Press Ensures Safe Operation For Assembly Company

Tox Pressotechnik has provided a press system designed to meet a series of ergonomic and safety needs, for an assembly company with handicapped employees. Vebo Werkstatt Olten eventually installed a Tox Press type CEB, consisting of a press frame of C-shape, a pneumo-hydraulic drive system, a Tox Powerpackage EKSD and a base frame. The press is equipped with a safety control, a swivelling control panel and a pedal switch, protective sheathing and a safety light grid. For universal use with most tools, the throat of the C-frame press is 200mm and the tool aperture is 200mm.

The pneumo-hydraulic Powerpackage cylinder Tox EKSD generates a maximum press force of 130kN at 6bar compressed air. The 100mm total stroke of the cylinder and the real powerstroke of 10mm ensure that the punching, forming or pressing-in/pressing position are attained at a very high speed and the press-force stroke is realised in a sensitive way. In order to limit the strokes and reduce mechanical loads, the drive cylinder is provided with total stroke setting and damping of the cutting impact.

The Powerpackage is equipped with a power bypass. The C-frame press, with its drive cylinder, is mounted on a base frame that also supports the circuitry and the control technique, as well as the protective sheathing with the safety light grille. Tox has mounted the C-frame press off-centre on the base frame so that longer piece parts (up to 500mm) can also be machined within the fully protected press area. The press control is coupled with the safety elements so that no bridging or other manipulations are possible. Usually the press is started by two-hand actuation, where both keys of the two-hand control are pressed simultaneously.

Due to the protective sheathing and the above-mentioned safety light grid, the press area is fully protected against the intervention of third parties. Tox has succeeded in realising the C-frame press system mainly from standard components taken from the Tox construction kit. Armin Bieri, department head of mechanics at Vebo Werkstatt Olten, said: 'We use the press in a flexible way for punching or separating and produce 33 different types on it of C-profiles for our customer. 'We then mount slides in the profiles and the C-profile with slide completes sun protection units and revolving shutters. 'The length of the C-profiles is from 75 to 500mm and they all can be machined within the protected press area,' he added.

Factory Master Used For Pipe-Assembly Manufacture

B and D is using the Factory Master system in the manufacture of fabricated pipe kits and assemblies, which are used on RR commercial, military, marine and power-generation jet engines. The integrated system can handle complex BOMs, purchase ordering and production procedures, enabling it to keep track of the entire process.

The Material Requirements Planning Report (MRP) allows customers to ascertain what is currently available and what is going to be available against sales orders. Factory Master enables: bulk purchasing of common components; greater proactivity; reduced 'fire-fighting'; time saved identifying and ordering requirements; and forecast of results in shorter lead times.

Hepcomotion Develops Actuators For X-Y-Z Systems

Hepcomotion has developed a range of actuators, enabling it to supply X-Y-Z systems for industrial and scientific tasks such as pick and place, automated assembly, inspection and product labelling. According to the company, X-Y-Z linear motion systems are widely used throughout industry. For many applications, using the same type of linear actuator in each of the axes is an adequate solution. However, with manufacturing economics focusing on greater productivity, X-Y-Z systems are increasingly being specified to automate vital processes.

Their speed of operation is often greater and their duty cycle much longer. The new actuators have been developed to address these different needs so that each axis operates optimally and contributes to the overall efficiency and longevity of the system. This concept still allows X-Y-Z systems to be constructed using standard, off-the-shelf components but accommodates the specific characteristics of the application. The Hepcomotion method is to recommend the most appropriate actuator to meet the criteria of a given application.

However, to illustrate the point, a typical configuration for a low-weight payload system would start with the company's PDU2 linear actuator as the foundation of the X axis. The Hepcomotion PDU2 is a cost-effective and compact actuator. It comprises a slotted profile into which fits a toothed belt drive and a carriage - an arrangement that effectively seals the unit. The actuator's Herculane wheels run virtually friction free on the inside surface of the profile, providing stable support for the carriage plate; felt wipers sweep debris from their path.

This also means that the wheels operate well without the need for lubrication. The Y axis of a typical X-Y-Z system is often required to have a particularly high load capacity and stiffness against twisting loads. The new Hepcomotion PDU2M is said to address this need. It shares the same technology and format as the PDU2 but with moment load capacity improved by 200 per cent and stiffness by 1,000 per cent. The direct load capacity is also 50 per cent greater. In practice, this means, for example, that designers can use a single PDU2M unit as a horizontal axis in an X-Z system, where previously two PDU2 units working in parallel would have been required to provide the necessary rigidity and strength.

The needs of the Z axis are different again, with enhanced linear force and higher gearing often required. The new PSD80 linear actuator is suitable for this duty, with drive from a smooth stainless-steel lead screw operating with a bearing polymer nut. Again, it uses the same Herculane wheel technology in a unit that is matched to the other axes in terms of performance, size and cost. A choice of motors and gearboxes is provided with all Hepcomotion driven actuators, for which flanges are provided to facilitate connection. A Smart Drive Taranis stepper motor drive and control package is also available.

Left, right or double drive shafts can be supplied as well as other options such as different carriage designs, holding brakes, positioning encoders, limit switches and cable carriers. The development of the company's Heavy Duty HDS2 product has introduced larger bearings, slides and racks, additional mounting elements and automatic lubrication systems. For instance, the largest vee bearing now measures 150mm in diameter and has a radial capacity of 100,000N (10 tonnes); these developments have opened up application possibilities in the heavy handling markets.

The largest aluminium beam now offered is a 300 x 200mm section and is strong enough to be used as a standalone X axis. With slides complete with rack drive fitted, the solution is often more cost effective than machining a steel beam with slides attached, according to Hepcomotion. The necessary rack lubrication facility is provided in the X-axis carriage, which typically forms the mounting structure for the Z axis. All Hepcomotion actuators fit together using standard components to create multi-axis systems that are guaranteed to perform better than similar units where 'general-purpose' actuators are used for all axes.

Lightweight aluminium T-slotted profiles allow the axes to be incorporated into frames, such as the Hepcomotion MCS Aluminium Frame and Machine Construction System or more complex machines. The company supplies its X-Y-Z systems as individual parts, in kit form or fully assembled multi-axis units. Its approach to X-Y-Z system design can be applied to configurations with a working envelope of just a few centimetres right up to those with dimensions of several metres.

Small-Scale Machine For Micro Injection Moulding

Engel has developed a small-scale electric injection unit with a 15mm screw diameter, suitable for micro injection moulding. Using an E-max 50/50 or an E-victory 50/28, it is now possible to achieve shot weights of less than 1g and part weights down to 0.1g with a high level of reproduction accuracy, according to the company. Two new drive variants with injection speeds of 330mm/sec (standard) and 550mm/sec (high) are available for the screw diameters (15/18/20mm).

The optimised screw geometry, in combination with a specially designed feed opening throat, enable the trouble-free processing of standard pellets with improved plasticising and reproducibility, even with this small diameter.

Beko Oil-Vapour Monitor Gains TUV Certification

Beko's Metpoint OCV oil-vapour monitoring system for chemical and pharmaceutical production processes has been certified by TUV Nord in accordance with the requirements of ISO 8573-1, Classes 1 to 4. According to the company, even 'oil-free' components give no guarantee for 'oil-free' compressed air, owing to the contamination of the ambient air/intake air. In most cases, a certain residual oil content cannot be entirely avoided in standard applications.

The precise monitoring of the oil-vapour content, which is possible at any time, is important. In particular, in critical production processes in the chemical and pharmaceutical industry, in food production and surface coating, the analysis and control of compressed-air quality is a crucial factor, according to Beko. The network-compatible Metpoint OCV offers constant monitoring down to the range of a thousandth mg/m3 and features a touch-screen display and 24/7 process reliability through online measurement.

IMTS 2010 To Feature CNC Control Developments

Fanuc CNC America will showcase advanced CNC control developments at IMTS 2010, along with industry solutions to meet strict automotive, aerospace, medical, heavy industry and job-shop requirements. The company, which will be found in Booth S-8919, will present the new model 30i-B Series CNC Control, the 0i-D/0i-DMate Control with newly enhanced functionality, the new 35i-B CNC Control for transfer-line machines, new five-axis volumetric error compensation and various industry solutions. The new Fanuc CNC 30i-B Series Control is an upgrade from the 30i-A Series.

The 30i-B Series offers enhanced features and functions, with advancements in operability and maintainability including a USB memory port, enhancements in the dual safety check, a new punch press and laser functionality. For advanced machining with high accuracy, the 30i-B provides advancements in high-speed five-axis capabilities, with architecture and software algorithms to reduce cycle times while improving part accuracy and quality. The machine is said to combine reliability and high-speed five-axis features for complex processes.

The 30i-B also features High Speed Smooth TCP, high-speed multi-path PMC, an enhanced tilted working plane and high-speed smoothing functions, enhanced DSPs for advanced servo control such as multi-axis control and high-speed current control and arbitrary speed threading. In addition, the 30i-B has enhanced FSSB and network performance, improved diagnostic functions for MTTR reduction and enhanced DSP for advanced servo control, according to the company. The 0i-D/0i-D Mate Control offers improved features and functionality that are claimed to be cost effective.

These include nano interpolation, Al contour II control, jerk control, a tool management function and grinding functions. The new 35i-B Control, based on the 30i-B series, is intended for transfer-line machines. Suitable for simple high-speed drilling and transfer machining, the 35i-B is equipped with a touch-screen machine operator panel and embedded Ethernet. Fanuc CNC's new five-axis volumetric error compensation increases machining accuracy by evaluating the tool location and orientation error throughout the machining volume. This is said to offer improvements over axis-only error compensation.

Unison Launches All-Electric Tube Benders At Mach

Unison launched a range of all-electric tube bending machines, ideal for most small- to medium-diameter applications involving high-precision small batch sizes and expensive materials, at Mach 2010. Incorporating a real-time Ethernet control system architecture and a new release of programming and control software, the machines are said to enhance the shape-forming capability and flexibility of servomotor-controlled bending. The new UK-built Breeze machines bend faster, exploit advanced multi-axis synchronisation capabilities to support sophisticated roll forming, improve the tool adjustments that can be employed during the bending cycle to generate ultra-precise part shapes and offer a visual collision-checking programming feature as standard.

They also feature an open architecture that can be adapted to integrate an application-specific capability or to build work cells. An all-electric architecture provides tube benders with performance benefits in terms of setup speed, repeatability, lower energy consumption and noise reduction when compared with traditional hydraulically powered machinery, according to the company. At the heart of Unison's new Breeze machine range is a real-time machine and motion system based on the deterministic Ethernet-compatible Powerlink protocol. A 100Mbit/sec network links all of the servomotor drives required to control bending operations.

The speed of the network makes it possible to co-ordinate the movement of the various servomotor axes used during bending - such as the carriage, the plane of bend and the clamp roller - more rapidly, allowing the company to improve the speed of bending for many common tasks by around 10 per cent. The quality of bend shapes and wall thicknesses can also be improved thanks to finer real-time control over the motion profiles used by key bending axes, which move as the rotary draw bending process takes place, such as the carriage and the follower die. The real-time interpolation of multiple axes is also supported by the machine's new motion control architecture.

In particular, this allows Unison to equip machines with flexible roll-forming tools that are able to vary the radius of bending with precision during the bending cycle. Other benefits include improved diagnostics and data collection, which can assist with both programming and maintenance, and connection to factory networks for changing programs and reporting production metrics, for example. The company is also releasing programming and operating software for the tube benders. Among the new and improved features in Version 10 of its Unibend package is a collision-checking capability that helps users to program the machine for new parts. Bending operations are visualised using a 3D model of the machine.

If users see any potential collision problems, bend sequences can be reversed and intervening carriage and rotation movements can be employed to ensure the part can be manufactured easily. Programming itself can be achieved in about a couple of minutes by entering new ISO, XYZ or YBC values (distance tube is pushed out, rotation and degree of bend), linking from computer-aided-design (CAD) or measuring machines, adapting an existing template or interactively teaching the machine. Unison's software-controlled tube bending machinery incorporates a new networked control architecture. Almost all tube bending machines are configured around a base design to suit the user's intended applications, including or excluding facilities as required.

Unison is currently seeing an increase in demand for work cells that integrate tube bending with other processes. The new Ethernet architecture provides flexibility for configuring and building integrated machines and cells; the control network can be very long, allowing physically large processes to be accommodated, and one network controller can handle hundreds of motion axes and other control system resources such as sensors. The networked nature of the control system architecture makes it easier to upgrade systems later in their lifecycle to integrate processes such as loading, end forming and unloading, for example. The company can supply the new architecture on any all-electric tube bending machines capable of handling tubing with diameters up to 180mm (7in). Machines can be fitted with single- or multi-stack tooling and with two or more bending heads.

Hydrocarbon Fluorimeters Monitor Oil-Spill Extent

Chelsea's range of hydrocarbon fluorimeters is being deployed in the Gulf of Mexico to monitor the extent of the oil spill. Originally designed for military use, these reliable, robust, high-sensitivity fluorimeters have previously been used to detect crude and refined oils in a range of environments. The UV Aquatracka and the Uvilux submersible fluorimeters monitor the concentration of refined (360nm) or crude hydrocarbons (440nm) in a range of coastal, oceanographic and freshwater applications.

They have been designed to be deployed independently, as well as from submersible vehicles, diver held, moored, profiled or as part of a flow-through system. These robust, compact, lightweight instruments are suitable for shallow and full ocean depth. They are also suitable for long-term deployment and will be used to monitor the extent of the pollution caused after the oil slick has dispersed. The UV Aquatracka displays real-time, live data via the Chelsea supplied GUI. Similarly, real-time data from the Uvilux can be transmitted via a Bluetooth wireless link to either a PDA or a PC.

Veolia Filters Aid Effluent Wastewater Treatment

Glen Water has selected Hydrotech Discfilter technology from Veolia for a project that is providing final effluent wastewater treatment and a sludge disposal solution in compliance with EU Directives. The Hydrotech Discfilter is considered to be a flexible technology that uses a series of segmented discs to support a woven media (polyester or stainless steel). The Hydrotech Discfilter was selected for use on the Omega scheme due to its modular design and compact layout. Under normal operating conditions the Hydrotech Discfilter will remain stationary.

The influent enters the inside of the unit via a central drum, which houses a series of paired filter elements that remove particulate solids from the influent. As the water passes through the woven filter, solids are captured on the inner face of the element. Accumulation of these captured solids reduces the hydraulic throughput, which results in an increase in head loss over unit. At a predetermined influent level, the unit automatically initiates a backwash, which flushes away the captured solids from the inner face of the filter, resulting in clean elements media being presented to the influent.

The Hydrotech Discfilter uses the filtered water produced by the process for backwashing. The benefit of this system is that power consumption is reduced by only backwashing to meet on-site demands. The dirty backwash water produced by the Hydrotech Discfilter process is collected by a trough located within the unit. Backwash water is discharged under gravity for onsite disposal or blending to the head of the works. The backwash water volume produced by the Hydrotech Discfilter is typically between one per cent and three per cent of the maximum design flow. Filtration is continuous throughout the backwash cycle and once the cycle is completed, the Discfilter stops rotating.

For the Northern Ireland Water Omega project, the Hydrotech Discfilter has been applied in both its tank and frame using both the 1700 and 2200 versions. The tanked version has been designed to be a stand-alone model that can be adapted to any site where a suitable base is available. This Hydrotech Discfilter is housed inside a stainless-steel tank for direct installation at site. The frame version has been designed for installation inside a concrete chamber and has the flexibility to be adapted for use inside an existing sand filter structure. The Hydrotech Discfilters are providing tertiary treatment at four sewage treatment works in Northern Ireland: Armagh, Richhill, Ballyrickard and North Down Ards.

Armagh has been designed to serve a population equivalent of 21,000. The scheme uses two HSF 2212-2F filters, capable of meeting the projected 2030 design horizon of 50,000PE. Richhill, which currently receives about 1,300m3/day of mainly domestic wastewater, has been designed for a 2030 loading of 5,000PE; this duty is met by two HSF 1706/5-2F filters. Ballyrickard receives wastewater from a 50,000PE catchment and discharges treated effluent into Strangford Lough via Newtown Burn; consequently the Northern Ireland Environment Agency has imposed a more stringent consent on this discharge. Here, the duty is met by three HSF 2214-2F filters, each rated for 50 per cent of the flow.

The North Down Ards works is a new facility that will rationalise the existing wastewater treatment systems in the surrounding catchments. It treats combined domestic and industrial wastewater from a 110,000PE to meet the requirements of the Urban Wastewater Treatment Directive. After sequence batch reactors, tertiary treatment uses four tank-mounted HSF 2220-IF filters prior to UV treatment. The Hydrotech Discfilter has proved a cost-effective and reliable solution for tertiary treatment applications. The compact design means a small footprint compared with other technologies such as sand filters and the low wash-water consumption gives it a clear hydraulic advantage.

Standard modular designs in four ranges can individually treat up to 400 litres/s (any flow rate can be treated by applying further Hydrotech Discfilter units to suit on site conditions). The units are available in a choice of materials: ABS plastic or stainless steel for the discs and 304, 316 or Duplex stainless steel for frames and tanks. The woven media can be supplied to suit any application with a range between 10 and 500 micron. The Hydrotech Discfilter is considered to have a low head loss, low power consumption and minimal maintenance requirements.

Ethernet Cables Incorporate Flexlife Cable Jackets

TURCK has announced Cat 5e Ethernet cables that are Gigabit capable and are particularly suitable for harsh environments. The cables incorporate incorporate flexlife cable jackets, which are resistant to abrasion, crushing forces and chemicals.

The Ethernet cables are available with four or eight conductors (two and four pair counts). The cables may be specified with straight or right-angle RJ45 or M12 connectors, accommodating diverse application requirements.

Aker Delivers Floating Platform To Statoil

Aker Solutions has designed, engineered and assembled a semi-submersible platform for the Gjoa oil and gas field offshore Norway that is expected to help significantly reduce carbon emissions. With a topside weight of 22,000 tonnes and hull dry weight of 15,000 tonnes, the Gjoa deck measures 110m long and 85m wide. The platform's highest point is the flare tower at 143m.

More than 500 Aker Solutions engineers have been mobilised to design the platform, from Oslo, Norway, and Mumbai, India. During the final assembly at Stord, peak manning reached 3,000 skilled operators. Installation of the mooring system, transportation and installation of the Gjoa platform is carried out by Aker Solutions' subsidiary Aker Marine Contractors.

PFC And FV Technology For Research And Development

GYS, a welding gear and battery charger manufacturer, has invested in Power Factor Correction (PFC) and Flexible Voltage (FV) technology across a range of MMA for its research-and-development centre. PFC technology offers the user a range of benefits, including a reduction in power consumption. The requirement for less power also allows the user to weld at higher levels on a lower power supply. Using GYS's PFC-equipped MMA machines will allow high-duty-cycle welding at 160A (sufficient for 4mm rods) on a regular 13A power supply.

Normally, a 160A machine without PFC is capable of welding only 3.2mm electrodes at 125A using a 13A fused plug. Inside electrical cables, energy travels at various frequencies. In the UK, we use energy at 50Hz, but up to 25 per cent of that energy travels at either higher or lower frequencies called diffractions. Mathematical models show that all of these diffractions add to each other for certain frequencies (also called harmonics) and a significant amount of energy travels at these frequencies.

Welding equipment without PFC technology can only draw the energy at 50Hz, which is not very efficient, while equipment with PFC technology is able to draw all the energy that is available from all the frequency levels. GYS is also equipping machines with FV technology. FV machines can operate at any voltage from 85V to 265V. Suitable for 110V applications and whenever there is a likelihood of variations in voltage, for example, on site with a generator and maybe with long extension leads, the combined technology of PFC and FV welding performance can be enhanced where there is only a suboptimal power source available.

For instance, the GYSMI 196 FV is capable of welding 3.2mm electrodes on 110V on very long extension leads. These technologies are currently incorporated into the GYS range of inverter MMA. TIG and plasma machines include the GYSMI195, a 230V 160A MMA machine; the GYSMI 196FV, a MMA machine and Master 200FV, a 200A PFC and FV MMA/TIG inverter; the TIG200DC HF FV; TIG 207AC/DC HF FV TIG machines; and the 31FV plasma cutter.