rme62 s01 titel - static.dc.siemens.com

July 2|2006

s

motionworld

Systems and Solutions for Machines and Plants

IMTS2006, Chicago

Solutions for Every IndustryIMTS 2006, Chicago

Solutions for Every Industry

True Six-Sided, FullyAutomatedMachining

World’sLargest MetalSpinningMachine

True Six-Sided, FullyAutomatedMachining

World’sLargest MetalSpinningMachine

motion world 2/2006 IMTS

motiow

Industrial Gas and Chemicals8 Production on a Grand Scale

Siemens solutions integral for world’slargest metal spinning machine at FibaTechnologies

Medical10 Complex Tasks Made Easy

Sinumerik 840D simplifies dual-spindleturning center control at CNC Industries

Job Shop12 Changing the Paradigm

Progressive automation technology helps operators “learn as they go”

Job Shop14 On the Progressive Edge

Flying optics laser with new Sinumerikpowerline CNC helps Iowa shop soar

3 EDITORIAL

TRENDS

IMTS 20064 Productivity in Motion—

Solutions for IndustrySiemens introduces its latest solutions at IMTS 2006 in Chicago

CASE STUDIES

Automotive and Medical6 Rising to the Occasion

Siemens control package expands Stamamilling/turning center performance range

Siemens will once again exhibit its newest rangeof products and solutions for virtually everyindustry at IMTS 2006 in Chicago

Capable of true six-sided machining, theStama System 7 milling/turning center isequipped with a Siemens control package

A Sinumerik 840D CNCand Profibus control allfunctions of MJC’s OSC-24300 at Fiba Tech-nologies, the world’slargest metal spinningmachine of its kind

64 8

Stam

a A

mer

ica

Cover picture:CNC Industries Elk Grove Village, IL

Siem

ens

AG

2 CONTENT


This year’s IMTS in Chicago will showcase the impressiveU.S. machine tool market recovery. After the recessionearlier this decade, domestic machine tool production andimports have grown at two-digit rates over the past threeyears. Aerospace manufacturing plants and job shops inparticular keep investing at record-breaking levels.

For Siemens, the time is therefore right to introduceour new Sinumerik solution line CNCs and innovativeSinamics drives. After exhibiting the 802D sl at WESTECand EASTEC earlier this year, we will present the 840D slat IMTS for the first time in the U.S. Features to help ourcustomers be more competitive in tomorrow’smanufacturing environment include a network-centricdrive architecture; auto-detection of components viaelectronic name plates; and one universal, scalable drivehardware for servomotors, linear motors and motorizedspindles. The 840D sl is available with PC-based or thin-client front-ends.

Tomorrow’s environment is increasingly not onlydefined by products alone, but also by value-addedservices to enhance machine tool productivity throughouta machine’s entire life cycle. Siemens is a trendsetter inthis area and offers a suite of services—many of themunique—for both machine tool builders and end-users. Our Mechatronics consulting specialists, for example,provide dynamic Finite Element analyses to reducemachine design time and to help avoid costly design errorsearly on. The Sinumerik Machine Simulator enables realmachining environment simulation on a lab PC to developa real PLC code. Virtual Production software simplifies theoptimization of machine cycle times and parts surfacefinish without time-consuming, real-life test runs.

Job shop productivity benefits from our ShopMill andShopTurn software packages, allowing interactive graphicas well as ISO G-code programming. Also, with setup timebeing a key issue in small-batch production, our easy to-use setup features reduce machine downtime to aminimum.

We welcome you to our booth (Lakeside Center, boothD-4208) to witness the latest Siemens innovations duringIMTS 2006 in Chicago. See you there!

Wolfgang RubrechtGeneral Manager Siemens Energy & Automation Chicago

Sample precision parts produced on the Indexsix-sided multi-machining centers with SiemensCNC technology at Model Screw Products

16

MJC

En

gin

eeri

ng

& T

ech

nol

ogy

Dearreaders,

Inde

x C

orp.

onworld

Multi-Spindle Machining16 Keeping Standards High

Siemens CNC helps Model Screw Products score positively with customers

SHORTLIST

18 Deckel Maho Gildemeister; Schaumburg, IL

aba z&b Inc.; Orangeburg, SC

Brooklyn Technical Services; Brooklyn, CT

19 DIALOGUE

3EDITORIAL

man machine tool builder Stama, a globalleader in machine tools, is exhibiting itsMC 726 MT machine. Equipped with a Sinu-merik 840D, Stama will highlight the pre-cision and performance capabilities of themachine in medical parts manufacturingwith live demonstrations.

The Transline System Solution and Sinu-merik 840D continue their success in theautomotive industry. The Transline systemutilizes common hardware and softwarecomponents to transform the Siemens con-cept of “Productivity in motion” into real-world applications for total factory automa-tion. Siemens will be presenting the newTransline solution line as part of an excit-ing interactive display at the IMTS, togetherwith Safety Integrated technology.

Used in combination with Siemens lin-ear and torque motors, the new Sinumerik840D solution line is also of particularinterest for the aerospace industry. With itsproven reliability and speed, the 840D con-tinues to be the first choice in high-speed,five-axis aerospace manufacturing. To boostproductivity, the control offers aerospaceusers innovative high-speed features such

Job shop

Competitive pressures demand flexibleproduction and reliable quality. Combinedwith the ShopMill and ShopTurn soft-ware packages, Sinumerik CNC technologyoffers tremendous flexibility and benefitsfor conventional machining. For this mar-ket segment, Siemens is exhibiting the newSinumerik solution line series of controls,including the 802D sl for small- and medium-sized milling and turning applications; thePC-based 840Di sl; the 840D sl with Shop-Mill and ShopTurn as well as the new HT8handheld unit. Also new for job shops: theSiemens 1FT7 servomotors, Weiss spindlesand the OP08T operator panel. Milltronics,a machine tool builder from Waconia, Min-nesota, will debut its VM20 machine withSinumerik 840D solution line during live,five-axis machining demonstrations at theSiemens booth.

Medical, automotive and aerospace

Witness the advantages of five-axis machin-ing with the Sinumerik 840D powerline. Inthe medical manufacturing sector, the Ger-

“Productivity in motion” is the promiseSiemens makes as the world’s leadingcontrol manufacturer to provide yousolutions that not only save time, but also increase productivity.Moreover, Siemens brings its long-standing experience, dedication andingenuity to every project it takes on—no matter how large or small. At this year’s IMTS, Siemens will bepresenting its new line of innovativesolutions and services for machinetool manufacturers as well as end-users.

The new hardware and software tech-nology headlining at this year’sSiemens booth include the latest

CNC solutions for the job shop, medical,automotive and aerospace manufacturingindustries.

Siemens to introduce its latest solutions at IMTS 2006 in Chicago

Productivity in Motion—Solutions for Industry


4IMTS 2006

TRENDS

as TRAORI, NURBS and Spline Interpolation,without compromising precision or surfacefinish.

CNC training

At this year’s IMTS, Siemens will also beoffering demonstrations of SinuTrain, thetraining and programming software forSinumerik CNCs. SinuTrain is a CNC simu-lation training package available on CD-ROM which can generate and simulate NCprograms for the DIN 66025 programminglanguage as well as for ShopMill, ShopTurnand ManualTurn. Programs written withSinuTrain can ultimately be used on actualmachines, provided that SinuTrain isadapted to the Sinumerik CNC on whichthe program is to be executed.

Solutions for global services

Siemens exhibits on display at IMTS alsoinclude global services solutions for theU.S. machine tool market, among themreal-time models featuring ePS NetworkServices, Virtual Production and Mecha-tronics Support.

ePS Network Services is an Internet-based service from Siemens that supportsmaintenance processes while simultane-ously forming a platform for cross-com-pany service and support between OEMs andmachine operators. Services can be config-ured on ePS servers over secure Internetconnections from anywhere in the worldvia a standard PC, an Internet connectionand a Web browser. As a result, customersare provided with detailed information tolocalize machine faults much faster, thusenabling a quicker analysis without theneed for direct machine access, or in any

More information:www.siemens-imts.comE-mail: [email protected]

Siem

ens

AG


5

Siemens experts—everything from theinitial machine conceptualization to thefinal completion. This offers machine toolbuilders the opportunity to combine forceswith Siemens staff, i.e. with the experts oftheir control and drive technology supplier.Working closely with the OEM’s engineers,the Siemens experts provide assistance indeveloping innovative ideas and end-user-specific machine concepts which are pre-cisely tailored to their needs. Each solu-tion comes equipped with state-of-the-artSiemens CNC technology and top-notchfunctionality. �

way influencing the production process.ePS will demonstrate its Web-based solu-tion together with the Sinumerik 840D onthe Stama machine during live demonstra-tions at the booth.

Virtual Production offers OEMs and end-users higher quality and shorter produc-tion times. With the help of a software tooldeveloped by Siemens, the process chainis subjected to a simulative analysis foreverything from the CAD/CAM system to theworkpiece surface. Instead of resortingto repeated testing on the actual machine,programs can be optimized on the com-puter— the only exception: the numericalcontrol program, which is simulated on areal machine.

Mechatronics Support enables OEMs todesign their machines in cooperation with

W ith over 4,000 machines in useworldwide, Stama America, theNorth American affiliate of Stama

Maschinenfabrik GmbH based in Schlier-bach, Germany, was interested in buildinga highly flexible machine capable of milling,drilling, thread cutting, external/internalturning, facing and contouring, that wouldoffer more customers the ability to alsouse it on shorter runs. Short setup andchangeover times were distinct goals of theSystem 7 design team. Therefore, the con-trol selection process became all the morecomplex, Gerhard Ulmer, director of salesat Stama, recalls.

“Further compounding our challenge,”Ulmer comments, “we had a great demandfor a high degree of accuracy under pro-duction conditions, because our automo-tive and our medical customers require it. 0.02 millimeters true position under

The System 7 fromStama combinesfive-axis machiningwith trunnion-mounted twinspindle technologyfor vertical orhorizontalmachining

Siemens control package expands Stamamilling/turning center performance range

Rising to theOccasionIn developing the new System 7 milling/turning center of the German machinetool builder Stama, the control solution proved particularly challenging. The innovative machining center combines a single five-axis milling spindlewith one or two turning spindles and trunnion-mounted workpiece positioning,thus enabling true six-sided, fully-automated machining of blank bar stock orfrom a chuck. The successful turnkey package supplied by Siemens included aSinumerik 840D with NCU 573.5.


6Automotive and Medical

CASE STUDY

All

pict

ure

s: S

tam

a A

mer

ica

System 7 (MT Series) from Stama, a milling/turning machining center

for complete six-sided machining ofsmall and medium batch runs


7

1.67 Cpk conditions are typical for our twin-spindle machines.”

Extending twin-spindle applications

The inherent advantages of twin-spindlemachines include a smaller footprint, powersavings, increased productivity and areduction in overall cost per part. Thus,the machines are ideally suited for fewerand longer production runs. While Stama’sTier one automotive and other customersfit this profile exactly, the builder sought todesign a machine also suited for its Tiertwo/three automotive, as well as its high-precision, short-run customers.

From the very beginning, the consider-ations of the Stama design team were

driven by the main concern of its cus-tomers: namely, how to devise a solutionthat would allow twin-spindle and single-spindle work to be processed economicallyon the same machine. Clearly, the machinewould require a very high level of motioncontrol, accuracy and multi-function capa-bility. Customers needed the option tomachine one piece simultaneously with twospindles, run separate smaller parts oneach spindle independently or to changetooling on one spindle while the other ismachining (zero-based tool-changing). And,for true six-sided machining, one spindlewould need to function as the rotary actua-tor for the workpiece. To pack all of these fea-tures into a single machining center and notprice it out of the competitive market was amajor concern for the Stama team.

The control solution of choice: the Sinu-merik 840D with NCU (numerical control

unit) 573.5—a CNC with an open archi-tecture and PC-based design capable ofhandling up to 31 axes and 10 channels.Siemens motors, power supplies and driveswere also part of the System 7 turnkey pack-age, as was the TRAORI software suite ofSiemens. The software, which is based ontransformation orientation, drives the cut-ting motions relative to the position of theworkpiece, not the NC program. With thehelp of this “look ahead” function, it alsospeeds up cutting time and overall finish-ing time on the part. This is an especiallycritical feature for Stama’s automotive cus-tomers and the complex materials cut forStama’s medical customers. Gerhard Ulmerobserves, “We did some modifications of

their software for the particular needs ofour customers, but the base model andthe flexibility of the CNC package madeSiemens the only choice for Stama on theSystem 7. It’s the first true control packagefor a mill/turn machine in the world.” Accord-ing to Ulmer, customers have reportedthroughput time savings of 30 percentminimum on the System 7 as compared totheir previous machines or methods.

Up to the challenge

As a result, Stama was able to achieve thedesired programming for the single ortwin spindles in all configurations. Ulmerremarks, “It doesn’t matter if the machineis running as a five-axis mill or a lathe.Other CNCs we considered had to switchtheir operational mode, while the Sinu-merik 840D can run any program seam-lessly.” He favorably notes the control’s

robust and safety qualities, which areessential for the medical market especially.“When cutting cobalt chromium, Nitinol(nickel titanium) and other alloys widelyused in the production of medical implants,surgical tools and instruments, tool wear isquite common.” Up to 30,000 tool changesa day are not uncommon, according toUlmer, who cites the rigidity of the Sys-tem 7 frame and the out-of-tolerance tooldetection capability of the CNC as key fea-tures for the medical customers Stamaserves worldwide.

Reliable support

In Ulmer’s opinion, the cooperation withSiemens engineering played a particularly

important role during the developmentprocess on the new milling/turning center.“The Siemens engineering staff was in-house at Stama from the outset. We hadpreviously worked with another CNC sup-plier and never received such service. I cansay without hesitation that the SiemensCNC was key to the development of the Sys-tem 7, as well as for our System 8, designedfor the larger workpieces and chucks. It wasa true example of simultaneous engineer-ing on our part and theirs to devise the bestresult.” �

More information:www.SiemensCNC.comE-mail: [email protected]

High-precision medical implants, surgical tools andinstruments are made on the Stama System 7, often from very hard-to-machine alloys such as cobaltchromium and Nitinol (nickel titanium)

In addition to the U.S. government andindustrial gas distributors throughoutthe U.S., Fiba Technologies, founded in

1958, ranks major industrial and specialtygas as well as chemical suppliers among itscustomers worldwide. The company spe-cializes in pressure vessels, tubes and otherindustrial equipment for storing and trans-porting high-pressure and liquefied gasesand chemicals.

The machine for this particular applica-tion, the OSC-24300, spins the ends oflarge steel pipes to fabricate an unfired,seamless, integrally forged pressure ves-sel. Driven by a 300 horsepower motor andweighing over 125,000 pounds, the giantmachine incorporates a tube handling sys-tem as well as an automated inductionheating system. Each tube is spun with anecking-in and/or bottom forming opera-tion performed at each end.

Hand-in-hand communication

The Spin CAD software of MJC is a Windows-based operator interface software thatallows the machine programmer to gener-ate spin passes on a computer using “pointand click” technology. All machine func-tions and editing are controlled and storedwith the help of Spin CAD. Once the pro-gram is complete, Spin CAD generates a G-code program that the Sinumerik 840DCNC utilizes to form the part.

A Sinumerik 840D CNC was configuredfor two-axis control, Z and rotation onboard

the massive machine. To sim-plify the programming, therotation axis uses a standardhydraulic cylinder with feed-back converted from inches todegrees of rotation. Both axesare powered by a Siemens HLAModule, while Profibus com-munications handle the datainterchange between the CNCsystem, operator panel andPLC.

The MJC machine in opera-tion at Fiba is fed by 1,000ampere of 480 volt power and250 horsepower of hydraulics


Siemens technology integral for world’s largest metal spinning machine at Fiba

Production on aGrand ScaleThe OSC-24300, built by MJC Engineering and Technology of HuntingtonBeach, CA for the Fiba Technologies production site in Westboro, MA, iscapable of spinning steel tubes up to 24 inches in diameter with a 1.5 inchwall and 40 feet long into pressure vessels for the industrial gas and chemicalmarkets, making it the world’s largest metal spinning machine of its kind. At the heart of the enormous machine measuring over eighty feet: MJC’s Spin CAD software and a Sinumerik 840D CNC with HMI software.

MJC’s Model OSC-24300 at Fiba Technologiesspins and forms tubes into pressure vessels over 40 feet long

An induction heating system and shaping tools close the end of the steel tube for seamless integrity

8Industrial Gas and Chemicals

CASE STUDY

overall. A typical setup for a machining jobgenerally involves four simple steps. First,the programmer writes the program on adesktop PC or directly into the machine’sCNC. The spin program is then accessedfrom the Spin CAD software, and the on-board Fiba software generates the G-codefile. In the third step, the operator sets thehome position on the machine. Finally, theoperator activates the part handling device,loads the part to be spun and starts the cycle.

Taking up the challenge

Commenting on the selection process, MJCVice President Dave Grupenhagen recalls,“Fiba contacted us in late 2002 about build-

ing a machine to spin large diameter steeltubes into DOT-approved pressure vesselsused in the compressed gas, chemical andother industries. The high-pressure tubesare typically used on tube trailers and con-tainers to transport CNG, hydrogen, heliumand other industrial gases.” According toGrupenhagen, Fiba was unable to find aspinning machine manufacturer who waswilling to build a machine to their desiredsize. One company manager even told Fibait wasn’t possible to build a machine onsuch a scale that would work. “That was allthe motivation we needed at MJC,” Grupen-hagen adds. “Within three months, a pre-liminary design meeting was held and we

were awarded the contract.” The next sixmonths were spent completing the designengineering, which included the tube han-dling system and automated inductionheating system. “All fabrication of majorcomponents was done at our Los Angelesfacility of MJC and, within eight monthsafter the release of our engineering draw-ings, the machine was tested using theheaviest steel tube with a 24 inch diameterby 1.5 inch wall and 40 feet long,” Grupen-hagen is pleased to report. �



All

pict

ure

s: M

JC E

ngi

nee

rin

g &

Tec

hn

olog

y

9

Sinumerik 840D simplifiesdual-spindle turning centercontrol at CNC Industries

Complex TasksMadeEasy

CNC Industries produces high-precision medical instruments,

mostly from heat-treated 17-4 ph stainless steel

DMG Twin 32 dual-spindle turning centerwith Sinumerik 840Dpowerline CNC


10Medical

CASE STUDY

All

pict

ure

s: C

NC

Indu

stri

es

families, though the vast majority usesSiemens CNC units, some with the com-pany’s ShopMill and ShopTurn softwarepackages. These complement the DMG suiteof software programs, designed especiallyfor the job shop sector, thereby providingfaster programming, tool path simulationand machine kinematic data.

An ideal combination

Bob Reed, DMG area sales manager servingCNC Industries remarks, “We have an idealcombination of machine, control and soft-ware to offer the customer. The materialsthey run, combined with their typical pro-duction quantities, translate into a realchallenge for the machine tool builder. Weneed to help them optimize their efficiencyon the very first part, while providing ongo-ing flexibility to meet the variety of theirworkload.”

Together with the Twin 32 and inte-grated Siemens CNC onboard, the companyhas been able to provide its customers thecomplete package. Moreover, to date, thecontrollers have required minimal serviceand no repairs, Kurt Wendhack is pleased toreport. �

A s the name already implies, theshop focuses on CNC machiningoperations, mostly milling and

turning. As general manager Kurt Wend-hack explains, “The majority of the work wedo today is in stainless steel, primarily heat-treated 17-4 ph.” This particular grade ofstainless steel has excellent strength andhardness qualities combined with superiorcorrosion resistance, making it ideal forvarious medical, surgical and dental appa-ratus, but also challenging for machinesto produce. But then, tight tolerances onshort- and medium-run parts are routinefor CNC Industries.

Complex, powerful, easy to use

At the heart of the operation are threeDMG Twin series dual-spindle turningcenters which handle multiple tasks.These turning centers are typically usedfor high-level machining of bar, shaft and chuck workpieces, and feature aunique work area designed around thedual-spindle configuration. With inte-grated drives on both the main andcounter spindles, the Twin Series turn-ing centers provide indexing of 12x servoturrets with 0.1 second indexing, 1.0acceleration of gravity, rapid traverse to1,181 inch per minute and 8,000 rpmspindle speeds.

Overall control of the axis and spindlemovement is handled by a Sinumerik 840Dpowerline CNC. “Combined with a PC-typeWindows operating system, the complexand powerful CNC is nonetheless easy touse, and allows us to store our programsright on the machine hard drive, though wemaintain back-up files as well,” Wendhackpoints out.

Setup ease and versatility

Setups on multi-function machines such asthe DMG Twin 32 models used by CNCIndustries can be an arduous task. As aresult, the ease with which setup data canbe input into the machine’s controllerplayed a key role in the company’s buyingdecision. “The functionality of the Sinu-merik 840D addressed this concern andmade a significant impact on our buyingdecision,” as Wendhack stresses.

The Sinumerik 840D is a sophisticatedCNC that offers a wide range of specializedfunctions for milling, drilling, turning,grinding and handling technologies. Thesystem offers users innovative featuresdesigned to increase productivity on themanufacturing floor, especially with respectto the challenging segments of high-speedand five-axis machining.

DMG utilizes a variety of controls with itsbroad product line of eight turning center



11

Established in 1977, CNC Industries,

a division of X-L Engineering

Corporation, is a high-precision,

20-person shop located in Elk Grove

Village, Illinois. While the parent

company is active in a diverse range

of markets, CNC Industries has

evolved from primarily being a

military subcontractor to its current

specialization as a supplier of high-

premium, production-run medical

instruments. A Sinumerik 840D

powerline series CNC has simplified

the overall axis and dual-spindle

movement control of the company’s

three DMG Twin series turning

centers.


12Job Shop

CASE STUDY

At Prince Industries in Livonia,Michigan, a unique blend of proto-type and production work keepsoperations in the 30,000 square footjob shop very busy. In the past, thechoice always came down to manualvs. CNC machine tools, depending onthe anticipated work load and jobquantity mixes. One day, a Sinumerik810D CNC with ManualTurn softwareonboard from Toolmex Machineryvirtually revolutionized operations atPrince Industries.

The company’s customers include avariety of tool and diemakers, air-craft component suppliers, heavy

construction equipment builders, energyproducers and steel foundries. The shophouses an assortment of milling, turningand grinding machinery of all types, every-thing from manual to full CNC. A majorityof the jobs involve shaft, ID and chuckerwork, usually in print-to-prototype andsmall quantity runs.

Learning fast

The predictably greatest challenge PrinceIndustries faces, according to owner HaroldEklund, is the programming and setup time

on the machines. Founded in 1978, thecompany has met the challenge in a varietyof ways over the years.

However, something happened thatwould forever change the paradigm atPrince. Eklund saw a Haco TUR630MNwith a Sinumerik 810D CNC and Manual-Turn software onboard from Toolmex Machinery in Schaumburg, Illinois. Hediscovered that the machine did not onlyallow for manual operation in a manualmode, a feature particularly helpful foroperators when needing to program froma print directly into the controller, butthat the software also offered a “learn asyou go” function especially useful for

Progressive automation technology helps operators “learn as they go”

Changing the Paradigm

With ManualTurnsoftware onboard,operators are able

to “learn as theygo” through the

programming cycle

All

pict

ure

s: P

rin

ce In

dust

ries


13

operators that do not possess extensiveG-code knowledge.

Improved control without compromise

The Sinumerik 810D is a compact CNC for drilling, milling and turning applica-tions, featuring full integration with theSimodrive 611 digital drive package. It issaid to be an ideal control for cost-opti-mized machine tools. Eklund explains,“This is the easiest control to program inour shop. Training new employees is espe-cially fast and simple.” Because a com-puter is not needed for G-code program-ming, generating a finished part has becomemuch faster, and does not result in any lossof accuracy or part quality. “By compressingthat time function, we’ve improved ourprofitability on a lot more jobs. Personally,

I also like the excellent threading control onthe machine,” Eklund adds.

The first part on the TUR630MN is donein a teach-in manual mode. After that, theCNC supports the elementary contours,stock removal mode and cycle modes forthread, cut, groove, undercut, drill andthread repair. The machine features a stepchain programming function entitled Easy-step that enables simple assignment ofgraphic symbols to the graphic elementsand block commands. Up to 50 undefinedelements can be calculated through the on-board contour calculator with contourhandwheel. Online simulation is also saidto be faster, with more reliable checking ofparametric values.

Attention to detail

The machine can handle a 4,400 poundworkpiece between centers with a 25 inchswing and a 4.1 inch spindle bore with dualspindle nose. Equipped with high-preci-sion brushless motors and drives, theTUR630MN gives Prince yet another dis-tinct competitive advantage, one that Ek-lund and his team have come to greatly ap-preciate: namely, the machine’s controlpanel moves along the entire length of thework bed. While it may appear to be a minordetail, the feature allows an operator com-plete access to the controls while inspectingeven the largest workpiece. “It is just onemore time saver and,” as Eklund observes,“all of these improvements make a big im-pact on our bottom line.”

Prince Industries processes all types ofmaterials on the machine, from varioustool steels to aluminum and Waspalloy.End-user applications for the parts pro-duced at the facility include anchor com-ponents for U.S. naval vessels, ballscrewsfor military aircraft, forging dies, prototypetooling and massive, one-of-a-kind con-struction equipment sections.

Reliable and easy to operate

Used primarily for axis movement andspindle control on the manual turn lathe,the CNC onboard has been very reliable.Eklund notes but a single service problemto date, “We burned out a main board andhad to call for service. Siemens discussed

the problem with us over the phone to di-agnose the situation, and then sent some-one out from their Chicago office with theproper parts. Our machine was up and run-ning again the very next day.”

Although a specific time-motion studyhas not yet been conducted, Eklund esti-mates that using the “learn as you go” pro-gressive automation lathe has resulted in at least a 10 percent decrease in the time-to-part for many of the jobs performed at Prince Industries. Eklund also empha-sizes the fact that the Siemens control andManualTurn software allowed him to keepthe same skilled operators running the ma-chine at the improved productivity level.

Tom Kob, division manager for Toolmex,agrees, “The machine fills a void for com-panies such as Prince which routinely run

prototypes and short quantity jobs. TheCNC here does not require knowledge of G-code programming and, as a result, anumber of very skilled manual machine op-erators can remain on the job and getmuch more accomplished.” The reductionin time-to-part is indeed substantial whileenabling the operator to progress into the CNC mode in stages. “It has been avery successful machine for us, preciselybecause it makes such a noticeable differ-ence for companies such as Prince,” Kobconcludes. �


Typical parts produced by Prince Industries: 20 inch diameter aluminum motorcycle wheels …

… and 5 inch diameter and 56 inch long landing gear components

Iowa shop soars on flying optics laser with new Sinumerik powerline CNC

On the Progressive Edge


14Job Shop

CASE STUDY

DC turbo resonator generatesfour kilowatts power output,enabling the laser to cut differentmaterials of various thickness

A Sinumerik 840D controls all laserpower, table motion and cutting bridge X- and Y-axis movement

Jan

co In

dust

ries

Siem

ens

AG

At Janco Industries in Sully, Iowa,

Joel Jansen had a thriving business

creating various structures out of

mild, some out of stainless steel for

the agricultural, food processing,

food service and construction

industries. However, during a visit

to IMTS 2004 in Chicago, he saw

something that would change his

view on his company and its future.

That something was the ECHO III

flying optics laser from Han Kwang

USA equipped with a Sinumerik

840D CNC.

Jansen admits that he had looked intolaser cutting in the past, but that theECHO III from Han Kwang USA, the

American affiliate of the rapidly growingKorean laser cutting machine manufac-turer, offered some noticeable differencesas compared to other units on the market.

The Panasonic resonator, which generatesthe laser beam, offered significant upsidesin terms of operating and maintenancecosts. In addition to the precision flying op-tics design, it was capable of making morecomplex metal parts with holes and cutoutsin less time with the help of its twin linear

drive motor system. Further, the shuttletable system ran at 1,200 inches per minutefor enhanced loading and unloading of theworkpieces: a real time-saver.

The dealmaker

The Sinumerik 840D CNC, however, withits user-friendly design for PC interface,substantial 10 GB hard drive, 2 MB memoryand network-based, remote diagnosticsupport, proved to be the real “dealmaker,”cited by Jansen as an essential element ofhis buying decision. AC servomotor drivesfrom Siemens also improved the speed andpositioning. Training was another criticalconsideration, as was local support. Finally,the fact that both Han Kwang and Siemenshad offices and training facilities inChicago played a role in making the deci-sion an easy one.

All of these factors combined with thesystem’s small footprint, fast positioningspeed, auto focus control for varying thebeam target with high precision and, asJansen observes, “a price that left the otherplayers in the dust,” solidified his purchase

choice. The advantages of the flying opticlaser design are several. The optics move inthe X- and Y-axis, thus the material re-mains stationary. Owing to the high pre-cision of the dual Siemens linear motordrives, the positioning is fast (170 me-ters/minute or 6,693 inches/minute) with

0.004 inch accuracy and the accelerationsubstantial (10 square meters/second or393 square inches/second), with constantinertial dynamics and, therefore, minimalwear on the rack and pinion assembly.

Quick production-oriented interaction

The Sinumerik CNC controls all of the laserpower settings, as well as axis movementand feed rates. With the DNC and LAN inter-face, the remote diagnostic capabilities allowJanco operators to quickly interact with pro-duction control, and even with Siemenspersonnel over the Internet for direct real-time troubleshooting and assistance.

Han Kwang’s Echo III laser provides thecustomer with auto focus control with 9.5millimeters (0.375 inches) maximum fo-cal length variation, achieved through airpressure deformation of a hardgold-coatedmirror. The 4 kilowatt unit enables materialthicknesses to be cut over a wide range, andis thus ideally suited for a job shop such asJanco. Mild steels from 1–20 millimeters(0.04–0.94 inches) and stainless steel from0.8–12 millimeters (0.03–0.47 inches) areroutinely processed at Janco to manufac-ture the various components the shop pro-vides for its diverse customer base.

Profitable programming

When programming the laser, Janco uti-lizes its own software as well as the onboardProDesign program, which automates theprogramming of sheet metal cutting ma-chines from CAD to the critical nestingfunction that directly impacts materialconsumption and a shop’s profitability, ac-cording to Joel Jansen. Additionally, be-cause the program allows various lead-in/lead-out settings for differing contours,more diverse parts can run simultaneously.This is yet another cost-savings feature.

Han Kwang, which operates a 412,000square foot facility in Korea, currently mar-kets its machines throughout Asia andNorth America. The ECHO III laser at Jancocan handle workpieces weighing up to 800kilograms (1,760 pounds). Software up-dates are performed through direct up-loads from the manufacturer, thus keepingJanco equipped with the latest versions ofall applicable programs. �



15

Janco Industries usesan ECHO III flying opticlaser to produceequipment structuresand components forthe ag, constructionand food processingindustries

Jan

co In

dust

ries

16Multi-Spindle Machining

CASE STUDY

Through the use of Index multi-spindle machining centers, aClearwater, Florida job shopcontinues to score high marks withprecision hydraulics, aerospace anddefense sector customers. ModelScrew Products, which employs astaff of 78 at its 42,000 square footfacility, produces various hydrauliccomponents for major OEMs andgovernment facilities. The companyrelies on Sinumerik 840D technologyto control spindle and axis movementof its two six-spindle automaticmachining centers.

Founded in 1914 by Hermann Hahn,Index builds various machine toolsand machining centers sold under

the Index and Traub brand names andmarketed to automotive, medical, aero-space, electronic, optic and other precisionparts manufacturers worldwide. Theseinclude CNC single- and multi-spindleturning machines, near net shape verticalCNC chuckers, Swiss Type CNC slidingheadstock turning centers, fixed head-stock, twin turret machining centers, CNClathes and heavy-duty CNC turning/millingcenters.

Model Screw Products (MSP) typicallyworks carbon steels (4140, 1117, 86L20,1215, 12L14 and 11L17) and tool steels (A2,S7) on a variety of machine tools, includingCNC multi-spindle, CAM multi-spindle,grinding, honing, broaching and diamondfinishing. Parts produced at the facilityrange from shafts and hydraulic ports torings, collets and caps. According to Tony

Farrell, general manager at MSP, “Our cus-tomers have very high standards, and weaccommodate them by maintaining anabsolute state-of-the-art machining andquality control operation.”

Relying on advanced CNC technology

Two of the newest Index machines at MSPhave made significant improvements in theproductivity, quality and especially the dataexchange process at the company, accord-ing to Farrell. The Index MS32C and MS32Pare both precision CNC, six-spindle auto-matic machining centers used for 1.25 inch

Siemens CNC a key factor for excellent customer rating at Model Screw Products

Keeping Standards High

Index multi-spindle CNCmachining centers at MSPare used to produce high-accuracy components forhydraulic systems anddefense ordnance

The work areaclose up

Model Screw Products produces parts ranging from shafts and hydraulic ports

to rings, collets and caps All

pict

ure

s: In

dex

Cor

p.

maximum bar and two inch chuck work toproduce medium- and high-volume turnedparts at MSP. And both feature an advancedCNC, the Sinumerik 840D, to control spin-dle movement and axis movement, mon-itor tool wear and to engage various safetyoptions on the machines.

According to Index, Siemens controlsare currently used for 99 percent of the axis and spindle motion at Index. “Thetypes of drives and CNC packages werequire at Index demand greater controlcapability for each individual axis and,with Siemens, 31 drives can be controlledwith one NCU processor.”

Index also emphasizes the memoryupsides, “Data programs can be stored ona hard drive for long-term storage whilethe current programs are being stored andused out of a RAM chip for better and fasteraccess.” In addition, the control can be uti-lized for better tool management.

Comprehensive capabilities

The Sinumerik 840D is a high-level CNC,offering machine builders and end usersalike a wide range of specialized functionsfor milling, drilling, turning, grinding andmaterials handling. Its capabilities alsoinclude nibbling, punching, metal forming

and laser processes. The advanced controloffers a variety of additional features toincrease shopfloor productivity, especiallyfor meeting the challenges of high-speedand five-axis machining.

Farrell goes on to point out, “These CNCcontrols allow us to store multiple pro-grams because of their substantial softwarecapabilities. Internet capabilities onboardfurther allow us to communicate directlywith our quality department on SPC (Sta-tistical Process Control) data, as well as withour customers for real-time productionscheduling. This enhancement especiallyhas made a tremendous impact on ourbusiness.”

One MSP operator characterizes the con-trol as very user-friendly with respect tothe setup, which uses plain language and“fill in the blank” answers as prompts onthe CNC monitor. Troubleshooting is alsoeasier, as is the programmed routine main-tenance on the machine, all controlled bythe CNC. Thanks to the Internet access,which enables real-time assistance, down-time is drastically reduced.

Meeting customers’ needs

Both the end-user (MSP) and machinebuilder (Index) agree that the support ofthe CNC supplier (Siemens) was essentialfor the successful implementation of thehigh-level control platform into their oper-ations. To verify quality at MSP, every partis inspected using a variety of dimensional,impact and other testing devices. Becausethe end uses of their components ofteninclude high-pressure hydraulics systemsand critical accuracy defense ordnance,MSP is particularly sensitive to the QC mon-itoring and documentation protocols itmaintains.

Various members of the Siemens staff,including the Siemens technical field serv-ice and engineering departments, assistedIndex engineering with the CNC applica-tion for the builder’s machine tools. A com-pany representative is quoted as saying,“They were there for us whenever needed,striving to meet our needs and to meet orbeat all our expectations.” �


17



18 SHORTLIST

These and other interesting applications are described in detail under:

www.siemens.com/read-motionworld

At aba z&b, Inc. (Orangeburg, SC), asingle Sinumerik 840D CNC replaced threeprocessors and independent operatingsystems on what is considered to be the world’s largest creep feed grindingmachine—with highly satisfactory results.

A new line of dual-spindle productionmachines from DMG (Deckel MahoGildemeister), headquartered in NorthAmerica (Schaumburg, IL) incorporatesSinumerik powerline technology to offerend-users decided benefits before, duringand after machining cycles.

Brooklyn Technical Services retrofitthree creep feed grinders with aSinumerik 802D at the HoneywellEngine and Systems facility in Greer, SC—a measure which proved to be avery cost- and production-efficientsolution.

DM

G

aba

z&b

USA

, In

c.

Broo

klyn

Tec

hn

ical

Ser

vice

s

DIALOGUE

infoinfoDo you want to find out more about automation and drive engineeringfrom Siemens Automation and Drives? Then visit our online informationplatform on the Internet:

www.siemens.com/automation/newscenterYou will also find up-to-date newsletters on the Internet as a free sub-scription, for example the Totally Integrated Automation Newsletter.Simply register with your e-mail address at:

www.siemens.com/automation/newsletter

onlineonline

event

motion world onlinePoint your web browser to:

www.siemens.com/read-motionworldand you can download the latest issue as a PDF file. The electronic archiveenables access to all previous issues. You can also send suggestions andcomments on the issue and the individual articles by e-mail. Your feed-back flows directly back into the compilation of motion world. Of course,you can make changes to your subscription here, as well.

eventFree Seminars for CNC ProfessionalsIn 2006 and 2007, Siemens will expand its popular Sinumerik 840D workshop series to deepen your expertise and keep your “Productivity in motion.”

Each workshop (one for operators and programmers and one for main-tenance professionals) will allow us to focus on your area of need; bringyou more demonstrations; and answer your “how to...” questions ingreater depth.

For more information, visit our seminar website:

www.SiemensCNC.com/seminars/mowo

motion world July 2/2006

PublisherSiemens Aktiengesellschaft,Automation and Drives Group (A&D), Gleiwitzer Str. 555, D-90475 Nuremberg, Germany

www.siemens.com/automation

Group Executive ManagementHelmut Gierse, Hannes Apitzsch, Dr. Peter Drexel, Anton S. Huber

Editorial Responsibility in Accordance with the German Press LawPeter Miodek

Responsible for Technical ContentsBernd Heuchemer

Editorial committeeJohn Meyer, Wolfgang Wilcke

ConceptChristian Leifels

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenP.O. Box 3240, D-91050 Erlangen, GermanyTelephone +49 (0) 91 31/91 92-5 01Telefax +49 (0) 91 31/91 92-5 [email protected]

Editorial staff: Christoph Manegold, Eric Woratschka

Layout:Jürgen Streitenberger

Copy editors: Sabine Zingelmann

Job number: 002100 RME62

DTP: Doess, Nuremberg

Printed by: Stürtz AG, Würzburg

Circulation: 8,000

© 2006 by Siemens Aktiengesellschaft München and Berlin. All rights reserved by the publisher.

This edition was printed on environmentally-friendly chlorine-free paper.

The following products are registered trademarks of Siemens AG:ShopMill, ShopTurn, SIMODRIVE, SINAMICS,SINUMERIK, SINUMERIK solution line, SinuTrain,Siemens Automation Solution Provider – certified

If trademaks, technical solutions or similar are notincluded in the list, it does not imply that they arenot protected.

The information provided in this magazinecontains merely general descriptions orcharacteristics of performance which in case ofactual use do not always apply as described orwhich may change as a result of furtherdevelopment of the products. An obligation toprovide the respective characteristics shall onlyexist if expressly agreed in the terms of contract.

Order No.: E20001-MC206-B100-X-4A00

19

JobShop machining made easy.

©2

00

6 Siem

ens En

ergy & A

utom

ation, In

c.

Competitive pressures demand flexible production and reliable quality. SiemensCNC technology offers you the flexibility and benefits of conventional machining.Experience far better accuracy, precision and performance in all your tasks. AtIMTS, see how the latest innovations for the job shop industry, including the newSINUMERIK solution line CNCs and the all-new ShopMill and ShopTurn softwarepackages, can set your “Productivity in motion.”

Visit www.siemens-imts.com for more information.

Siemens Energy & Automation, Inc. • 1-800-879-8079 • [email protected] • www.SiemensCNC.com

Visit us atIMTSBooth

D-4208

solutions

06 IMTS MWM JS Solutions 6/5/06 9:27 AM Page 1

rme62 s01 titel - static.dc.siemens.com

Documents