Product category:
Ballscrews, Linear Guides, Jacks, Dampers
News Release from: IKO Nippon Thompson | Subject: LWH rails and slides
Edited by the Engineeringtalk Editorial
Team on 22 December 2000
Machine builder opts for separate
slide/cylinder
When Concept Automated Systems needed to build a fully automated rotary production machine for an international telecommunications client, they turned to IKO Nippon Thompson
When Whitstable based Concept Automated Systems needed to build a fully automated rotary production machine for an international telecommunications client, they turned to Milton Keynes company IKO Nippon Thompson for the expertise and products to help do the job Concept, arguably one of the UK's most respected builders of such machines, worked closely with their client in order to absorb every detail of their process requirements
This article was originally published on Engineeringtalk on 18 Aug 2000 at 8.00am (UK)
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Miniature slide units carry a heavy load
Miniature slide units manufactured by IKO Nippon Thompson are designed to function in a real working environment with an extended working life.
The machine replaces a manual production line to fabricate a co-axial type cable connector some 20mm long by 7mm diameter.
Each connector has to be accurately manufactured, crimped and dimpled from seven separate components which are loaded into vibrating feeders by the machine operator.
Once the machine is loaded and started, the components slowly vibrate towards the workstations which are mounted on two indexing tables, one with 14 stations, the other with 6 stations.
The main production process is undertaken on the larger indexing table while checking and discharge as finished article occurs on the smaller, 6 station indexing table.
The machine has large polycarbonate viewing panels which gives the operator full visual communication with the 20 workstations.
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The viewing panels are openable and are controlled by interlock safety devices which instantly stop the machine in the event that a door is opened.
For noise containment, the machine also has a polycarbonate roof.
The main indexing table and the indexer beneath it are of a hollow-shaft type, enabling a large diameter vertical services feed conduit or tube to pass through.
This continues up through the polycarbonate roof and turns through 90deg, hanging as a horizontal feed arm over the outside edge of the roof.
To this feed arm is hung a services and display mounting 'limb' onto which an HMI "Human Machine Interface' is mounted.
The horizontal feed arm and the display limb fitted to it can rotate 360deg about the machine so that the operator can move the HMI with him as he walks around the machine.
At each station on the primary and secondary indexing tables, IKO Nippon Thompson LWH rails and slides move the various tools forwards and backwards enabling the production process to be undertaken.
The tools are moved pneumatically via a series of tubes distributing compressed air from the single entry feed to the machine.
Concept Automated Systems were extremely careful when selecting separate components for the compressed air and sliding elements.
It would have been considerably easier to build the machine using tandem units but the air driven elements wear much quicker than the slides meaning that subsequent maintenance would have been more expensive.
Concept Managing Director, Martin Hills takes up the story.
"It is easy to be the cheapest.
It is a lot more difficult to be the best whilst still being competitive.
I believe we are extremely competitive while offering uncompromised quality both in our design and build disciplines.
Some, for example, would have elected to incorporate a combined slide and pneumatic cylinder for no other reason than it would have been more convenient at the build stage.
It would however have made for greater expense throughout their machine's operating life, for every time a cylinder failed it would have meant disposing of the slide and rail as well." Martin Hills has every confidence in the team he has assembled.
Each person is hand-picked, motivated and brings a particular set of skills to the team.
He also believes that by being mutually supportive and individually responsible, product quality is assured.
In essence the machine is a group of twenty individual robots arranged around the two indexing tables.
At each workstation, the tools for the various stages of the production process are mounted directly onto the IKO Nippon Thompson supplied LWH Series slides, the slide moves along the rail as commanded by the pneumatic cylinder where the work to be undertaken is then executed.
The indexing table then rotates taking the workpiece on to the next stage in the process.
As with any rotary machine, all of the stages are integrated into an overall process.
On two of the stations on the secondary indexing table, laser through beams are used for measurement plus one laser 'pin-check, plus two LVDT readings.
The HMI (Human Machine Interface) can display over 120 screens giving the operator every possible piece of information such as production output figures, fault details, operator function screens, etc.
even a flashing amber light so that a fault condition can be seen in a noisy working environment.
Concept take everything into account when building a machine.
For instance, the recently completed project underwent a 63,000 cycle 'run-in' test before being delivered.
Thus every aspect of the machine including the IKO supplied slides and rails, the indexers, the pneumatic cylinders, etc., were properly and thoroughly tested prior to handover.
In keeping with all Concept Automated Systems' products, the machine is fully CE compliant and is supplied with all documentation including risk assessment documentation, operator manual, etc.
On first analysis, the LWH Series chosen for this application seem over designed, but Martin Hills cautioned.
"The vibration feed method creates considerable movement in the machine structure.
Even though this unit weighs in at around 3 tonnes and has a significant steel frame, vibration can be a problem with smaller components suffering.
We selected the LWH Series because they offer sufficient torsional stiffness and rigidity to overcome any tendency to move." The company did look at alternative suppliers to IKO Nippon Thompson, but cited their willingness to offer technical assistance, quality, performance, price, delivery and indeed even the agreeable relationship with IKO staff as justification for their decision.
It is also notable that nearly all other major machines operated by the end user have come from an internationally recognised Swiss manufacturer.
This time however, the client preferred to have an alternative UK based supplier.
IKO Nippon Thompson produce a variety of units that are ideally suited to a wide range of applications including many where space saving and miniature sizing is critical.
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