Tag Archives: BernardandCompany

Hennig Introduces 2-1/2” Pitch Steel Belt Chip Conveyors

Whether the application involves producing/removing chips or moving parts/scrap pieces, Hennig can provide the chip conveyor for all machine tool requirements.  The company’s new 2-1/2” pitch steel belt can be made for most applications in the field when the standard 1-1/2” pitch belt is not effective for the particular conditions present.

Conveyors from Hennig, a leading supplier of chip conveyors to the global machine tool market, can be manufactured in widths from 4” to 80”, depending on the need.  The unique Hennig belt hinge is designed as one continuous piece, whereas many competitive brands do not have this feature.  The manufacturing of these belts is done on Hennig’s in-house press equipment.

Hennig recognizes the special requirements needed when designing a parts conveyor on which direct loads contact the belt.  Impact plates are just one of the many options to be considered when customizing a conveyor for these applications.

Chip volumes can also vary between applications, so speeds and sizes are always evaluated by Hennig’s engineers.  Special incline covers (top hat design) can be included when larger amounts of stringy/balled chips are to be evacuated from the machine.

As adjunct to this new 2-1/2” pitch steel belt conveyor, Hennig also offers complete filtration systems, as needed.  The company’s Chip Disc Filtration (CDF) systems can also be used with the new 2-1/2” pitch conveyor.  These systems can filter down to 25 microns and additional bag filters can be included to achieve the through-spindle requirements on most machine applications.

Whether the need involves moving chips into a hopper, evacuating larger volumes of chips through a plant wall into a truck/dumpster or hauling scrap parts from the machine, Hennig can assist machine builders and end users alike with any specific requirements.

Innovations and new developments in machine tool design present myriad opportunities for the engineers at Hennig (www.hennigworldwide.com), who have been designing and producing custom machine protection and chip/coolant management products for state-of-the-art machine tools for over 50 years. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Hennig has manufacturing facilities in the U.S., Germany, Czech Republic, France, Brazil, India, Japan, China and South Korea. Its North American repair centers are located in Machesney Park, Ill.; Chandler, Okla.; Livonia, Mich.; Blue Ash, Ohio;  Mexico City, Mexico; and Saltillo, Mexico.

For more information, contact:

Tim Waterman
Hennig Inc.
9900 N. Alpine Rd.
Machesney Park, IL 61115
(815) 316-5277
info@hennig.ame.com
www.hennigworldwide.com

Connect with Hennig online:       

European Contact:

Hennig GmbH, Überrheinerstr. 5, 85551 Kirchheim, Tel. 49 089 96096140

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James Tool Achieves AS9100 Registration and Completes Facilities Expansion

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New Managing Director for Hunter Asia/Pacific Operations

Mr. Peter Li will assume the new position of Managing Director for all Hunter Asia Pacific Operations, effective February 1, 2013.  Hunter is the world leader in automated matchplate molding machinery and mold handling lines for the foundry industry.

Peter Li’s 16-year career with Hunter has been dedicated to sales and manufacturing management in the Asia Pacific (A/P) territory. He was instrumental in the successful development of the company’s China operation, “Hunter Automated Machinery (Shanghai) Ltd.”  Today, Hunter builds machinery and other equipment in China to serve the A/P market.

Peter will be responsible for A/P marketing and manufacturing programs, including the Shanghai plant, the expansion of our agent network and the integration with new partners where necessary for Hunter to compete effectively in the local markets.

For further information on this announcement, interested parties may contact:

HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Attention:  Bill Hunter, CEO
Web: www.hunterfoundry.com
Connect with Hunter Foundry online:    

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JetSlinger from Hunter

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Oilfield Technology: The Perfect Machining of Threads On Delivery Pipes and Casings

Whether we are talking about North America, Asia or Russia, within the oil and gas industry, there is a spirit of optimism. Geological discoveries have led to a massive increase in the estimated reserves in many countries. Along with these discoveries, the potential for the use of innovative technologies has also increased. According to the expert estimates, oil production in the Gulf of Mexico alone will rise from the present 1.3 million to 1.7 million barrels a day during the next decade, with demands for the highly sophisticated technological equipment required to accomplish it increasing as well. Two examples are delivery pipes and casings.  To create the connection safely and in perfect alignment depends on the threads on the pipe ends. With its USC turning machines, the specialists from EMAG Leipzig have not only created a tool that specializes in this application – and one that has perfected the production sequence for these threads – but also developed complete solutions that guarantee component quality and process integrity.

Economic key performance indicators for suppliers to the oil and natural gas industry change rapidly. An impressive example of this is found in the USA. The USA hopes to reduce its dependence on oil imports and instead invest heavily in new technology. An indicator, for the US, are imports of equipment technology for the American oil and gas industry, which the U.S. Department of Commerce for 2012 show an increase of 33 percent, compared to the previous year. The experts also expect a production boom in South America and Asia. For Brazil, the foreign trade experts at Germany Trade and Invest (GTAI) predict a “high level of growth in new reserves“. And on the other side of the globe, the investment volume in the oil and gas sector of Vietnam alone has reached 40 billion USD, according to GTAI.

The experts at EMAG Leipzig are aware that this extraordinary dynamic has a direct impact on the production of the required technology. For decades, the machine builders at Leipzig have been specializing in the machining of delivery pipes and casings for the oil and gas industry. Many users can no longer do without their special know-how in demanding thread production. Frank Schiffler, Head of Sales, fills us in on the background: “We are talking about a gigantic production output. One steel mill produces up to 2 million metric tons of pipes per annum. Component quality is paramount for these because the pipe threads have to be totally leak-proof and must carry the enormous total weight of pipe and oil during the delivery. The machining centers used must ensure that the quality and efficiency of the threads produced is 100%.”

Flexible solutions for the production of pipes

The USC series from EMAG Leipzig Maschinenfabrik represents an extraordinary, sophisticated solution for this particular production requirement. Flexibility is very important in the construction of these turning machines. Not only do the different machine sizes allow for the complete-machining of different sizes of pipes with external and internal threads to API and GOST standards, they can also cut all proprietary threads. “The larger oil field technology producers have their own thread standards.  We can adjust our machines perfectly to their demands“, explains Mr. Schiffler. For instance, all workholding and centering equipment is configured to suit individual requirements. The same applies to all automation components. As a result, the customer has an extremely fast production solution that automatically loads and unloads the components in 12 to 20 seconds (depending on pipe size and thread type), then carries out the 3-part threading process – from facing to chamfering and finally threadcutting. The output ratio therefore increases enormously, compared with that of traditional turning machines.

However, there are two important factors that must be taken into account when machining threads on delivery pipes and casings: processing quality and process integrity. The quality is guaranteed by a perfectly adjusted machine, with proven EMAG technology and the know-how of the speciality machine builders from Leipzig come together. The whole process benefits from the following important design details:

• The machine base is made with Mineralit (a polymer concrete) and guarantees the stability and the vibration-resistance of all machine components.
• The main drive forms an integral part of the spindle unit. Its frequency-controlled, maintenance-free AC asynchronous motor provides a high torque rate, which allows for the simultaneous machining of both ends of the pipe.
• The pipes are safely clamped in front and rear chucks that – depending on workpiece requirements – can be actuated pneumatically, hydraulically or mechanically.
• The pipe ends are stabilized during the machining process by the insertion of vibration-reducing mandrels, resulting in the highest possible precision.

“This quality is a feature of all our USC series machines,” acknowledges Mr. Schiffler. Depending on the machine used, the max pipe diameter can be any dimension from 2⅜” to 20”.

Complete solutions guarantee process integrity

When faced with high production rates, fast machining processes and expensive pipe blanks, machine downtimes are particularly costly for the manufacturer. For this very reason, the process integrity of these machines is another key development area in Leipzig. “We design complete solutions for our customers, who – in turn – benefit from the quality of the EMAG components“, explains Mr. Schiffler. “In addition to that, we integrate, for instance, measuring stations, crack detection equipment, embossing and plating units and, of course, a monitoring system that covers all components. At the end, what we supply is a production system that guarantees the greatest possible degree of process integrity.“ Of similar importance in this context is the worldwide service presence of the specialists. Not only are both user and maintenance staff trained to perfection, a 24-hour 365-day telephone service is also available. This ensures that possible machine downtimes are reduced to an absolute minimum.

Projects from A to Z

How do the special machine manufacturers assess their market opportunities over the next few years? Mr. Schiffler’s judgement on the market’s dynamic is a positive one: “We already are the market leader in machines for the threading of oil and gas pipes; and we intend to further extend this position.“ One formula for success in this field is the famous “Made in Germany“ – which is a sign for quality. Over 70 percent of the machine components are made and assembled at EMAG in Germany. Every customer comes to Leipzig for the machine acceptance, where the first test run, using the actual pipe blanks, is carried out. Only then will the machine be installed at the production site. “Our particular quality of service kicks in long before the machine is built, or the central claim made by EMAG Leipzig would not be a valid one. Our name stands for projects that are carried through to perfection from A to Z, and that represent all-round solutions.“

See the USC series in action HERE.

For more information:

Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com

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Floor-level Cabinet Oven from Grieve

No. 981 is a 350ºF, electrically-heated floor-level cabinet oven from Grieve, currently used for curing flat urethane sheets at the customer’s facility.  Workspace dimensions of this oven measure 48” W x 48” D x 60” H.   18KW are installed in Nichrome wire elements to heat the oven chamber, while 2000 CFM, 2-HP recirculating blowers provide horizontal airflow to the workload.

This Grieve oven has 4” insulated walls, 2” insulated floor, top-mounted heating chamber, Type 304, 2B stainless steel interior, stainless steel exterior with #4 brushed finish, double doors front and rear, plus a special sealing flange to allow the oven to seal into a wall between a cleanroom and the fabrication area in the customer’s facility.

Controls on No. 981 include a digital indicating temperature controller, manual reset excess temperature controller with separate contactors, recirculating blower airflow safety switch and a 30-hour shutdown timer.

For more information, please contact: THE GRIEVE CORPORATION, 500 Hart

Road, Round Lake, Illinois 60073-2835 USA.  Phone: (847) 546-8225.  Fax: (847) 546-

9210.  Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank

Calabrese.

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Small Grinding Center Offers Big Productivity Boost

Automobile manufacturers all over the world were able to enjoy an increase in their sales figures, this year! The biggest increases were experienced in the USA, China, India and Russia. However, the rapidly increasing number of vehicles built also brought some production challenges – for instance, the sub-contractors must deal with the increasing output levels and also need to ensure that process safety and component quality do not suffer. In fact, even the smallest components with complex geometries must be produced with increasing levels of precision.  In the development of the VLC 100 G Vertical Grinding Center from EMAG, our grinding specialists have made sure that the machine concept offers efficient, error-free machining processes for the production of small chucked components.

Small chucked components are typically produced in large quantities. The demand for components, such as gearwheels, planetary gears, chain gears and flanged components for cars, for instance, have necessary quantities that typically go into the millions; and short cycle times in the production of these components have become mandatory. For instance, the internal contour of a gearwheel must be ground in the shortest possible time and the machine’s workholding unit must be loaded with a new workpiece just as quickly. In many production environments, this represents a critical moment, because the idle time is commonly a decisive factor in establishing the economic viability of the whole process.

Automatic loading scores heavily

High output levels – short cycle times. This is exactly why the VLC 100 G Vertical Grinding Center from EMAG, for small chucked components with a maximum diameter of 100 mm, was developed. The machine utilizes its onboard pick-up system to load itself. And while one workpiece is being machined, the operator – or the automation system – is putting the raw-parts on the conveyor belt. This reduces idle time and increases output rates. Another benefit is the vertical machining concept; the design ensures that the grinding sludge falls to the bottom of the machine unhindered, where it is then transported out of the machine. (Click HERE for a video detailing the VLC 100 G Vertical Grinding Center)

Quality control is integrated

Measuring processes can also be integrated into the machine, making quality control an integral part of the whole process. The measuring probe is located between the machining area and pick-up station, where it is protected from contamination.

In use are two different grinding wheels

An important feature of the VLC 100 G is that it offers the possibility to use two grinding spindles, which can be used to perform different grinding operations, or to handle both rough- and finish-grinding work.  In other words, the first wheel performs the “rough” job of removing excess material from the raw-part at high feedrates (the CBN wheel is specially designed to absorb the necessary forces), while the second wheel (with different specifications) takes over the finishing work to guarantee a perfect surface finish on even the most challenging geometries. With the help of this intelligent tooling combination, EMAG design engineers have succeeded in drastically reducing the grinding time of even very complex components. “For the removal of large amounts, two wheels offer a shorter cycle time than one, with the first wheel designed to do the rough-grinding and the second one in charge of finish-grinding work,” explains Dr. Guido Hegener,  Managing Director of EMAG Salach Maschinenfabrik GmbH in Germany.

A convincing machine concept

The combination of fast loading and efficient grinding processes leads to a very compelling machine concept. The VLC 100 G works very well with the dynamic developments in automotive production. Now, with the rapid increase in required quantities, the demand is for new machine concepts that can be integrated into existing production without any problem. With the VLC 100 G, two features enable it to be integrated without any problems. “Programming the workpieces with our new EMAG NAVIGATOR software is simple and intuitive, saving valuable setup time. For many production environments, this is an advantage that should not be underrated,“ confirms Dr. Hegener. Furthermore, the exceptionally small footprint for the VLC 100 G should make the work of every production planner easier. The stand-alone machine occupies about 4.5 square meters (48 square feet), making sure that the growth of a production facility of this kind will not be limited by floor space requirements.

The advantages of the VLC 100 G

• Compact grinder with the highest precision
• The machine can accommodate both internal and external grinding spindles.
• Integral automation, short travel times = short chip-to-chip times
• Vertical machining = unhindered chip flow, with the grinding sludge falling to the bottom
• Optimal access = fast setups
• Great process safety through the use of an optional measuring probe

For more information:

Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com

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Universal Turning Solutions for Manufacturing Companies

Better component quality at a lower price? VL 5i, a vertical turning machine that is custom-made to fully meet the demands of the small and medium size manufacturing company.

With their VL 5i the machine tool specialists at EMAG have developed a comprehensive solution for small and medium size manufacturing companies. It can be used for small and large batch production, and complete-machines workpieces of up to 250 mm in diameter in a single setup. Flanges, gears, gear shafts and steering pinions can be machined with as much efficiency and to the same quality as brake disks or cams. The machine features a powerful 28 kW workspindle with a top torque of 300 Nm, plus a turret that accommodates turning as well as driven tools and has an impressively short indexing time of 2.2 s.

Drilling and milling operations can be incorporated by equipping some or all of the 12 turret stations with driven tools. The outstanding feature in this is the EMAG turret drive that combines high speeds with outstanding performance and a small space requirement. For instance, the diameter of the turret is only 360 mm but accommodates 12 stations and has a maximum torque rating of 45 Nm.

Flexible automation included

Proof of the outstanding quality of the VL 5i is, first of all, its integrated automation system. It uses a recirculating chain conveyor equipped with carrier prisms that deliver the raw-parts directly to a pick-up station for machining. This station is located behind the machining area, so the operator can – at any time – insert new raw-parts at the front of the machine. It is hard to imagine a more flexible and, at the same time, more universal solution for the automation of a machine tool.

Short travel times = short idle times

Another advantage of the VL 5i is its short idle times. Changing workpieces is a very fast process, because the distance between the loading position and the machining position is only 550 mm. The importance the EMAG turning specialists attach to the machine’s efficiency can also be seen in the design of the guideways. They are located outside the machining area, where they are protected against chips and dirt. This reduces the maintenance effort and makes the machine less susceptible to breakdowns. The machine can also be equipped with an optional measuring station, located outside the machining area. Here the component is measured on its way from the tooling zone to the unloading station, while still in its original clamping position. The measuring results are not distorted by the entrance of chips, as the vertical turning operation provides for ideal chip flow conditions.

Energy efficiency is very important

The sustainable use of energy and resources completes the picture of an engineering solution that not only offers a small footprint but also eliminates unnecessary design details which is the reason why the machine builders at EMAG can offer this machine at an advantageous price-performance ratio.

For more information:

EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: info@usa.emag.com
Web: www.emag.com

Attention: Peter Loetzner

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“Energy Efficiency Award”: The ZF Group Honors EMAG Commitment

According to the “Future Panel” of the IW – the Institut der deutschen Wirtschaft (Institute for German Economic Research) – energy efficiency is becoming increasingly more important in the metalworking industry. The IW suggests that over 60 percent of the companies interviewed for the award are hoping for “a push forward toward innovation”. EMAG is an initiator of such innovations. Its experts develop machine tools and production processes that consume significantly less energy then its competition. In honor of this, EMAG has received the “Energy Efficiency Award” from the ZF Group. This award states that EMAG’s contribution has been honored as one of the top five.

From their efficient manufacturing technology to economical design and construction, the machine builders at EMAG have shown their in-depth know-how and experience in one of the most important fields of industrial development, to compete for the “Energy Efficiency Award” from ZF. The result convinced decision makers at ZF and EMAG’s competition entry called “Energy-efficient Production Machines” has been honored as one of the “Top 5 Projects“. In fact, in this particular sector EMAG was the only machine builder honored. Before the competition as part of its “Year of Energy”, ZF contacted approximately 600 of its suppliers, inviting them to participate in the competition. From 30 eligible entries, the specialists in driveline and chassis technology picked the top five. These five companies were invited to present their particular approach to efficiency on September 13^th at ZF, Saarbrücken.

EMAG has been focusing on energy efficiency for years

“We are very pleased to have received this award”, declared Dr. Guido Hegener, Managing Director of EMAG Salach, Maschinenfabrik GmbH. “It is an incentive for us to continue on the chosen path. Our focus has been on energy efficiency for years.” During his presentation Dr. Hegener highlighted the various developments at EMAG:

•  Attempt to replace less economical processes, such as the traditional grinding process, with more energy-efficient manufacturing methods, such as scroll-free turning or hard turning.  With these processes the energy requirement is up to 90 percent less. “Cycle times for these processes are noticeably shorter and the runtime of auxiliary equipment is reduced. This brings massive energy savings”, explained Mr. Hegener.
• EMAG engineers are also breaking new ground in the design of manufacturing systems. Within the framework of a collaborative research project, a software package was developed that allows for the energy consumption of machine components and complete systems to be determined at the development stage, on a computer.

“We have established how much energy each component consumes and where the biggest potential for savings lies”, explained Wolfgang Rummel, Head of Control Technology Development and Design at EMAG Salach Maschinenfabrik GmbH. He also referenced the concrete measures taken: EMAG includes the most efficient components in their standard machine design – for instance hydraulic packs with greater efficiency, low-wattage valves and intelligent auto-standby circuitry.

At the end of his competition presentation Dr. Hegener introduced a new overall objective: the development of the “sustainable factory”. He suggested that in future the production – together with the building in which it is situated and its technological contents – will be evaluated as a single entity. In conclusion, he expresses his belief that the measures taken to reclaim and recycle energy can lead to a potential saving of up to another 40 percent.

(text translation from above)

SAVINGS POTENTIAL PLATFORM 2

46.9% over existing machines

9.6% – optimization cooling systems

8.0% – hydraulics (e.g. DvP units)

6.9% – drive cooler with through-hole technology (only on Fanuc)

6.6% – reduced air seal, system pressure pneumatics

6.6% – standby circuitry

3.2% – IE2 motors (IE3 option)

1.9% – low-loss gear motors (option)

1.8% – frequency-controlled auxiliary drives (option)

1.7% – timed relief valves, flat-jet nozzles (options)

0.6% – low-wattage valves

53.1% – remaining machine consumption

At EMAG energy efficiency comes as standard.

Energy savings are implemented on the machines with Platform 2, as compared to similar earlier models = 46.9%.

For more information:

Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com

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Of Utmost Precision and Highly Productive: Laser Welding In “Transmission Manufacture 2.0”

“From Dual-Clutch Transmission to the classic differential: modern transmission technology is a pivotal research sector in the automotive industry. With new materials and altered geometries, designers optimize the functionality of the different gearwheels. Furthermore, these wheels are required in ever larger quantities, owing to the fact that the number of speed-gears in many passenger cars is on the increase. The innovations that promote the effectiveness of the production processes being applied include, for example, laser welding. With their ELC series of machines, the specialists at EMAG have developed integrated solutions for the application of processes with high output rates. The company’s in-depth knowledge of the production processes used for many transmission components has added to its competency in machine development.

(See the video HERE)

A first glance at a typical transmission component makes it plain where the challenges lie: even a small wheel with integrated synchronous gearing represents a relatively complex design. To manufacture it efficiently and at the highest precision calls for the two different parts to be produced separately and subsequently joined in a joining+welding process. It is at this point in modern transmission manufacture that laser welding comes into its own”, explains Dr. Andreas Mootz, Managing Director of EMAG Automation. “The process allows you to concentrate a carefully dosed amount of the energy emitted by the laser beam on the welding point, minimizing possible warping, while still  achieving high welding speeds.” Furthermore, the welding process from EMAG uses solid-state lasers of outstanding energy efficiency. Whereas a classic carbon dioxide laser will achieve an efficiency factor of just about eight percent, the EMAG specialists can rely on an efficiency factor of approximately 20 percent with their technology. In other words, the power used to achieve the same optical performance is noticeably less, with energy costs in the production department massively reduced.

Stationary welding device scores heavily

Similarly effective within the total process is the integration of different production sequences on the ELC system. For starters, the work spindle uses the pick-up principle to load itself. The components involved are then clamped and pressed together in the joining press. The clamping technology used ensures the highly accurate positioning of the components, providing ideal conditions for the welding process. The design of the stationary optic ensures great operating safety and optimal stability of both machine and welding process. Depending on the workpiece  material, the components can be induction-preheated prior to the welding process and brushed after it – and whatever is required, the process is completed in a single setup. The complete joining+welding process for a gearwheel takes just 12 seconds. This ensures that the components for a differential are thus finish-welded within no more than 40 seconds.

Laser welding leads to advances in lightweight construction

The differential housing, as an example, clearly shows the possibilities the laser welding technology opens up in the general development of vehicle production. For some time now, automotive companies have been replacing the screw-type connection between differential housing and crown gear with a welded seam. The result: the cost of materials reduces and the weight of the assembly falls by approximately 1.2 kg or about 2.65 lbs. “When looking at the advances made in lightweight construction in the automotive industry, this kind of savings means the world”, explains Dr Mootz.

The customer benefits from practical knowledge

Seen in context, the welding specialists from EMAG Automation in Heubach, Germany are able to look back on a truly impressive history of success. Over 50 ELC systems have been sold in the last decade. All leading automobile manufacturers are using them. EMAG is a world leader in solid-state laser systems for the production of transmission and powertrain components. How did this success come about? “It is of decisive importance that we have at our disposal a large reservoir of know-how in the manufacture of these components. We understand the entire manufacturing process, from turning and grinding, and from welding right up to the concluding ultrasound testing process”, emphasizes Dr Mootz. “We can develop and construct the whole of the process chain. This significantly simplifies the planning of new production sites and the expansion of existing ones.“

General market development is positive

The general market development does play into the hands of the German machine builder: It is not only the successful dual-clutch transmission that ensures the need for more gears. Conventional transmission systems also tend to have more speed gears, as this reduces gas consumption and improves the driving comfort. “Having said that, we are offering a well proven welding technology that provides an energy-saving, high-precision manufacturing process and, at the same time, helps to advance lightweight construction and reduce production costs. This is no doubt a very successful and persuasive combination”, concludes Dr Mootz.

For more information:

EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: info@usa.emag.com
Web: www.emag.com

Attention: Peter Loetzner

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