Fagor Automation has collaborated in two open houses organized by the Intaima Group (Taiwan) in Mexico City and Stuttgart.

The Intaima Group is currently made up by three Taiwanese companies: L&L, Jainnher and Millstart. This alliance of companies has been created to promote the development of the companies in the areas of R&D, production and sales and marketing.

Over the next few months, the group is expected to expand to include 10 companies and promises to be a serious conender in the future, with the backing of the Taiwanese government and collaboration with university centers in Taiwan for future developments.

At the open houses, at the invitation of Intaima, the group companies and Fagor Automation were able to make presentations on their respective companies before distributors from different countries, such as Mexico, Germany, the Netherlands and Sweden, to showcase the level of their companies. After the presentations, they enjoyed a meal provided by the Intaima Group, and the afternoons were dedicated to bilateral meetings between distributors and the companies giving the presentations.

It has been a very positive experience and we believe that in the near future, new business opportunities will emerge for everyone.

In the automotive industry, one trend has been consistent for years: Passenger vehicle transmissions are becoming smaller and lighter, although the number of speeds—and of toothed gear components—continue to increase. How does the entire assembly not become heavier?. The answer becomes obvious by taking a closer look at the individual components. A gearwheel, for example, consists of two components that are joined by laser welding. This allows the design engineers to work without screws—allowing the component to become lighter.

Integrating the into the production system

The benefits listed above explain why laser welding has become a core process in transmission manufacturing. However, this method cannot easily be integrated into a complete production line: because the actual laser welding process is preceded and followed by many other processes. Depending on the component, these may include checking, washing, joining of components before laser welding, a brushing process and a final ultrasonic inspection of the welding seam.

EMAG developing multi-stage production solutions

“Implementing comprehensive production lines that integrate laser welding into the overall sequence—is the special expertise of EMAG Automation”, says Dr. Andreas Mootz, managing director of EMAG Automation. “We are very familiar with the production sequence for central transmission components. Therefore, we do not just design another laser welding machine. With our multi-stage production solutions, we focus on creating a perfect process chain that operatesquickly, and very safely.”

Every detail of these systems is perfectly tailored to the component by our specialists based in Heubach near Schwäbisch Gmünd, Germany. Inspection methods, as an example: EMAG Automation has developed its own ultrasonic inspection method. “The trend goes toward zero-defect production that ensures the quality of every single welding seam. We can guarantee it with this technology”, says Dr. Mootz.

ELC series—a success story in transmission manufacturing

Of course, the laser welding machine itself is perfectly configured as well. It is always a customized solution, based on the ELC series machines—each model being ideally suited for different types of components. For example, the ELC 160 HP machine is a special solution for gearwheels. On the other hand, the ELC 160 model provides an all-round solution for many automatic transmission and dual clutch components. Another major success factor is the cooperation between EMAG Automation and EMAG Maschinenfabrik in Salach. By combining their resources, they can implement the complete production sequence for transmission components—from welding to turning and grinding. “In this way, production planning has become so much easier. This is a huge benefit that is continually increasing its market recognition “, concludes Dr. Mootz.

Bystronic, provider of state of the art sheet metal processing systems and services has agreed an innovation partnership with Lantek, leaders in software solutions and the development and deployment of software systems for the optimized production of sheet metal, tube and profile parts.

The two companies have entered into a long term technology partnership and a strategic global alliance whereby Lantek will provide Bystronic with manufacturing management software systems and consultancy expertise.

Bystronic wants to satisfy their customers’ needs with a reliable and robust manufacturing management system which has been widely tested worldwide to support its excellence in machines and its global sales network. Lantek brings its global presence, its software engineering expertise, and its unique and powerful manufacturing management system, providing an ideal match for the manufacturer. Together, Lantek and Bystronic will be able to accelerate the pace of key developments.

The aim is for the companies to collaborate to develop an MES system which will be seamlessly integrated with Bystronic‘s machine systems and software, resulting in a solution which will excel in cooperating with the Bystronic’s systems, raising them to the next level of productivity and efficiency.

The collaboration between these two industry leaders will help in the realization of the digital factory for both Lantek and Bystronic customers. The combining of the resources and experience of these two industry pioneers in machine tools and software is a critical step in driving innovation and making the digital factory a reality. Together, Bystronic and Lantek have a great legacy and will be instrumental in building the most advanced sheet metal production facilities ever constructed.

Alberto Martinez, CEO, Lantek said, “I am thrilled that Lantek is now a technology partner for Bystronic, a symbol of innovation for machine tool builders worldwide. The Lantek technology portfolio is wide and deep, and Bystronic’s excellence in machine construction is world renowned. With innovation a part of the DNA of both companies, this partnership will help Bystronic’s customers transform how they manage Bystronic machines and transcend the established boundaries in the sheet metal industry.”

Bystronic CEO, Alex Waser, says: “With Lantek, we have gained a strong partner who will help us expand our existing software portfolio with new solutions. This partnership will provide our customers with twofold know-how. Together, Bystronic and Lantek will develop innovations that will guide users into a world of digitally networked manufacturing.”

Both Lantek and Bystronic are celebrating their 30th anniversary this year, so the alliance marks this milestone for the two companies. For Lantek, the agreement will underpin its strategy which focuses on the digitalization of sheet metal companies worldwide.

In a Ford Motor Company factory in Cologne, Germany, KUKA’s LBR iiwa robot is helping to transform their production line into Industry 4.0 – the 4th industrial revolution – in which humans work hand-in-hand with robots and factories become smarter.]

The robotic factory of the future can be found in Cologne

The LBR iiwa on Ford’s production line help to install heavy shock absorbers into the popular Ford Fiesta, a task that was very difficult to implement with traditional automation. This left the human workers on the line to do repetitive, ergonomically difficult and technically challenging work in a fast paced environment all on their own.
Worker and robot work together hand in hand.
Humans and robots augmenting each other’s strengths

Now, with the LBR iiwa, the human workers can focus on ensuring the production is running smoothly, while leaving the heavy and straining tasks to the robot – each augmenting the other’s efficiency and particular set of skills. This is one of the key tenets of Industry 4.0 and LBR iiwa is the perfect robot to do it safely and flexibly thanks to its unique set of integrated sensors that make it extremely touch sensitive and dexterous. Not to mention it’s pretty fun to be able to get a backrub from, and have a coffee with, the LBR iiwa. The workplace of the future is here today!

GF Machining Solutions, a division of GF, and EOS, Krailling (Germany), have entered into a strategic cooperation agreement to offer customers innovative solutions combining both companies’ technologies. The two companies have agreed to focus on the mold and die sector. They will develop exclusive solutions for mold makers, a market in which GF holds a leading position thanks to its EDM, high speed milling and automation technologies.

The additive manufacturing technology offers for such customers the possibility to generate metal inserts featuring cooling close to the surface, thus allowing for a shorter mold cooling sequence and therefore a much faster plastic injection cycle time. GF and EOS will undertake the integration of the additive manufacturing machines into the production process of mold inserts, including the necessary software and automation link with downstream machine-tools and measuring devices.

“We welcome very much this strategic partnership”, says GF CEO Yves Serra. “GF and EOS complement each other very well to offer the large customer base of GF Machining Solutions a unique set of technologies.” “The cooperation allows us to increase the value for customers within the mold and die sector, by integrating conventional and additive technologies. This is a large step towards seamless production and we join forces with a strong and experienced partner.” says EOS founder and CEO, Dr. Hans J. Langer. The first solutions will be shown at the EMO 2015 to take place early October in Milan (Italy).

ABB, the world’s leading power and automation technology group, has won an order worth $52 million to boost the flexibility and efficiency of Changan Ford Automobile Co., Ltd.’s new production facility in Harbin, China. The robots will be used to make Ford’s new Focus model. ABB will provide robots including the IRB 6700 and IRB 7600 for Changan Ford’s new highly-automated “Body in White” welding production line. Included in the order is ABB’s GateFramer car body framing positioning system, capable of producing up to six vehicle models on the same line, with just 18 seconds needed to switch to a different model.

ABB robots at the new Changan Ford plant will bolster the carmaker’s flexible manufacturing allowing it to respond swiftly to changing consumer sentiment and demand while simultaneously reducing investment costs compared to traditional production lines. ABB has worked with Changan Ford since 2007, with ABB robots producing the joint venture’s Ford Mondeos at manufacturing plants in Chongqing. “Changan Ford and ABB have a longstanding relationship, and we are pleased to see ABB’s solid reputation for providing outstanding and reliable technology and excellent project management capabilities gain customer recognition once again,” said Pekka Tiitinen, president of ABB’s Discrete Automation and Motion division. “Improving industrial productivity is one of the major drivers of ABB’s business growth under the ‘Next Level’ strategy. ABB’s flexible, intelligent manufacturing technologies help customers effectively reduce their investment costs and enhance their productivity and respond to the market needs in a timely fashion.”

The IRB 6700 robot family, a new generation of large industrial robots, was introduced to the market in 2013. More robust and 15% more energy efficient than its predecessor, its maintenance has been simplified, making it the highest performing robot for the lowest total cost of ownership in the 150-300 kg class. ABB also will provide Changan Ford with comprehensive and advanced Body-in-White solutions, including a flexible car body conveying system and laser welding system, as well as the robotic Roller Hemming system which is used for the production of the vehicles’ four doors and roof. ABB’s industrial robot technologies cover the entire automobile production process, including stamping, Body in White, painting, and powertrains.

Automobile customers include international automakers such as BMW, Honda, Volvo and Great Wall Automobile. ABB Robotics is a leading supplier of industrial robots – also providing robot software, peripheral equipment, modular manufacturing cells and service for tasks such as welding, handling, assembly, painting and finishing, picking, packing, palletizing and machine tending. Key markets include automotive plastics, metal fabrication, foundry, e lectronics, machine tools, pharmaceutical and food and beverage industries. A strong solutions focus helps manufacturers improve productivity, product quality and worker safety. ABB has installed more than 250,000 robots worldwide.

Mandelli Sistemi has an experience of over 80 years in the world of machine tools. During these years it has reached the top of the market not only nationally but also at an international level by designing and building machines used in different application sectors. However, it has consolidated its position in two main sectors in particular: energy and aeronautics.

The aeronautic industry is a strategic sector for Mandelli as the main aircraft manufacturers estimate that the world fleet will double in size in the next 20 years from the current 20910 to 42180 with 36700 new airplanes and a $ 5.2 trillion turnover. The main factors for this result are the expected economic growth, especially in the BRICS countries, that will attract businessmen from all over the world, increment in tourism and reduction in the ticket prices.

Mandelli is ready for the challenge with its range of machining centers suitable for working hard material with a complex shape, often requiring turning and milling operations. The raw parts are usually plates which have to be “machined from solid” or they can be forged parts or castings with a considerable amount of allowance to guarantee the absence of defects in the material: the machine tools must, therefore, be very stable for heavy stock removal during the roughing operations, but at the same time, they must also be dynamic and accurate in the finishing operations of complex profiles. Mandelli’s response to this was the Multitasking Machining Center, able to automatically switch from operations with rotating tools to the standard machining operations of a vertical lathe. Mandelli laid its roots on multitasking machining many years ago: way back in 1992 it build the M8 U/T Machining Center, then it passed on to the Storm 1400 with the introduction of the tilting head, followed by the new Spark Line that includes turning/milling machine models for which Mandelli took heed of its past experiences and focused on the fixed table solution. This type of configuration produces excellent performances in terms of stock removal volume and machining precision. The large size rolling guides and the FEM optimised structure are the perfect match between dynamic features and machining rigidity. The Spark Line includes two turning models, respectively able to hold components with Ø1600 and Ø2000 swings and have a loading capacity of up to 7000 kg. The Spark A/T has recently been equipped with various accessories which can be loaded automatically and which further improve the machining flexibility: an extension for turning operations up to a depth of over 600 mm, an angular head for the drilling of internal diameters, motorisation for the facing tools. All these options are available with automatic tool change on the actual accessory.

]]> https://mfgtechupdate.com/danobat-reinforces-its-specialization-with-bgm-machines-for-grinding-ball-valves/ Tue, 23 Jun 2015 09:01:03 +0000 http://mfgtechupdate.com/?p=5861 The Oil & Gas sector has always been a highly demanding industrial market. The shortage of available energy resources, increased activity in deep waters, high pressures, low temperatures, extreme conditions, etc,  in addition to the absolute need for high productivity and  reliability make it a challenging industry in a complex world. DANOBATGROUP has a business […]]]>

The Oil & Gas sector has always been a highly demanding industrial market. The shortage of available energy resources, increased activity in deep waters, high pressures, low temperatures, extreme conditions, etc,  in addition to the absolute need for high productivity and  reliability make it a challenging industry in a complex world.

DANOBATGROUP has a business area specialized in turnkey solutions for the Oil & Gas industry. The company has been working together with the world’s leading manufacturers such as Aker Solutions, Cameron, Metso, Mogas, NOV, Tenaris, Tpco and Vallourec among others, providing high value-added solutions in the manufacture of parts such as pipes, couplings, high pressure valves, ball valve seats, balls for ball valves, and more. In this occasion DANOBAT comes up with a solution for the machining of balls for ball valves: the DANOBAT BGM mahine. The BGM is able to machine diameters up to 2100 mm and materials with a complex machinability such as stainless steel, duplex and superduplex HVOF. Its long-standing experience in the field of grinding technology is materialised in this product family. Machining is performed with a segmented grinding wheel and the power spindle ranges from 25 to 85kW.

DANOBAT BGM machines govern the force exerted on the   ball during the machining process, thus guaranteeing the surface finish requirements set by the client. Also, centering of the workpiece is performed by controlling the two axes to adjust the height of the wheel spindle to the horizontal work spindle axis. Furthermore, during the machining process, measuring can be done before and after grinding with the purpose of obtaining a more controlled result. The operator can monitor and make adjustments to the entire process through the graphic 12″ NC panel with CNC or PLC technology and specific software for grinding balls of ball valves.

The bed is also designed and optimised to achieve the best results, facilitating the removal of residues produced during the grinding process so as not to damage the workpiece or the machine components. Even so, both the linear axis and the spindles are protected against residues with pressurised metal bellows to ensure the durability of the BGM. These machines offer several possibilities for customisation to suit the needs of each customer and each process. Optional equipment includes, among others, turning capability, diamond dressing and automatic tool changes. These configuration modules facilitate several automation processes and as a result enhance the productivity of the machine.

However, DANOBAT solutions for this specific sector do not end here. Apart from the earlier mentioned system, the company offers a comprehensive solution for machining the ring of the valve seat of between 100 to 1700 mm, and its manufacturing plant in Germany, DANOBAT-OVERBECK, manufactures machines  such as the IRD model which has been conceived to grind smaller valve balls.

A growing relationship with Italian automotive supplier Faustinelli s.r.l. leads to a new service agreement and a robot package with Integrated Vision, providing key advantages such as more flexibility, faster setup time and easier handling. Mild weather and well-drained soil makes the northern Italian region surrounding the city of Rovato perfect for cultivating grapes and winemaking. In this area companies ranging from small- to medium-sized are mostly involved in the food and beverage and engineering industries. With its workforce of 30 employees, Faustinelli fits the area well, specializing in precision machining of mechanical parts for water pumps and steering produced for the automotive industry.

The company’s relationship with ABB Robotics harkens back to 2010-2012 when two robotized cells were equipped with an IRB 1600 and an IRB 2600 for picking and placing of machining tools. Shortly thereafter, a Robot Care service agreement was signed with ABB Robotics. In 2014, pleased with the service of the Italian Service Team, Faustinelli ordered two reconditioned robots: an IRB 1400 and an IRB 1600 with Integrated Vision. Impressed with the resulting added flexibility and lower setup time, yet another reconditioned IRB 1600 with Integrated Vision was ordered at year’s end.

“Integrated Vision ensures full flexibility,” says Dr. Diego Scarsi, Managing Director, Faustinelli s.r.l. “Just one click, and the robot park can start again with a new part.”

Faustinelli’s Chief Technologist Stefano Zani adds that the new feature has dramatically shortened system setup time. “Integrated Vision lets me create a new job 50% faster than before. Being integrated with RobotStudio, I no longer need to use two programs to setup a new robot operation. Thanks to ABB’s advanced algorithms, no special measures and/or corrections are needed when creating the job. Everything is designed to be quick, easy and efficient, which translates into increased quality and productivity.”

From humble beginnings with just one Robot Care service agreement to a full-fledged product and service package, ABB Robotics’ relationship with Faustinelli highlights how service is truly scalable—and hints at a strong relationship into the future.

Summary of service agreement benefits:
Peace of mind with ABB keeping the robots running
High productivity
Fewer unplanned stops
Longer life due to world-class maintenance
Fixed costs

Summary of Integrated Vision benefits:
Increased flexibility
Shortened setup time
Ease of use while integrated with RobotStudio

(Photo: ABB)

Perfect for high-volume job shops as well as aerospace and construction manufacturers, the Mazak INTEGREX e-1250V/8 Multi-Tasking machine combines full 5-axis milling, powerful turning and pallet changing to productively process complex parts up to 57″ in diameter and 63″ high in single setups.

The machine employs a 10,000-rpm, 50-hp milling spindle with a B-axis tilt of -30/+120 degrees for accurate 5-axis operations, while a 500-rpm, 54-hp direct-drive C-axis turning table with roller gear cam technology eliminates backlash for smoother, high-precision rotation in heavy-duty cutting operations. High-speed and high-torque milling spindle specifications are also available so the machine can successfully meet a broad range of application requirements involving materials such as titanium, aluminum and steel.

Mazak situated the machine’s automatic tool changer, available in tool storage capacities of 42, 84, 120 or 162 tools, near the CNC so operators can perform quick visual tooling checks. Such positioning also puts the cutting tools closer to the spindle for faster change outs. Furthermore, this high-speed, rack-type tool magazine is expandable after the machine’s initial installation. Axis travels on the INTEGREX e-1250V/8 measure 73.82″ in X, 49.21″ in Y and 52.95″ in Z. The axes incorporate Mazak’s MX Hybrid Roller Guide System to achieve high levels of durability and reliability that result in long-term accuracy. The innovative way system increases vibration dampening, extends tool life, handles higher load capacities and eliminates tramp oil in the coolant via a greener grease-based lubrication system.

The machine features Mazak’s all-new MAZATROL SmoothX CNC, which offers the industry’s fastest processing capabilities. As a key component of the company’s new SMOOTH TECHNOLOGY process-performance platform, the CNC offers several productivity advantages that reduce machining cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form die-mold machining. Highly beneficial to part manufacturers focused on high-volume production, the INTEGREX e-1250V/8 comes with a two-pallet changer that provides unattended operations and off-cycle part setup. This simple, efficient form of automation allows operators to load, unload and inspect parts on one pallet while the machine works on the other undisturbed.

For those seeking lights-out operations, the machine also integrates with the company’s PALLETECH System, an advanced pre-engineered palletized manufacturing solution.