HMC builder provides technical support

When a foundry, more used to batch machining, took on volume production of transmission parts, it sought a machine tool supplier, which could provide technical and fixtures back-up.

When a foundry, more used to batch machining, took on volume production of transmission parts, it sought a machine tool supplier, which could provide technical and fixtures back-up.

The new intelligent All-Wheel-Drive Ford Transit has been awarded the prestigious International Van of the Year 2007.

Premiered at the Hanover Commercial Vehicle Show, this is the first time the much loved tranny has been available from Ford with an All-Wheel-Drive transmission.

It will be in the dealers from early 2007.

On behalf of Ford, the transmission housing is being cast by M J Allen (Non Ferrous Founders) at its foundry in Ashford, Kent and is being machined by M J Allen-ENC using the Heller MCi 16 horizontal machining centre.

The All-Wheel-Drive Transit is based on the rear drive 140PS 2.4 litre Duratorq diesel model, and has been created to provide increased traction capabilities without infringing road performance or ground clearance.

The all-mechanical system ensures that while the rear and front wheels are turning at the same speed the van adopts conventional rear-wheel drive.

When the system senses the rear wheels are starting to turn faster than the front wheels it automatically engages driveshaft clutches to split the drive with the front wheels.

When front and rear wheels are turning at the same speed again, the system disengages automatically.

The four wheel drive system is housed in a modified gearbox casing which uses the same six-speed gearbox as the conventional rear-wheel drive 140PS Transit.

The All-Wheel-Drive System has been conceived, designed and developed by Eddie May, Engineering Director at County Trak, a subsidiary of M J Allen, and will be produced for Ford by M J Allen at its own foundry and machine shop.

Group managing director of M J Allen, Tim Allen, said: "It has been an exciting but complex process to bring this project to fruition.

Our engineers have worked in close collaboration with Ford's own engineers to complete all the prototyping and testing, which is the same as for a new vehicle.

We are now embarking on the manufacture of pre-production parts and will be in production in the new year." M J Allen is a vibrant, adventurous group of companies - 'opportunistic' in Allen's words - which has never been afraid of a challenge.

Founded in 1957 by group chairman Mike Allen in family outbuildings the company was initially a pattern makers.

A controlled and perceptive expansion programme has created a fully integrated group of companies which includes an iron foundry, a non-ferrous foundry and a machine shop for the precision machining in addition to the still- substantial pattern shop.

Production of the new All-Wheel Drive transmission system for Ford is a complete and deliberate departure from the company's traditional portfolio of work.

"It has represented something of a challenge," Allen said.

"Our area of expertise is to take a drawing and turn that into a machined casting.

We are accustomed to small batches and 'one-offs'.

We wanted to complement that type of work with regular, scheduled production.

The Ford All-Wheel Drive transmission system is our ideal opportunity." Patterns and castings for the transmission housing are produced easily within the company's existing facility, though a new gravity die casting system has been installed in the non-ferrous foundry.

Additional machining capacity is necessary because the M J Allen machine tools have been selected specifically for the precision machining of large castings in low volumes so are not ideal for production machining.

Armed only with its inherent engineering expertise and an intention to excel in production as it has in all other areas of its business, M J Allen engineers sought a machine tool partner which could - and would - help it develop a production system capable of meeting Ford's notoriously rigorous demands.

The company has selected a Heller MCi16 horizontal machining centre for the work.

The machine suits ideally M J Allen's production requirement, as well as providing capacity for ramp up, but the choice of machine was made because of the response by Heller's engineers to the initial enquiry.

"Production machining is a radical departure from our traditional areas of expertise and understanding and as such takes us outside of our natural 'comfort zone'," Allen said.

"We wanted a machine tool supplier which would give us time and understanding, and in whose expertise and engineering capability we could trust absolutely.

Heller have given us that.

From the outset, they have given us excellent assistance, designing the production process for us, recommending manufacturing techniques, designing the fixtures to give us the best and most versatile machining system.

They have worked with our engineers to create the tooling package.

We could not be more pleased, and their work so far has inspired us the assurance that however fast this project develops and whatever complexities we face in that development, Heller's engineers will be ready, willing, able, and enthusiastic to work with us.".

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