter, and containers andtrucks are more often full before becoming too heavy. Volume, notweight is increasingly becoming the limiting factor.
The same istrue for warehouses where capacity is given in volume andconveyor systems are more often limited by volume rather than byweight.
In this scenario, traditional weight-based tariff systemsare no longer appropriate and carriers and postal services areincreasingly adopting volume based price tariffs.
Whereverparcels in different sizes, shapes and weight are collected,transported, stored and distributed, cost-effectiveness dependson achieving the optimal utilisation of the available space forwarehousing and of equipment for transportation.
Accuratelyestablishing the size of the various packages is always thebiggest bottleneck in parcel handling.
Datalogic's solutionis the VS8000 - a device for object volume measurementrepresenting a valid alternative to traditional automaticmeasurement systems for materials handling applications.
Based onthe mechanical and optical architecture of Datalogic'sDS8100 laser scanner, the VS8000 scans at speeds of up to 2000scans per second and covers a standard measurement area of 800mmx 800mm, providing an extremely fast and reliable dimensions andvolume estimation of objects moving along the conveyor.
The veryhigh scan speed and real time processing features allow beltspeeds of up to 5 metres per second, enabling the gap betweenparcels to be reduced to only 50mm.
The VS8000 can be rapidlyintegrated in omni-directional reading stations, with nomodifications to existing structures.
Set-up is fast and easywith the intuitive Monitor Configuration Program.
With theVS8000, Datalogic offers an excellent alternative to existingdimensioning systems.
The VS8000 is more cost-effective andeasier to use and install than traditional measurement systemsand, above all, makes new process automation and optimisationcapabilities available to all materials handling operators.
HMC undergoes a second rebuild
A heavy duty Cincinnati HMC has been rebuilt again,this time employing the capabilities of Renishaw's calibration and machine tool performance testing systems.
HMC undergoes a second rebuild In 1989, Leeds-based Dana Spicerneeded a large, heavy duty CNC machining centre, to mill, drill,and bore the ends of 2-metre long axle beams, for heavy off-roadvehicles. The ideal machine, with a bed length of 5-metres, wouldallow pendulum machining, thereby increasing production. However,new machines of this type were costly and resulted in the companyapproaching rebuild specialist Murrall and Lang for a solution.Ten years later, it was 'd�j� vu' for theBirmingham-based company, when it welcomed the opportunity toonce again re-manufacture the machine, but this time employingthe capabilities of Renishaw's calibration and machine toolperformance testing systems.
Murrall and Lang had alreadymodified a 2-metre machining centre to accommodate pendulummachining in the summer of 1989 and convinced Dana Spicer of thecost benefits.
With a contract signed, a Cincinnati 20HC 2500(2.5 metre) travelling-column horizontal machining centre wasfound in the USA that would machine these parts, if equipped witha suitable front base.
The volume of the axle components dictatedthat a pallet shuttle system would be economic, allowingunloading and loading whilst machining continued.
To accommodatethis, Murrall and Lang designed a special shuttle table with twoindex tables and fixtures, and a CNC movement of 2.5m from oneposition to the other.
Suitable guarding protected the operator.Therefore, in addition to the usual horizontal axes of X(2500mm), Y (1000mm) and Z (600mm) and the shuttle axis, themachine has two indexing axes giving a total of 6 CNC axes.
Thisconfiguration was arrived at after joint discussions when themachine was first modified in 1990.
After producing axles fornearly a decade and having questioned the ability to maintain themachine, Dana Spicer - having once again considered new products,which still proved very costly - decided to have the machinere-manufactured by Murrall and Lang for a second time.
Havingexperienced the benefits of Renishaw's QC10 ballbar systemsin the 1990's, Murrall and Lang had no hesitation inutilising this technology and purchasing Renishaw's ML10laser calibration system to aid the re-manufacture 'asnew', of the Cincinatti HMC for a second time.
Partner, BobMurrall explained.
'We had successfully produced a machineto Dana Spicer's tolerance specifications in 1990 using asecond-hand Hewlett Packard (HP) calibration system.
Today, HPequipment is neither cost-effective nor comparable to thetechnological capabilities of the Renishaw systems.''It was our experience of the QC10 ballbar system, that ledus to invest in the ML10 laser calibration equipment,' addedMr Murrall.
'The ballbar is so reliable, it automaticallyidentifies, quantifies and prioritises machine tool errors.
Inseeing it used here, many of our customers, including DanaSpicer, have subsequently invested in the technology.' TheY2K re-manufacturing process included a complete mechanicalrebuild, with all worn parts being reconditioned or replaced, acomplete rewiring, the fitting of new digital axis and spindledrives, and a new Siemens 840D CNC control.
The process took lessthan six months and fully met customer specification.
To improvereliability, the customer wanted to maintain accuracy by axiscalibration and compensation.
This required the use of theRenishaw laser calibration system; part of Murrall andLang's quality control system.
'When you arere-manufacturing a machine, your alignments should be well withinachievable levels of adjustment, allowing the alignments set bythe original manufacturer to be achieved.
In fact, the QC10ballbar and ML10 laser system allow us to achieve tightertolerances than was possible when the machine was firstmanufactured.
Whatever we attain here, we can reproduce at thecustomers' premises.
The Renishaw ML10 laser calibrationsystem is portable, easy to use and has built-in temperaturecompensation, allowing our customers to machine components farmore accurately than once possible,' continued Mr Murrall.At Dana Spicer, the 20hp Cincinnati machine, with spindle speedsof 3300rpm, is fed by two 30-tool chain-based magazines.
Axlebeams are machined from forgings which tend to vary in size dueto the forging process.
To obtain the best metal conditions, oncethe component is mounted in the fixture, a spindle mountedRenishaw MP700 high accuracy probe is used to check length androtation.
Corrections are applied automatically to find thecomponent centre, and if necessary to rotate the programdimensions, so as to produce the best component from the forging.'The rebuild option allows a company to purchase a specificmachine at a third of the cost of a new machine.
HMC undergoes a second rebuild In 1989, Leeds-based Dana Spicerneeded a large, heavy duty CNC machining centre, to mill, drill,and bore the ends of 2-metre long axle beams, for heavy off-roadvehicles. The ideal machine, with a bed length of 5-metres, wouldallow pendulum machining, thereby increasing production. However,new machines of this type were costly and resulted in the companyapproaching rebuild specialist Murrall and Lang for a solution.Ten years later, it was 'd�j� vu' for theBirmingham-based company, when it welcomed the opportunity toonce again re-manufacture the machine, but this time employingthe capabilities of Renishaw's calibration and machine toolperformance testing systems.
Murrall and Lang had alreadymodified a 2-metre machining centre to accommodate pendulummachining in the summer of 1989 and convinced Dana Spicer of thecost benefits.
With a contract signed, a Cincinnati 20HC 2500(2.5 metre) travelling-column horizontal machining centre wasfound in the USA that would machine these parts, if equipped witha suitable front base.
The volume of the axle components dictatedthat a pallet shuttle system would be economic, allowingunloading and loading whilst machining continued.
To accommodatethis, Murrall and Lang designed a special shuttle table with twoindex tables and fixtures, and a CNC movement of 2.5m from oneposition to the other.
Suitable guarding protected the operator.Therefore, in addition to the usual horizontal axes of X(2500mm), Y (1000mm) and Z (600mm) and the shuttle axis, themachine has two indexing axes giving a total of 6 CNC axes.
Thisconfiguration was arrived at after joint discussions when themachine was first modified in 1990.
After producing axles fornearly a decade and having questioned the ability to maintain themachine, Dana Spicer - having once again considered new products,which still proved very costly - decided to have the machinere-manufactured by Murrall and Lang for a second time.
Havingexperienced the benefits of Renishaw's QC10 ballbar systemsin the 1990's, Murrall and Lang had no hesitation inutilising this technology and purchasing Renishaw's ML10laser calibration system to aid the re-manufacture 'asnew', of the Cincinatti HMC for a second time.
Partner, BobMurrall explained.
'We had successfully produced a machineto Dana Spicer's tolerance specifications in 1990 using asecond-hand Hewlett Packard (HP) calibration system.
Today, HPequipment is neither cost-effective nor comparable to thetechnological capabilities of the Renishaw systems.''It was our experience of the QC10 ballbar system, that ledus to invest in the ML10 laser calibration equipment,' addedMr Murrall.
'The ballbar is so reliable, it automaticallyidentifies, quantifies and prioritises machine tool errors.
Inseeing it used here, many of our customers, including DanaSpicer, have subsequently invested in the technology.' TheY2K re-manufacturing process included a complete mechanicalrebuild, with all worn parts being reconditioned or replaced, acomplete rewiring, the fitting of new digital axis and spindledrives, and a new Siemens 840D CNC control.
The process took lessthan six months and fully met customer specification.
To improvereliability, the customer wanted to maintain accuracy by axiscalibration and compensation.
This required the use of theRenishaw laser calibration system; part of Murrall andLang's quality control system.
'When you arere-manufacturing a machine, your alignments should be well withinachievable levels of adjustment, allowing the alignments set bythe original manufacturer to be achieved.
In fact, the QC10ballbar and ML10 laser system allow us to achieve tightertolerances than was possible when the machine was firstmanufactured.
Whatever we attain here, we can reproduce at thecustomers' premises.
The Renishaw ML10 laser calibrationsystem is portable, easy to use and has built-in temperaturecompensation, allowing our customers to machine components farmore accurately than once possible,' continued Mr Murrall.At Dana Spicer, the 20hp Cincinnati machine, with spindle speedsof 3300rpm, is fed by two 30-tool chain-based magazines.
Axlebeams are machined from forgings which tend to vary in size dueto the forging process.
To obtain the best metal conditions, oncethe component is mounted in the fixture, a spindle mountedRenishaw MP700 high accuracy probe is used to check length androtation.
Corrections are applied automatically to find thecomponent centre, and if necessary to rotate the programdimensions, so as to produce the best component from the forging.'The rebuild option allows a company to purchase a specificmachine at a third of the cost of a new machine.
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