Product category:
Flexible machining cells and systems (FMS)
News Release from: Colchester-Harrison | Subject: Tornado A50 two-axis 'Lights-out' turning cells
Edited by the Manufacturingtalk Editorial
Team on 30 April 2004
Turning cells play central role in SME
initiative
Two two-axis 'lights-out' turning cells have very quickly taken a central role in a GBP 500,000 automated machining initiative designed to present cost-effective manufacturing techniques to SMEs.
Two Colchester Tornado A50 two-axis 'Lights-out' turning cells have very quickly taken a central role in a GBP 500,000 automated machining initiative designed to present modern, cost-effective manufacturing techniques to small and medium-sized manufacturers (SMEs) in West Yorkshire The machines installed at KITS, the Brighouse-based Group Training Association, that is renowned for its engineering training excellence and by the Leeds College of Technology (LCOT) have so far been used by dozens of SMEs since their installation
This article was originally published on Manufacturingtalk on 5 Jul 2001 at 8.00am (UK)
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Sited in Manufacturing Metrology Centres set up at KITS and LCOT, the unmanned machining Colchester Lights-out packages feature Colchester-developed MBF 1000 integrated barfeed, swarf conveyor, tool monitoring and sister tool replacement, as well as Renishaw in-process gauging and production scheduling software.
The idea behind adopting the Colchester cell configured systems is to provide an introduction to SMEs of the benefits of automated machining as part of a successful awareness programme initiated jointly by the National Physical Laboratory and the Department of Trade and Industry.
Originally run by LCOT as an 18-month pilot, the Manufacturing and Metrology programme has enabled a number of SMEs to develop more professional and practical metrology routines, from gaining an appreciation of the effect on the business of improved measurement practices.
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The 'Lights Out' unmanned turning package developed by Colchester for its Tornado range of lathes is now available on the latest two-axis 220 and three-axis 220M as well as existing A-Series. machines
As a result they have the opportunity of not only reducing waste, scrap, rejected goods and machine downtime but generate new business opportunities, increase productivity and hence profitability.
Due to its success the project is now run by both LCOT and KITS, with each organisation maintaining similarly-equipped Manufacturing Metrology Centres where the Colchester Lights-out systems are complemented by an array of precision measuring/calibration equipment and supporting software.
Explaining that KITS has been at the forefront of engineering training for nearly 35 years, and has enabled over 3,000 young people to enter the workplace with a recognised apprenticeship qualification, John Wray, Centre Co-ordinator said: "The Tornado Lights-out package has proven to be the perfect practical demonstration of advanced machining and process control." He follows on to explain: "The initial Manufacturing and Metrology programme highlighted how companies are missing out by not capitalising on the advances in metrology and as part of that 'technology awareness' programme it became clear that while lots of companies have CNC machines, only relatively few even gave unmanned machining a second thought." He then maintains how they have been able to open so many eyes to what can be achieved and says: "Being able to show how on- machine measurement can work and in a fully proven production package means we can also demonstrate a production solution to any company, additional benefits such as automatic bar feeding, in-process gauging and correction.
When we get down to detail such as automatic measurement of each bar in the magazine which on the Tornado, provides immediate calculation of the number of workpieces that can be machined from each bar and with integration into the scheduling software on-board in the Fanuc control to provide production data, they are truly surprised." The Tornado A50 is a two-axis slant bed machine that can accommodate bar up to 42mm diameter and has a spindle speed of 6,000 revs/min.
In the Lights-out package the MBF 1000 bar magazine is fully integrated with the Fanuc control where it can be programmed using dialogue input.
It has no mechanical stops to set and takes minutes to change from, say, hexagon to round bar.
As each bar is measured, the machine's onboard software computes the number of pieces that can be made from each bar and recalculates when to stop the automatic production cycle to complete the programmed quantity.
The production scheduling software enables direct on-machine control over workpiece batches while the tool monitoring, based on axis torque loading, will initiate sister tool replacement from the 12 station VDI turret or stop the machine if the problem is deemed more serious.
Through the on-board Renishaw LTO2 optical transmission probe, workpiece accuracy can be monitored, tool offsets automatically updated or the machine stopped, if a problem is detected.
As part of the equipping of the Manufacturing Metrology Centre some GBP 500,000 of funding was made available from regional development agency Yorkshire Forward and the European Regional Development Fund, which led to a joint panel from KITS and LCOT to select the machines and other equipment suppliers.
Continues Wray: "It wasn't a case of choosing equipment based purely on price," he says.
"It was more about selecting machines that are in widespread use in industry and creating working partnerships.
We wanted to establish relationships with companies that would give us added-value benefits to our needs and provide full support when needed.
It also helped that Colchester Sales is such a local company in nearby Heckmondwike and has a good reputation." The core activity at KITS is the provision of a variety of mechanical, fabrication and electrical engineering qualifications under the Modern Apprenticeship framework and this accounts for some 90 per cent of intake.
In addition, it also provides a host of management and supervisory, health and safety, motor vehicle and skill development training courses.
Like all Group Training Associations, the emphasis is on the assessment of an individual and on their competence - the programmes are skills-based rather than time-based, though on average each young person spends four years on the books.
Around 80 to 100 trainees pass through each year, with half being already employed and KITS normally finding places for the remainder.
Working within the centre are experienced professionals who are able to combine knowledge of production and precision measuring techniques with shopfloor experience.
For example, time-served toolmaker, Wray has now spent 17 years as an instructor backed by equipment suppliers, group training associations and local college and higher education establishments.
So far the metrology project is half-way through its two-year funding term, during which time it is charged with introducing 320 companies in West Yorkshire to the Manufacturing and Metrology programme.
In doing so it offers consultation, benchmarking and recommendations, as well as acting as a 'lending library' for best in class equipment.
"When official funding for the project finishes in 2005, we have to be self-sufficient," concludes Wray.
"At the moment the future of the Manufacturing Metrology Centre looks assured, as our philosophy of identifying - then satisfying - industry's needs is seeing increasing numbers of SMEs take advantage of the free assistance as part of our 'try before you buy' concept.
"This applies to consultancy and even loan of trial equipment including co-ordinate measuring machines, digital height gauges, a vertical machining centre, surface tables, CAD/CAM systems and various projectors, as well as surface finish measuring equipment and software.
In particular, our machine checking service such as ballbar CNC machines is especially popular," he says.
But Wray maintains: "Because of the nature of our broad-based training, in the future the Colchester Tornado Lights-out package will be gradually introduced to trainees during their specialised training periods.
We have found as more young people gain experience of unmanned production techniques, more companies will be able to capitalise on the rewards technology can provide to improve profitability.".
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