24 minute read
CNC Machinery & Equipment
VWM delivers improved CNC router performance for Screentek
Based in Chorley, Lancashire, Screentek is a successful British designer and manufacturer of high quality furniture for offices and corporate spaces. With high expectations from their customers, Screentek’s manufacturing capability likewise needs to be on point.
With Screentek having many CNC machining centres from different manufactures, it was time to look at upgrading some of the older machines with newer, faster machining capabilities and to increase production with a flexible machine and software system.
Screentek’s Head of Operations, Martyn McKendrick, began to research numerous CNC router supplier options, one of which was VWM Woodworking Machines based in Trawden near Colne in Lancashire. He reached out to Managing Director Jason Varey and had an initial discussion. After checking out numerous other potential suppliers, Martyn opted to work with VWM.
“Screentek decided to source their CNC router solution from us not only because of the inherent high quality and very competitive pricing of our machines, but also our strong service-oriented ethos,” explains Jason. “Our superior site back-up often wins us work and it turned out to be a key issue here, that and our broad product range of machines VWM offers stands us in good stead with our customers.”
Jason also points out that Screentek opted to go with them because of the breadth of machines and industry expertise that they provide. VWM offers machines and equipment from the likes of Robland, Lange, Salvamac, Casolin, Steton, Falachi, Inventair, Purtsch and others.
Screentek decided on the highly capable Technos 2132 MD CNC router – a set-up which is ideally suited to nesting production. “The 2100mm x 3200mm table machine (Y and X axes) is our largest table size in the MD range featuring a 250mm working depth on the Z axis,” explains Jason.
“Complimenting the wide range of machining available on this machine is a 12-position tool rack sited at the rear of the machine. This allows it to perform automatic tool changes throughout the program giving a wider range of tooling options when machining – and to speed up production time.
“Additionally, there is a fixed tool probe at the rear of the machine to guarantee accuracy between the tools on depth of cut as there is no manual setting needed. The machine also has automatic stops around two faces of the bed to locate boards correctly every time.
“The 9kw router head is capable of delivering all of Screentek’s machining needs with an inverter driven at varying spindle speeds up to
24,000rpm. All axes are designed with servo motors on precision helical racks. The servo motors are controlled from Premium Innovance Servo drives to ensure accuracy every time with rapid axes speeds of 50m/min. This is accompanied by two EuroVac 250m3 vacuum pumps and the manually-operated eight-zone matrix bed to ensure all parts are held securely during operation. The brains of this machine is the Syntec 60CA controller which has a very user-friendly operating system.” In terms of what the new machine has meant to Screentek, Jason says: “It has improved their performance as our software is much more user-friendly and has far more features than before. Also the Technos machine is a more accessible machine which also benefits from quicker feed rates and a far superior vacuum system enabling the customer to successfully complete nesting production.”
The machine is fitted with reduction boxes to the X and Y axes for greater power, light beans to the loading area, a machine guard rail to three sides and full CE regulation.
How has VWM navigated the challenging last two years, what does the future look like? “The past two years have been an excellent trading period for us,” says Jason, “we anticipated that from July onwards in 2021, it would be a very quiet period and this would continue through to June 2022, but this did not happen. Looking forward, we have two full joinery shop fit-outs scheduled in January and five CNC machines to install as well.
“Looking back, Covid was a fantastic trading period for us. We did struggle a little with certain supply chains, but on the whole, it was a fantastic growth period – in 2019 we supplied 19 CNC machines and that rose to 23 on 2020 and this number continues to grow. Couple this with our other product lines we have seen a very sharp up turn,” says Jason.
“For some time our most attractive product line has been our impressive Technos range of CNC routers – if you consider you can have a machine delivered and installed in a week period from as little as £23,950 it represents amazing value for money. We then offer a range of machines all the way up to high production units which can run shift patterns in the most demanding production environment.
“So a customer can feel totally comfortable in investing in one of our machines as they can
The machine is fitted with reduction boxes fitted to the X and Y axes for greater power
The Technos 2132 MD CNC router is an idealchoice for manufactures requiring nesting capability
grow with us without the need to source from somewhere else and that makes life a lot simpler for our customers – we offer very competitive prices, good quality machines and outstanding service backup all from under one roof.”
Although confident Jason is aware that the current economic situation will have an effect. “We can see a small downturn coming but we think it’s more a seasonal one rather than a recession – UK companies produce some excellent products, and this will continue to grow as our manufacturing gets stronger, our stock levels are still very good, so we are not worried at the moment.
“The challenges for 2023 are really down to the economy,” says Jason, “if we continue to talk ourselves into recession then it will happen, but most manufacturing sectors are still going very strong and as long as we can get supplies in then demand will continue to be there. In terms of products, we have an exciting range of laser products arriving in February 2023, so we are opening up a new market place for ourselves in this sector,” concludes Jason. 01282 870077 www.vwm.co.uk
Kimla CNC technology; routers, waterjets, fibre lasers
Daltons Wadkin have been sole distributors for Kimla CNC machines for over ten years. During that time the brand has gone from strength to strength with the continual development of cut-ting-edge routers, waterjets and fibre lasers.
‘Kimla are unique in the market. They have approached the design of their products from a very different standpoint to the majority of other CNC manufacturers. This is immediately evident in the overall build quality but can also be seen in the software and control system,’ comments Daltons Wadkin Managing Director, Alex Dalton.
Founded by award winning Polish entrepreneur Przemysław Kimla, the company spent its first years developing software and electronics, providing CNC systems for third party manufacturers. This included manufacturing PLC’s, inverters and drives – a complete eco system for computer numerical control. It soon became apparent that in order to exploit the full capabilities of the system, Kimla would need to make their own machines. Twenty-five years on and Kimla have over 250 employees across three locations producing a minimum of one CNC machine every day.
>>
“I have visited the Kimla factory many times and each time I go there is something new to see,” enthuses Alex. “Year on year growth is over 25% – a key aspect driving this demand is an unwavering commitment to innovation and excellence. Almost every aspect of the machine is manufactured in house; monolithic frame; high precision surface grinding; software; PLC; inverter and more. The result is an uncompromised CNC machine with mechanics and electronics working in harmony.”
Further expansion of Kimla’s manufacturing capability is well underway with a fourth site due for completion in 2023. The new purpose built factory will boast a production area of almost 300,000sq ft and will allow Kimla to keep pace with soaring demand. “A key aspect driving this demand is an unwavering commitment to innovation and excellence. Almost every aspect of the machine is manufactured in house; monolithic frame; high precision surface grinding; software; PLC; inverter and more”
The Kimla range includes three-, four- and fiveaxis CNC routers and knife cutting systems, from compact prototyping models through to high production machining centres for processing solid wood, wood-based panels, composites, non-ferrous metals, rubber, foam and other advanced materials. Particularly useful is the option for an increased Z axis height up to 2100mm.
Waterjet models are popular for customers working with glass, stone, granite, marble and ceramics which are among the hardest most brittle materials encountered in industry. Working up to a thickness of 200mm or more, one of the principle advantages of CNC waterjet machines is the width of cut, less than 1 mm, allowing cutting out of extremely intricate shapes and precision cutting of tight corners.
New to the Daltons Wadkin portfolio for 2022 is the Kimla range of fibre lasers for processing ferrous and non-ferrous sheet metal. An evolutionary jump from CO2 lasers, fibre lasers deliver uncompromised performance when coupled with Kimla’s unique CNC motion technology. With automatic pallet loading, compact operational footprint and a choice of laser powers up to 12kW, the Kimla’s range of fibre lasers are aimed at manufacturers looking for a dynamic and highly efficient cutting system. >>
One of Kimla’s key areas of innovation is in their linear drive technology. Again, developed and manufactured in house, linear drives are an option on most models, but standard on each axis on their fibre lasers. High powered electromagnets produce frictionless movement – with no wearable parts, speed, acceleration and accuracy is increased tenfold over traditional rack and pinion systems. At the heart of every Kimla CNC is their patented Dynamic Vector Analysis (DVA) control system – processing up to 20,000 lines of G-code per second for smooth regulation of the feed speed resulting in an unrivalled finish across a range of materials.
Regardless of what make or model machine you consider for your own production needs, per-haps the most important aspect to consider is support and back up. This is where the symbiosis of Kimla and Daltons Wadkin create a winning formula.
Daltons Wadkin has developed a specialist core team of CNC engineers within their support services department, dedicated to looking after Kimla customers across the UK and Ireland. This includes regionally based technicians for on-site support, a technical help desk for telephone and net assistance and extensive spare parts inventory held at their Nottingham facility.
To arrange a demonstration or for more information on the Kimla range of products and services call Daltons Wadkin on 0115 986 5201. info@daltonswadkin.com www.daltonswadkin.com
Absolute safety and 4.0 craftsmanship from SCM
SCM presents Blade Off, the predictive safety system for circular saws recognised with an award at Xylexpo in October and the new compact three-axis Startech CN K machining centre.
Absolute safety and programming simplicity as well as control for artisan workers with less experience using tool machines, as well as the chance to benefit from all the digital advantages – the latest products from SCM in joinery which made their debut at the Xlyexpo 2022, meet all these important objectives.
Blade Off
In Milan at Xylexpo, Blade Off, the exclusive technological solution applied to SCM circular saws, won the XIA Xylexpo Innovation Award in the ‘panel machining’ category.
Blade Off is a predictive system of direct detection that eliminates any kind of accidental contact between the operator’s hand and the blade. This is thanks to smart sensors that can identify and recognise the human body from materials that can come into contact with the blade. The system triggers even before the blade is accidentally touched or the operator gets too close, by activating a barrier that protects the whole danger area around the blade.
Should a possible collision situation arise, the system automatically excludes the blade and stops the program running, without damaging any part of the machine.
A further bonus, that makes this system even safer, is that the detection is not based on reelaborations/predictions made by algorithms, nor optical detections that could be read as calculation errors or poor visibility of the video camera.
Furthermore, the protection is enhanced on three sides of the machine (piece entrance and side approaches to the blade) to prevent any kind of contact, even caused by inappropriate or accidental movements.
The system also activates with high cutting speed, without slowing down machining, and includes the possibility of an unlimited reactivation, that does not influence the cutting precision nor the machine’s performance.
Another important advantage is the possibility of viewing and monitoring the operating status of the machine thanks to a useful LED light positioned on the blade’s protection.
STANDARD MACHINERY FROM UK STOCK
>>
Startech CN K
The Startech CN K is a compact three-axis machining centre which also made its debut at Xylepxo. It was developed for any kind of routing, decorations, scoring, production of signs and 3D model prototype.
The CN K also provides machining in absolute safety: its integral cabin, with internal LED lighting, guarantees the operator’s safety and keeps the surrounding area clean, as well as dramatically reducing the noise produced by machining.
The three-axis machining centre is unique in its kind with its 2.4kW electro-spindle with R25 attachment generally used on more powerful machines.
Another significant advantage is its easy programming thanks to the ‘open’ virtual humanmachine interface to import G-code from any kind of CAD/CAM software.
Furthermore, optional extras have been devised specifically to ensure no limits are imposed on the user’s creativity: the interpolating fourth axis (turning) that can be positioned on the worktable, the pneumatic suction cup kit to attach the piece (again on the worktable), and the detection sensor at tool height to guarantee maximum reliability.
Startech CN Plus
Startech CN Plus is the CNC drilling centre designed for SMEs as well as large joinery workshops that produce off-line or host prototyping departments. Indeed, the machine has eight separate vertical spindles, six horizontal spindles, the blade in X and a version with milling unit.
One significant advantage is its excellent flexibility: furniture parts can easily be created without having to reposition the tools and without intervention from the operator to set up the worktable and machine when the panel sizes change. Set-up and implementation times are reduced to a minimum thanks to a speed of 40m/min.
Excellent advantages in small spaces: Startech CN Plus takes up just 5m2 in space. At Xylexpo, SCM’s CNC drilling centre was one of the leading solutions for the Smart&Human Factory for the artisan worker: an integrated cell for flexible and customised production from the raw material to the finished piece of furniture, including the Invincibile SI Xcircular saw and the ME 40TR edgebander – three machines for an orchestrated work that dramatically reduces times and margins of error. www.scmgroup.com
Shortened lead times for a number of Masterwood CNC machines
Project 485L – long bed five-axis CNC
As suppliers of parts and materials, across all industries, endure the ongoing global struggle, Masterwood GB was facing delivery times of up to six months for new machines. As the demand for these is still going strong, Masterwood GB have pre-ordered a range of machines, to go into production at the Rimini factory in Italy.
The machines are built to mid-range specifications, with the ability to retrofit additional options, such as waste conveyors and a fourth axis, so every machine can meet the customer’s requirements without the need to compromise. Alternatively, items initially added to the machine can be removed if not required, to avoid unnecessary costs for the customer.
When a Masterwood customer in Northern Ireland found their 18-year-old CNC was no longer viable for repair, the decision was made to purchase a new Masterwood Project 470L. As the machine was near completion when the order was placed in early October, delivery from Italy and installation was completed in just four weeks.
The current range of stock machines available from Masterwood GB includes: – the versatile four-axis Project 470L, also available as three-axis – a Winner 250, Masterwood’s entry level short bed CNC; suitable for doors, windows, cabinets and other bespoke work – a Winner 485L, fixed specification full five-axis long bed CNC – TF 600 KT, the latest addition to the
Masterwood CNC drilling range. High speed drilling on all six faces of a panel, plus routering above and below with a six-position tool changer.
Masterwood continues to develop its full range of CNC machinery, as well as the recently added beam saws and panel saws, which have already been selling well across Europe and received high praise from customers for their quality and build strength. Special machines for doors, windows, and frames are still an integral part of the Masterwood range, and with the option of automation and full production lines, Masterwood can provide solutions to business, large and small.
With the support of KDT Machinery and Masterwood’s own software house, the Italian manufacturer is moving forward with upgrading existing software design packages, as well as creating new packages. The software available covers standard windows, traditional box windows, door sets, staircases, cabinets, nesting, and 3D, for three, four and five axis machines. A new version of the longestablished MasterWorks CAD/CAM system is under development and will be available on new machines, and as an upgrade for existing customers.
Masterwood GB can offer bespoke demonstrations on a range of products and software at our showroom near Gatwick Airport. On show we have a five axis pod and rail, fouraxis matrix bed, compact drilling machine, high speed drilling machine, and a beam saw.
For more information and prices, or to arrange a demonstration, contact Masterwood GB 01293 402700 office@masterwoodgb.co.uk www.masterwoodgb.co.uk
TF 600KT – for high speed drilling and routering
Framing the future with Weinig
With a heritage spanning over 150 years, the upholstery specialist, Alstons, has become one the best-known sofa manufacturers in the UK and continues to provide furniture outlets with British-made sofas from its premises in Colchester. Following the sale of the business in 2015, the award-winning manufacturer has continued to invest in its 8000sq m manufacturing facilities, purchasing a new Weinig Opticut S90 Cross Cut Saw and Powermat P1500 Moulder with EM100 feeder to increase output and reduce running costs in its saw mill.
In 2020, the decision to replace two of the companies most integral machines in its sawmill was taken. “After 23 years of service, our trusted Weinig Opticut 200 roller-feed cross cut and Weinig 23E moulder – which we had been using to manufacturer Birch piece parts for sofa frames – were showing signs of age,” begins Michael Parker, Facilities Manager at Alstons.
“We look after our machines and make sure a Weinig engineer comes to service them each year but there comes a time when you have to weigh up the practical implications of running an older machine. At some point, they will become obsolete and spare parts will be impossible to find. The fact that Weinig still holds parts for a 23-year-old machine is testament to the build quality of these machines but we needed to think longer term and the knock on effect a failing machine could have on production at a later date. Then there was a question of technology, speed and automation. Machinery has come a long way in 23 years and we didn’t want to get left behind.”
Weinig’s Powermat 1500 has increased output and reduced running costs
In 2020, the cross-cut saw was replaced with a brand new Weinig Opticut S90 push-feed Cross Cut Saw, which removed the manual work involved in passing timber through the old saw, providing more accuracy to the ‘cut-to-length’ product and avoiding a further secondary cross-cutting process later in production. With a clear distinction between the output, quality and cost-savings associated with the new machine, the Weinig 23E moulder followed suit. In the summer of 2022, it was replaced with a Powermat 1500 and EM100 feeder. “The cost and time-saving benefits of running the two new machines side by side was immediate,” recalls Michael. “The set-up times on both machines were more than halved and the need for manual set-up and regular adjustments were a thing of the past.”
Alston’s moulder took the longest to set-up when working on small batch runs that required one of five different radiuses and profiles. “It was a laborious process and required a certain level of skill,” says Michael. “The operator had to change the cut-ter blocks, wind the heads up and down and amend the top, side and bottom pressures every time we wanted to complete a short production run. Now, the Powermat 1500 is pre-programmed and ready to go at the touch of a button.
“Weinig’s Powerlock clamping system also allows us to change tools within a matter of seconds safely and it’s really easy to do. This has seen the set-up times on this machine reduce from 20 minutes to just five. When you think we could be running 10 different jobs on the moulder in one day, the easy set-up process alone saves us over three hours a day and that’s before calculating the increased speed of the production cycle and reduced handling associated with EM100 feeder we installed alongside it.”
Additional time saving has also been put down to the moulder’s user-friendly design, which includes its intuitive machine controls and tool accessibility, and the additional EM100 feeder. “The EM100 feeder allows for cut to length material to be fed via the hopper feeder rather than feeding long lengths and then cutting after-wards. The long timber lengths caused some slippage from time to time and made working with timber as long as 4.8 metres labour intensive. Now, operators are not pushing timber through. They simply load the hopper and the machine does the rest. This not only streamlines the production but also feeds the machine uniformly, which eliminates marks on the timber.”
Intelligent tooling options were also included on Alston’s Powermat 1500 and supplied by an external tooling specialist. “We opted for a reversible Tip Tooling system with constant radial settings,” says Michael. “This allows the machine to run at higher speeds of 8000rpm and not 6000rpm and, if required, gives us the flexibility to remove more material more quickly, accurately and to a better finish, adding to our efficiencies. This was an upgrade but we knew it would allow us to effectively machine lower grade timber suitable for sofa frames.”
The intelligent inverter-driven motors also simplify the running and maintenance of the moulder. Michael says, “Like many manufacturing companies, skilled labour is often difficult to come by. The Powermat 1500 offers a solution. The machine monitors the complete machining process, including the top pressures and notifies the operator if it detects any potential problems, avoiding damage and expensive maintenance costs. The machine also comes with a remote monitoring package that allows engineers to dial into the PLC and access the machine’s diagnostics remotely to reduce any future repair costs. We’re yet to use this but it’s something we’re looking to use on both machines in 2023.”
Alston’s energy consumption has also greatly improved. “We couldn’t have fore-seen the energy crisis but we’re pleased we made the changes when we did,” admits Michael. “The overall running cost of the moulder has reduced from 74kW to 58kW per hour and the speed each batch is completed has reduced by 20%. Plus, each energy-efficient IE3 motor offers us a 15% saving. It soon adds up. We’re also able to turn the motors down to reduce energy consumption when performing simple jobs like ripping.”
Due to the speed and accuracy of both machines, the sofa manufacturer now machines the same amount of timber in four days as it previously did in five – not only reducing energy consumption but also giving Michael the flexibility to use his operators in different areas of the mill. “Our wood mill is the most labourintensive part of our business but thanks to machines like these, we see this changing. We will al-ways need a skilled team of frame-makers and upholsterers on the floor but technology will allow us to create a more streamlined production process that makes our employees’ lives easier.”
Michael adds: “In my eyes, Weinig is one of the best machinery manufacturers in the world and they offer the best after-sales service we’ve had. You often read about happy customers saying all the right things but in our case, this is the honest truth. Weinig’s spare parts team and engineers are highly knowledgeable and really helpful – the best I’ve come across in 20 years.
“We’ve built a brilliant relationship with the team in the UK and they understand our business. The spare parts team know what we need, even when we don’t. They are like a family to us and that’s how it should be. They’ve even been happy to take calls on a weekend when we’ve needed advice. You simply don’t come across this level of service anywhere else. You might think you’re paying a premium for Weinig machines but when they last over 20 years, this pales into insignificance. You get what you pay for, so why would you look anywhere else?” www.weinig.co.uk
Simple set-up times save Alstons three hours a day
Digital readout
