News from John Hart - Volume 12, Number 2
Pivot
Mill
Turn
Mazak Multi-tasking Machines Mazak multi-tasking is changing production techniques throughout the world. Combining flexible milling and turning operations in a single multi-tasking machine has revolutionised the way modern factories now process raw material into finished parts.
In this issue of HartBeat we look at the latest technologies that have been released, we examine the benefits of multitasking and provide real life examples of companies who have changed not only their individual production processes but also the way they run their entire businesses.
Hob
Drill
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>> From the Managing Director’s desk In the past 12 months we have been extremely busy with our involvement in many exciting new machine tool, robotics and turn key projects across the country. We have drawn on our almost 60 years of experience and knowledge to provide the best technology solutions to enable our customers to be successful. For this trust and support, we wish to convey our sincere thanks to our many long term loyal customers as well to the many new customers who have recently joined the John Hart family. In addition to our more traditional machine tools, the area of high technology solutions is continuing to grow in importance for our customers as they must now compete on the world stage. This entails a commitment to not only supplying the latest technologies from our world leading Principals, but also providing the support necessary to keep them operating at their peak efficiency. We have a large and well organised Service team with offices throughout Australia staffed by professional service engineers plus a full time on site resident Mazak engineer, supported by our Electronic and Spindle Repair Facilities and a large on site Spare Parts Department. We were particularly delighted that Mike O’Connor returned to the fold as our National Service Manager earlier this year. Mike has worked outside the industry for the past 5 years and has been able to bring back with him different but related experiences, fresh ideas and a maturity to build on his vast knowledge of the industry. In addition we have: • employed additional staff in Qld, SA and NSW • sent all our service engineers to Mazak for training and familiarisation
• had Mazak engineers visit Australia for hands on training • acquired additional service & testing equipment so our engineers can be on site for the shortest time possible • been upgrading our SRF and ERF facilities to offer both a new capability and a quicker response • scheduled additional Service Engineers for training in the US, Japan • further Hexagon training at DEA All new machine tools and robots are imported with the CE mark to fully comply with the Australian Standard AS4024.1 with respect to safety and Australian Communications Authority radio communication (EMC) compatibility requirements, applicable since January 2004. It is worth noting that the whole area of OH&S has taken on a new dimension with wide implications for our industry. At John Hart we have had to constantly reinvent ourselves to ensure we remain at the forefront of our industry. We continue to strive to improve in everything we undertake and again this year we are embarking on many new projects. Our program in the coming 12 months involves: • the completion of our new robot demonstration and training centre • giving more focus to our accessory business • following through on our internal training programs to build on our skills base • releasing many new innovative multi-tasking machines from Mazak • introducing the new Mazak Hyper Gear laser machine • releasing Fanuc’s new 3D vision system and heavy payload robots • introducing new Hexagon Metrology products • upgrading our web site to make it more dynamic and user friendly John Hart is vitally involved in the process of technology transfer and we are totally dedicated to working with our customers, using our experience and the right technology to bring about their long term success. We wish to again thank you for your continued support and we look forward to working with you in the year ahead.
>> Mazak number 1 in the world Yamazaki Mazak was recently ranked number 1 in the world for “pure” machine tool manufacturers by the Metal Working Insiders report on machine tool manufacturers for 2003. The ranking was based on the worldwide sales of machine tools and closely related equipment. Yamazaki Mazak has become the world leader in machine tools manufacturing due to their long term commitment to research and development, the quality and productivity of their products as well as the excellent service support structures offered throughout the world.
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Yamazaki Mazak Gildemeister DMG Mori Seiki Okuma Makino Daewoo Haas Hyundai
US$1,152 million US$1,106 million US$776.9 million US$770.3 million US$550.3 million US$311.6 million US$260.2 million US$188.9 million
1 : Reduced Part Cost “Done in one” reduces overall part cost with fewer machines, operators and fixturing.
2 : Increased Throughput Fewer part setups reduces material movements, improves material flow and production effiiciency.
3 : Even Work and Cash Flow Entire batches can be completed continuously, reducing work in progress and keeping invoicing consistent.
4 : Increased Part Accuracy “Done in one” reduces compound errors and increases part accuracy.
5 : Fixturing and Tooling “Done in one” eliminates expensive fixturing.
6 : Unattended Operation Multiple processes in one setup allows unattended operation.
7 : Reduced Set-Ups Reduced set ups by combining multiple processes.
8 : Reduced Non Value - Added Time Reduced non value-added time by eliminating product queues between machines.
9 : Reduced Lead Times Reduced lead times by increasing flexibility to produce both small and large complete batch runs.
10 : Increased Profitability Reduced fixturing, improved efficiency and product quality increases profitability.
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>> Traxon smart machining system World leaders in oil level control systems in industrial compressor units are Traxon Industries in Bunbury WA. In compressor units used primarily in refrigeration systems in supermarkets, refrigerant oils can be Hamish Todd (JH), Wayne Cattach (CEO) transient around the and Brad Eacott piping system for long distances. Maintaining consistent oil levels is vital to the performance and operation of the compressors.
Integrated into the system, the Integrex 100 is a multitasking lathe that performs “done in one” machining of components. The result is a system which automatically produces regulator casings to exacting quality and environmental standards. Traxon exports over 80% of its product overseas and CEO, Wayne Cattach and machinist Brad Eacott worked closely with John Hart engineers to ensure the system meets their requirements for flexibility and accuracy to match market demand for their product.
To ensure the system is maintained properly at the specified levels, Traxon developed and patented a floatation device. The revolutionary regulator is able to monitor oil levels in the individual compressors and maintain correct volumes of oils at all times and through a wide variety of system conditions. Traxon’s regulator is contained in an aluminium casing which is machined on a Mazak Integrex 100 with GL 100 robot together with a John Hart designed and built work conveyor, washer and drying system. The whole system is controlled by a PLC.
Sections of the production system
>> Oilpath achieves high flexibility Oilpath Pty Ltd which is situated in Adelaide, is the only designer and manufacturer of hydraulic control valves in Australia. Oilpath’s strength is their ability to provide standard valves with a wide range of standard and specialised options, fitted both in the factory and in the field by their network of distributors. Oilpath now exports between 15% and 25% of their production into a variety of industries including transportation, construction, agricultural and industrial equipment.
reduce the stock build up, which was becoming a problem due to minimum batch sizes required in the current process.
From this they realised that a whole new approach was needed in their production process. They needed to be able to reduce their standard deliveries from four days down to a more competitive one day. They also knew they had to
customer demand.
To achieve these goals, Oilpath needed the latest and most flexible technology available. They needed a system which could recognise any of the company’s 13 valve castings and produce any of the 347 possible part numbers automatically, including specials, from a master machining schedule.
Having looked at the options, the solution was found in the Mazak Variaxis 630 with a 12 pallet Originally Oilpath sat down with Palletech system. The Variaxis 630 the engineers from John Hart to has five simultaneous axis capability, look at a project to machine valve 120 tools, 22kW main spindle, bodies on one machine. Dave Lucas (JH), Matin Baker (Managing Director) and variable pressure through spindle Ron Agnew (Factory Manager). During the discussions, Oilpath coolant, a part recognition system, a looked at the difficulties they faced in the market and where Palletech smart scheduling system and in process gauging. they needed to improve to stay ahead of the competition. The system is extremely flexible and now produces the Overseas competitors were a major issue, because through required range of completed parts quickly, accurately and economies of scale they were able to import large batches efficiently. The system is fully automatic and can select of cheaper products into Australia. This enabled them to sell appropriate programs from the scheduler and machine from stock almost immediately, which was significantly faster complete parts in a single setup. Batch sizes range from than Oilpath. a single part to large quantities and supply now matches
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This combination of John Hart production experience and Mazak technology in partnership with Oilpath has resulted in a world class production system.
>> UN series – machining centres for mass production. Unique, Ultra Narrow machines for mass production applications, the UN Series horizontal and vertical models have created an enormous impact since their recent release. Unlike competitors’ narrow machines which have very small work envelopes, the Mazak UN machines have work capacities similar to conventional 400mm square pallet machines – all in a width of 695mm for the UNV and 990mm for the UNH machines. The UN Series machines are not only compact with a small imprint, but they readily lend themselves to unmanned operation with easy adaptation to accept work holding systems and robots and offer very convenient maintenance access. The new range has been a great hit with the automotive industry sub contractors where quality, accuracy, price and floor space demands are critical. UN-600H Table size
UN-600V
400mm x 400mm
Travel X/Y/Z Rapid traverse rate Spindle
510/400/380mm
600/360/400mm
120000/60000mm/min
60000mm/min
20000rpm, 7.5/5.5 kW
Tool shank type Tool storage capacity Machine size
MAS BT-30 20 tools 990 x 3200 x 2470mm
695 x 3200 x 2690mm
>> Aero Spec utilises technology for success Aero Spec Engineering Pty Ltd is an Australian owned and family run business established in Melbourne in 1973. The company is still run by brothers Nick and Mark Linke who are both hands on Directors. Aero Spec Engineering are precision engineers and toolmakers supplying components and special purpose jigs, fixtures and machinery for the automotive, mining, medical, food, defense, transport and aviation industries. With over three decades of experience in the industry, they are committed to producing the highest quality of workmanship for their customers.
The VCN510C also features the world famous Mazak Fusion 640 CNC which is the only true fully conversational controller available. The machine was fully networked with the company’s intranet system, allowing instant downloading of complex CAD generated programs to the controller from their office computer. In addition, the Fusion 640 has a 2Gb hard drive which itself is able to store hundreds of standard programs at the machine. Speaking with Mark and Nick Linke, they noted the reasons they chose their latest Mazak were the quality and leading edge technology of the Mazak, the speed and ease of job setups and the back up from the John Hart service team.
With recent company growth, Aero Spec Engineering sat down with Nick and Mark Linke with their Mazak VCN510C the engineers at John Hart and In addition to their VCN510C, Aero discussed the best available solution to meet their increased Spec Engineering also have a Mazak Quick Turn Nexus production needs. 250M lathe which features milling on the turret. As a result they chose the Mazak Vertical Centre Nexus 510C with a fourth axis and OneSpace Designer modelling and Hypermill CAM software. The VCN510C features a 18.5kW 12,000rpm mill spindle, 36m/min rapid traverse and a 1300mm x 550mm table.
Aero Spec Engineering is a great example of a company that sat down with the experienced engineers at John Hart and worked out the best solution to meet their needs. They invested in world leading Mazak technology, which is fully support by John Hart and they have taken their business to the next level.
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>> OH&S compliance – new machines For some time it has been the responsibility of end users of all machinery, including machine tools to ensure that their equipment satisfies and complies with the various Australian Standards and State Regulations and Acts. Over the last 2 to 3 years the state work safety authorities have been more stringent and vigilant in their enforcing of the various regulations. John Hart has always tried to ensure that the machines that we sell are of the highest safety standards required at the time. However, many end users of machinery will not be aware of their new obligations to comply with the Radiocommunications (Electromagnetic Compatibility) Standard 2001 issued by the Australian Communications Authority. This standard relates to the Radiocommunications Act of 1992 and is a part of a long standing international effort to reduce electromagnetic radiation emissions from all sources. What does this mean to a John Hart imports all user of industrial equipment machines and robots such as machine tools? with CE marking It means that any machine imported into Australia from January 2004 (there was a 2 year amnesty) must comply with this standard. It is the legal responsibility of the end user to ensure that equipment installed into their premises from this year fully complies. If it does not comply it is the end user’s responsibility to modify the equipment to comply – which would be very expensive to achieve on an existing non compliant machine. John Hart customers can be assured that all new equipment imported from January 2004 complies with this standard.
John Hart imports all machines and robots with CE marking to satisfy all Australian safety and EMC standards. Customers should ensure that when they are considering offers for new equipment that all suppliers are offering equipment that: • Complies with all Australian Standards and Regulations, preferably by being CE marked to comply with the following EC directives as applicable: Safety of Machinery – ISO 12100, ISO 14120, IEC 60204-1, EN 12415/12417/12478, EN 292-1/292-2/418/775 Electromagnetic Compatibility – IEC 61000-6-2/ 61000-6-4, CISPR 11/EN 55011 Low Voltage Equipment – IEC 60204-1/60034/60947 (Be sure that the "CE mark" does not only refer to something obscure like the colour of the paint!) • Is supplied with a signed manufacturer’s "Declaration of Conformity" stating the various standards and directives that the machine is built to, the machine build date, serial number and technical file number. • Is supplied with a signed Hazard Identification, Risk Assessment and Control Evaluation document from the machine supplier or manufacturer. Only then can you rest assured that you have met your legal obligations and your machine is safe to install and operate and when an inspector knocks on your door you have the documented evidence to prove compliance.
>> Renard Tooling achieves “done in one” Renard Tooling Technics has been one of Ballarat’s best known toolmakers for over twenty years, establishing itself as a specialist to the automotive, FMCG, steel, advanced rubber and plastic moulding industries since 1982. With a solid reputation for quality, Renard wanted to stay focused on remaining ahead of the market by identifying advanced technologies they could utilise to drive new business opportunities.
users, Renard gained greater confidence in their final machine selection. They chose the Mazak Integrex 200-MkIII because of its advanced features, proven track record, high quality manufacture, and user friendly software which combined to allow them to hit the ground running. All this was backed by skilled engineers from the John Hart Service Team.
Renard visited Mazak’s headquarters and central The result since Scott Pfeiffer and Wayne Howden (machine operator) with the IG200 manufacturing facility in Nagoya, installation has been Japan and it was here they were able to see first hand the faster turnaround on jobs due to “done in one” processing, most advanced machine tools. Spending time with the reduced part set-up and programming times. They have also Mazak engineers and discussing their specific requirements reduced the complexity, historically associated with existing enabled them to find the best multitasking solution. machining techniques, allowing Renard to seek out more challenging and rewarding projects. In seeing how the Mazak machines were designed and built,
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coupled with feedback from other local Mazak machine
>> JIMTOF - Japan International Machine Tool Fair 2004 The Japanese machine tool show JIMTOF 2004, was again held in Tokyo during November of this year. Visitors came from around the world to see the latest machine tool technology being shown by the largest machine tool manufacturers. The resurgent Japanese economy ensured a high level of local interest which was in sharp contrast to shows of recent years. This was reflected not only in the number of attendees but also in the quality of the stands and the numbers of new products. Mazak was again the standout stand featuring a truly impressive line up of the latest and most advanced multi-tasking technologies. Other notable exhibitors were Fanuc Robotics, SMW Autoblok, Renishaw, Losma and Hexagon Metrology.
Highlights from the 26 machines on the Mazak stand included: • Angulax 900 • Cybertech Turn 450MT • HCN 5000 and 6000 • Integrex E-1550V/10 • Multiplex triple 8200Y • Nexus QTN 100MS • Nexus QTN 200MY • UN600V & H • Variaxis 730 - 5 Axis
>> Nordon chooses a multi-tasking solution for success Nordon Hydraulics was founded by Norm Johnson in October, 1972 in Brisbane, Queensland. Guided by a passion to provide quality, service and satisfaction to their customers, the business first started out servicing hydraulic cylinder equipment. They worked on everything from a barber’s chair to excavator cylinders all the way through to mass produced cylinders for agriculture. Through this exposure to so many different designs of infield hydraulic cylinders, the company moved to develop their own range of hydraulic cylinders. After years of design and testing they were able to release the “Standard Range” of hydraulic cylinders. This change in direction was a significant event in the history of the company as it set the foundation for their expansion into manufacturing their own products.
Recently with business expanding, Nordon looked to their long term partners, John Hart to come up with the best solution to meet their production needs.
Mark Geltch (Production Manager) and Norm Johnson (Director).
After discussions about the process and careful consideration of the technology available, the new Mazak Quick Turn Nexus 200MS with a second spindle, milling on the turret, parts catcher and bar feeder was chosen. The Mazak has a 200mm chuck, a 26kW 5,000rpm spindle, a 4,500rpm rotary tool spindle and a maximum machining diameter of 380mm. The Mazak system is a highly efficient, fully automated multi-tasking solution which allows unmanned operation and complete part processing in a “done in one” set up. The result has been a 30% increase in productivity over previous methods.
Commenting on their third Mazak machine Parts made on the Mazak Today Nordon Hydraulics manufactures solution, Norm identified the need to hydraulic cylinders for a wide variety of increase production, technology offered by Mazak and the industries including the agricultural, earthmoving, transport experience and support offered from John Hart as the main and machinery industries. reasons for going with the John Hart / Mazak solution.
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Mazak releases new multi-tasking machines
new!
Multiplex Multiplex 3/triple 8200Y Chuck size
200mm
Travel (X/Y/Z)
250/100/615
Turning Spindle
5000rpm/22kW
Rotary tool Spindle
4500rpm/55kW
>> Now with optional lower turret and increased speed
Cybertech Cybertech Turn 450MT
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Chuck size
305mm - 610mm
Max swing
860mm
Turning Spindle
2400rpm/37kW
Rotary Tool spindle
10,000rpm/37kW
>> Versatile large capacity lathe with optional lower turret
new!
new!
Nexus QTN200MY
QTN250MY
Chuck size
200mm
250mm
Bar capacity
65mm
77mm
Stroke X/Y/Z
230/100/575
Turning spindle
5000rpm/26kW
Rotary tool spindle
4000rpm/26kW
4500/55kW
>> Now with optional ‘Y’ axis
new!
Nexus HCN 5000 Pallet size
500mm x 500mm
Travel (X/Y/Z)
730/730/740
Rapid Traverse
60m/min
Spindle
18,000rpm
Tool Shank
BT40
>> 40 taper horizontal Nexus
Integrex
new!
Integrex e 1550V/10 Pallet size
1000mm x 1000mm
Travel (X/Y/Z)
1875/1550/1345
Rapid Traverse
40m/min
Milling Spindle
10,000rpm/37kW
Turning Spindle
300rpm/37kW
>> Intermediate sized Integrex e - V series machines
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>> Introducing the HyperGear 510 The recent unveiling of Mazak’s latest 2D laser processing machine, the HyperGear 510 has caused quite a stir with metal fabricators throughout the world. The new HyperGear 510 uses custom linear motors to deliver rapid traverse rates of 120m/min at a staggering 3g acceleration on all axes. The increased use of sensors, refined programming, readahead controls, flying optics design and new algorithms make the HyperGear up to 20-30% more productive than other machines on the market. The HyperGear 510 flying optics design maintains a fixed beam length utilising a specially designed U-axis. This increases cutting accuracy by maintaining uniform laser power across the full table range. Machine software automatically calculates the laser's optimum cutting speed and acceleration for each contour of a component. The nanosecond PREview 640 CNC control automatically determines the best method of piercing the entire sheet so that no area on the sheet becomes too hot, preserving cut quality.
With many customers throughout Australia having difficulty finding skilled operators, the HyperGear 510 now allows one operator with a lower level of training to be able to operate several machines simultaneously. The new HyperGear 510 incorporates many "world firsts", including: • The first automatic torch changer and nozzle changer systems • The new PREview 640 CNC control • The first hyperlinear drive design • The first laser to diagnose and repair cutting-related problems in process • The first laser to automatically notify operators in advance of required maintenance
To ensure maximum productivity during work-piece processing, sensors detect when any of four automatically interchangeable torches require changing or may need a new nozzle, then the machine replaces the torch and/or nozzle without operator intervention.
>> Technology brings success for Sharp Tooling About two years ago Sharp Tooling, a general engineering and special cutting tool manufacturer in Sydney sat down with the engineers at John Hart to look at ways of increasing their production capability. The result was the addition of a Mazak Integrex 200Y multi-tasking machine to their factory. Managing Director Albert Carrion made the choice because he was confident that the new multitasking technology would take his company into the future.
occasionally one offs which explodes the myth that large production runs are required for multi-tasking machines. The combining of turning and milling in the Integrex has reduced compound errors inherent in multiple set-ups, which has increased part quality. The user-friendly Mazatrol Fusion 640MT CNC conversational controller is easy to program, even by inexperienced operators. Stock in process has been reduced, overall machine programming time has been reduced, machine setups have been reduced, delivery times have been improved and their customers could not be happier.
Looking back Albert can now see the fruits of his foresight. His production process has been revolutionised in the way work moves through the Ariel Felicano (Operator) and Gary Finch (Foreman). Building on the great results brought factory. Historically, jobs would sit by his first multi-tasking machine, on the floor between different machines, waiting to be set Albert recently looked to the market and decided to up for a process. As a result, multiple set-ups were required purchase his latest Mazak, an Integrex 200SY. He chose on machines with different controllers and often difficult this Integrex model because he considered it to be programming systems, stock was tied up in process and technologically superior to all other machines available. tooling and fixtures costs were higher. The Integrex 200SY has all the benefits of the multi-tasking With the introduction of the Mazak Integrex 200Y multiseries but with the addition of an optional second spindle. tasking machine, Sharp Tooling is now able to quickly and The second spindle provides even greater flexibility with easily set up jobs for “done in one” production. in machine part transfer allowing second processes to be The majority of jobs on the new machine are short runs and performed automatically. The result is even fewer part set-ups.
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>> Hexagon visit In early October 2004, Mr Giulio Bollito General Manager, Commercial Operations and Tan Boon Sun Sales Director, Hexagon Metrology Asia Pacific Pte Ltd visited John Hart to provide an update on the recent series of takeovers by Hexagon Metrology in the CMM world. Hexagon Metrology now own Brown & Sharpe, DEA, Leitz, Sheffield, Wilcox & Assoc, Tesa, CE Johansson, Romer, MIRAI, Cimcore and several other well known companies in the field. Under the new arrangements, John Hart continues offer and support Brown & Sharpe, DEA and Leitz plus a new product range called Cimcore PCDMIS which is a portable arm CMM. Mr Bollito briefed staff on the new Hexagon regional facilities in Singapore which feature new offices, showrooms, training facilities and spare parts centre. The meeting served also to strengthen the links between the two companies who enjoy a long and close relationship. Mr Bollito was also able to visit several customers to round off a very brief but fruitful visit.
>> Christchurch Engine Centre has the capacity When they needed to measure a fan blade set with a diameter in excess of 1.7m for the new IAE V2500 jet engine, the engineers at the Air New Zealand and Pratt & Whitney Christchurch Engine Centre thought they had met their match. However with help from the experienced engineers at John Hart they were able to meet the challenge. The best machine for the application was the Global 20.33.15 fitted with the PCDMIS CAD++ software. The Global series is a range of extremely fast, high accuracy CMMs which have been recognised throughout the world as the industry standard.
Centre’s temperature controlled metrology room. As they already had PCDMIS software on their recently upgraded B&S Xcel CMM, they were up and running on the new machine straight away. The new Global CMM allows measurement of large plasma coated rotor path liners and stator vane tips, blade tip diameters, snap and interface dimensions of their aircraft engines.
Talking with the process engineers at the Christchurch Engine Centre, they noted the machines large capacity, the PCDMIS software, the track V2500 jet engine record of Brown & Sharpe The Global CMM was the right choice because of its CMMs and the level of support provided by John Hart as advanced design, market leading software, large capacity factors in choosing the Brown & Sharpe. and excellent after sales support. The machine was also The installation of the Global 20.33.15 into the Christchurch chosen for it’s long term versatility, being capable of using Engine Centre was the result of John Hart working with them laser and contact scanning applications without requiring a to implement the latest technology, to increase the centre’s controller or software upgrade. overhaul capabilities. The Global CMM was installed and calibrated by John Hart and Hexagon CMM engineers into the Christchurch Engine
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>> John Hart Support – the buck stops with us!
CMM calibration
Electronic Repair Facility
At John Hart we regard service as our long term commitment to support customers to the highest possible standards. We have been in the field consistently supporting customers for over 40 years now and we continue to work very hard to not only be the best in the industry but to deliver on what we promise! When the chips are down and you need fast reliable skilled service, we understand the importance of a timely response. John Hart has a history of following through and we never walk away from any issue, no matter how hard the problem may be. With John Hart service you have support you can rely upon. John Hart has a large and well supported service network situated throughout Australia. We have also developed an additional level of support services with our national Spindle and Electronic Repair Facilities, and a large in house Spare Parts department. This two level approach has been developed over many years, enabling us to provide the best overall support of any machine tool company in the country.
Spindle Repair Facility
Our philosophy is to provide support in 5 main areas. These are: 1 : Experienced service staff John Hart Service has a large team of engineers who are situated throughout Australia, they are well trained, experienced and qualified. They are passionate about their work and are focussed on keeping your machine up and running. 2 : Factory support and market commitment John Hart Service has a resident Mazak engineer, a direct electronic link to Mazak Japan, all original machine detail specifications and a long history of close co-operation with our overseas principals. 3 : Spare parts Spare Part Department maintains an extensive stock of in house spare parts. Our experienced Spare Parts team is trained to provide fast and accurate customer support. If not available locally, parts can be shipped in from around the world at short notice. 4: Electronic Repair Facility The Electronic Repair Facility is a factory backed facility which is able to quickly repair circuit boards, axis servo units, power supplies, spindle controllers, monitors and associated equipment for Mazak users throughout the country. The facility has factory trained engineers who use special electronic repair and testing equipment, have access to original drawings and use only genuine parts. 5 : Spindle Repair Facility The Spindle Repair Facility is a factory backed facility which is able to quickly repair spindles and milling holders. The facility has factory trained engineers who have access to original design drawings, special assembly and test equipment as well as using only genuine parts. All spindles are provided with a 12 month warranty when fitted by John Hart. John Hart’s service network is vast and provides a capability which is unparalleled. Our commitment is to continue striving for improvement and our reward will be more satisfied customers.
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>> The Fanuc ‘Intelligent Robot’ - a vision for the future At the recent Automate 2004 show held at the Melbourne Exhibition Centre, John Hart Automation & Robotics (JHA&R) displayed a 200Kg payload robot mounted on an 8m gantry, a smaller LR Mate robot demonstrating flexibility through using tool changers and a R2000i robot using the new Fanuc 2D and 3D vision systems. The world leading robot manufacturer Fanuc offers a full range of vision systems designed specifically to be used with Fanuc ‘Intelligent Robots’.
The result is an automated system which is extremely flexible in the way parts can now be presented to the robot and loaded into the machine. To be able to see this world leading fully integrated 3D vision technology, JHA&R would welcome the opportunity to run a trial for you at our facility in Melbourne.
This means the hardware and software of the vision system are designed to interface easily with the robot ("plug and play") making setup extremely simple. Vision systems have over the past few years, like robots, witnessed a vast increase in capability, user friendliness and robustness coupled with a reduction in up front and ongoing costs. Traditionally robots have required parts to be accurately (and often expensively) positioned in order for them to be located. Now, with the new Fanuc vision system, a robot can locate a randomly placed part’s position and angular orientation automatically. One major application for this technology is in machine loading, where suitable parts, castings or forgings arrive from the supplier in a stillage. The vision equipment is able to view the stillage contents and determine the position and orientation of the easiest parts to pick up. The robot will then automatically adjust its gripper approach angle and pick up the part on the correct plane.
Automate 2004
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>> Getting it right first time, every time! John Hart Automation and Robotics (JHA&R) has for the last six years utilised the state of the art Co-Create One Space Designer 3D solid modelling package for their project designs. Our designers are able to model machines, robot grippers, safety cells and even whole factories in three dimensions prior to manufacture. The result is reduced project design time, increased design accuracy, pre project viewing of the project concept and automatically generated part lists and component specifications. A good example is the recent design of a robot end-of-arm-tooling (EOAT) system for a palletising application in Melbourne. The customer’s brief specified that a robot was to handle a range of five cartons, each of from design different shapes and sizes with two different pallet sizes and one slip sheet. To complicate things further, the cartons had to be handled mechanically from beneath using tynes (not from above with vacuum cups) all within the robot’s capacity. Starting by solid modelling the robot, cartons, grippers and surrounding equipment (like conveyors) the designer was able to create a complete virtual robot cell.
Once the cell was designed, features within One Space Designer checked for and eliminated any potential clashes between the gripper and other equipment in the cell. At the same time One Space solid designer was able to calculate the mass of the gripper simply by specifying the material being used for the individual components. This insured the robot had the lifting capacity for the application. Once the design was finished, One Space Designer automatically generated detailed part drawings ready for manufacture. The result was a fully automated robot cell with a complex robot gripper, which had been completely designed and tested in the 3D prior to manufacture. The parts were then assembled quickly and without incident on time and on budget.
to finished product
>> Albins Off Road gears up Albins Off Road Gear was established in 1979 by Ivan and Kerry Albins. Originally starting out as general and mechanical engineers the company grew consistently when in 1988 they were able to invest in their first CNC machine tool. Having competed in off road racing for many years, including the National Championships, Ivan soon started to design and manufacture his own range of high performance parts for off road vehicles. From this Albins started to specialise in the design and manufacture of gears and transmissions for many vehicle types.
Looking to the future, Albins recently invested in a new Klingelnberg C28P CNC controlled Palloid Spiral Bevel Gear Hobbing machine. The C28P is the only machine of its type in the southern hemisphere and represents the absolute best in gear cutting technology. Talking with Ivan about the new machine he noted “after much research we purchased the C28P because of its superior strength over other types of spiral bevels and it’s quick setup time, even for one offs including hypoid applications. We also had no hesitation in ordering through John Hart, having already experienced their excellent service for our Mazak Variaxis machine”.
Soon after they invested in their first gear cutting Ivan Albins, Todd Ulin and Steve Nicholson machine and have since grown to 15 CNC machines and 27 staff. The ownership The partnership between John Hart and Albins Off Road of the business has also grown with long term employee brings together experience and the best technology to Steven Nicholson becoming a partner in the business. achieve long term success.
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>> Mazak electronic Spindle and Servo repairs Don’t get caught being talked into using non genuine Mitsubishi units in your Mazak CNC machine! John Hart is the only authorised Mitsubishi repairer in Australia following Mitsubishi repair procedures, using factory supplied circuits diagrams, originally specified Mitsubishi electronic components and all carried out with a Mitsubishi trained electronic engineer.
By using John Hart to service any Mazak breakdown resulting from a defective Mitsubishi servo or spindle unit, you get a guarantee of factory quality with a warranty that we and Mitsubishi will stand by. Next time you are offered a “cheaper” alternatively supplied unit, ask the question about where the unit came from and what guarantees Mitsubishi will place on the unit if it fails.
The use of cheaper or lower spec components and substitutes could actually cost you more money in the longer term.
Don’t take a chance, John Hart are the only authorised Mitsubishi machine tool electronic repairer in Australia and this gives you comfort that our electronic service is guaranteed.
Unauthorised repairers may supply you with a unit that looks the same as the original John Hart has a full range of Electronic Repair Facility and may even work for a short exchange units in stock to ensure period, but what damage will so machine downtime is minimised called equivalent components used to carry out repairs by and in the unlikely event that there is not one in stock, unauthorised operators locally be doing to other system and a priority repair to the customers unit can usually be expensive NC system components? performed within 24 hours.
Mist Filters Model
Throughput
D600
600m3/hr
D1200
1,270m3/hr
D2000
1,950m3/hr
D3000
3,200m3/hr
For your work holding needs
John Hart proudly offers the Sigma Pool range of gear cutting, grinding, forming and measuring equipment.
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Visit our new website!
www.johnhart.com.au Victoria
11 Winterton Rd Clayton, 3168 Tel: 03 9542 6262 Fax: 03 9542 6295
New South Wales
Unit 11, 3 Packard Ave Castle Hill, 2154 Tel: 02 9634 7011 Fax: 02 9634 7066
Queensland
27 Birubi Street Coorparoo, 4151 Tel: 07 3397 8322 Fax: 07 3397 8728
South Australia
483 Port Road Croydon, 5008 Tel: 08 8346 9068 Fax: 08 8346 9060
Western Australia 17 Belmont Ave Belmont, 6104 Tel: 08 9277 6100 Fax: 08 9277 3456