Wire Payout Drum minimizes welding quality defects

To increase precision and improve quality on automatic and robotic welding applications using metal cored wire, Hobart Brothers offers its eXacto-Pak(TM) Precision Payout Drum. The eXacto-Pak, also called X-Pak, pays out accurately to maintain the highest of weld quality by ensuring that wire stays consistently focused in the center of the joint. Available in 400 and 600 lb. drums, the X-Pak is specifically designed for high-volume production using .045- to 1/16-in. diameter wire. In addition to providing precision pay out, the X-Pak also protects wire from dirt and dust to promote contaminant-free welds.

Straighter Wire, Better Welds
The X-Pak essentially eliminates quality defects attributed to wire wander, including undercut and lack of sidewall fusion, while also improving wire feedability. To provide better weld joint tracking by ensuring that the arc is consistently focused in the center of the weld joint, X-Pak pays out wire in a straight and reliable pattern. Keith Packard, tubular wire product manager, Hobart Brothers, cites the drum's special design for providing such benefits. "In robotics or automated welding, any system is going to be limited in its ability to track the weld joint. With the X-Pak's design, the wire comes out so precisely and hits the same spot each time, so you don't have to be concerned with whether you are going to have an accurate weld placement. You will."

To prove that point, Hobart Brothers conducted a "Wire Straightness Shoot Test," in which a MIG gun was held six inches away from a sheet of dense grid graph paper and wire was fed through the gun until it punctured the paper. The procedure was repeated multiple times, resulting in only a 15mm wire deviation when using the X-Pak and a 75mm wire deviation when using a competitive drum. With these results, Hobart Brothers shows the X-Pak's reliability and accuracy, while making certain that users will receive the highest quality payout drum possible.

Improved Productivity
Along with providing precision wire feed and superior weld tracking capabilities, X-Pak improves productivity by reducing the amount of downtime needed to change liner and contact tips due to excessive wear. Packard explains, "The X-Pak creates less cast to the wire as it feeds out, so there is significantly less friction on the welding components. This is going to save time and money with any welding system, not just in terms of parts, but also labor." By lessening the amount of quality defects, the X-Pak further reduces the need for rework and increases a welding system's overall throughput time.

Dynabrade's Versatility Grinder

Excellent For use in an Extensive Variety of Manufacturing Applications

Dynabrade's Versatility Grinder accepts a wide variety of different contact arms for hundreds of uses. This Stationary machine utilizes 1" - 2" wide x 72" long abrasive belts. Featuring a 1 HP variable speed motor, the abrasive belt can travel in either a forward or reverse motion.

Utilizing a compact, efficient housing design, the machine offers a pivot mount assembly, which allows the operator to adjust the sanding belt to any angle for optimum comfort. The linear belt tracking adjustment works with the tracking system to allow for superior abrasive belt speed and control.

The Versatility Grinder is also available with a full range of contact arms for a variety of grinding, deburring and polishing applications. The "Easy Access" belt guard allows for quick, simple changing of abrasive belts. The machine is ideal for use on cutlery, golf clubs, medical implants, architectural hardware, firearms, prostheses, propellers and much more.

The machine features a 4" diameter vacuum port, allowing for connection of dust collection systems. An optional Vacuum Scoop is also available. The scoop pivots 90 degrees for optimum versatility. A full line of abrasive belts is also available. Made in the U.S.A.

Abrasive Wheel suits high-production pipe cleaning machines

The new Upblast EZEFIT(TM) Wheel by Wheelabrator® is ideal for high-production pipe cleaning machines that must meet the stringent surface preparation requirements of the pipe coating industry.

The wheels mount in the blast cabinet and are positioned under the pipe to maintain a close and consistent distance to the underside portion of the pipe regardless of the pipe diameter. This location results in the fastest removal of rust, scale and other contaminants while achieving the mandatory surface profile for effective bonding of the protective coating.

The Upblast EZEFIT wheel design has been retrofitted on Wheelabrator machines and other manufacturers' blast machines. The range of pipe sizes cleaned range from 2" up to 120 inches in diameter. The new wheel is easier to maintain than previous designs and has longer wear life with lower abrasive consumption.

The unique design of the EZEFIT wheel offers the inherent advantage of bi-directional rotation and lower replacement parts inventory through the ability to serve clockwise or counterclockwise wheel applications with a single style wheel. Wheelabrator has capitalized on this advantage with a direct-drive or belt-driven design that offers standard or custom base mounting for increased versatility.

PFH Parallel Gripper

a new size for its long-stroke 2-finger parallel gripper series PFH. With a total finger stroke of 300mm (11.8"), the new size 150 of the PFH parallel gripper family is especially designed for handling large and heavy components. Besides its high grip force of 2,200N (500lbf.), the PFH also stands out with fast finger opening and closing times of less than one second.

The pneumatic drive of the gripper, consisting of a dual-piston system, is synchronized by a rack and pinion. The drive produces a gripping force of 2,200N (500lbf.), which is applied uniformly ensuring the precise handling of a most varied array of workpieces. In addition, the low internal friction makes the gripper highly efficient, while simultaneously minimizing wear. All guide and drive elements of the gripper are protected against the ingress of coarse contaminants by a stable, three-layered sheet steel/roller belt cover.

Considering the dimensions and the size of the stroke of the PFH 150, its closing and opening times of around 0.8 seconds are extremely fast. This is possible due to end position damping, which also ensures a quiet return to the end position. The air supply can also be connected without hoses, and the PFH 150 can be flexibly attached on two sides in three screw directions.

Hurco Introduces Massive Machining Center

INDIANAPOLIS-Hurco Companies, Inc., announced the launch of its biggest vertical machining center ever-the VMX84. With X/Y/Z Axis travels of 84/34/30 inches, this massive machining center broadens the company's product line to meet the needs of customers who produce large parts, molds, and dies. VMX84 customers can choose from spindles speeds of 10K, 12K, or 15K.

All VMX Series machines from Hurco are known for their sturdy construction and exceptional accuracy due to larger ball screws and bigger servo drives. The increased metal removal rates and higher feed rates on the VMX machines decrease part cycle times significantly. Like every Hurco machine, the VMX84 features the most flexible control in the industry.

The flexible Hurco control combined with the newly released WinMax® control software provides the highest level of shop floor flexibility and software productivity for both G-Code and conversational users. Hurco customers using WinMax® will experience measurable process improvements due to 25 new features including Advanced Verification Graphics with 3D solid rendering, dynamic rotation, and real time tool display; Swept Surface; and NC/Conversational Merge. The new WinMax® control software also includes hundreds of enhancements that streamline programming, such as reduced keystrokes, touch screen navigation, an intuitive visual interface, and project management/file naming improvements.

Indent Marking Tool is designed for CNC milling machines

Dapra Marking Systems has announced the availability of the DMwriter, a unique indent marking tool for CNC milling machines. Using compressed air through the spindle, or from a secondary air supply to actuate carbide stylus, the DMwriter can mark as fast as 120 inches per minute, much faster than standard engraving tools. Alpha-numeric characters and logos can be generated using standard engraving software to create the marking layout.

With a 5/8" shank, the DMwriter is designed to fit standard toolholders and eliminates the need for secondary marking operations. It is capable of marking parts up to 62Rc, with the depth of the marks dependent upon the air pressure used. Unlike engraving, the low-stress indent marking performed with this tool does not remove any material from the part.

CNC Machining Center suits nested base manufacturing

Hendrick introduces the 20ZXGN-ATCT6-NBM CNC Machining Center featuring a 6 station rotary automatic tool changer mounted on the front of a 12 HP high frequency router spindle for rapid tool change on the fly, 5 x 5 32 mm drill block with independent drill actuation by CNC program and high speed accurate machining capabilities. A new heavy structure design and improved CNC control software yields feed rates up to 2500 inches per minute and positioning accuracy of +/- 0.002 inches with repetitive accuracy of +/- 0.0008 inches. The moving gantry design utilizes AC servo drives, linear ways and ball screws on all axis for smooth and accurate movement. Other features include PC controller with built in CAD/CAM software, vacuum table machined for zoning and pod fixturing, low vacuum pressure safety cut off and air blast tool cooling. The affordably priced machine is available in many different table sizes.

ESI Software simulates and evaluates casting process

ESI Group has once again chosen the GIFA foundry trade show in Dusseldorf, Germany, to present its recent releases in casting solutions and meet its customers. From June 12 to 16 in Hall 15 at booth G14, get a comprehensive overview of the rapid developments in the area of casting process simulation. The company's multilingual casting team, representing Asia, Europe, and North and South America, will present the new ProCAST and QuikCAST solutions during meetings dedicated to your needs. For almost two decades, GIFA has been recognized as the most important casting trade show in the world, and ESI Group has presented its casting simulation solutions there since 1989.

The users of ESI Group casting solutions benefit from the multi-facetted range of products and solutions (advanced CFD, composites and plastics, crash impact and safety, stamping, vibro-acoustic, welding, etc.). A major focus during this GIFA edition will be on the link (inter-relationships) between cast-part properties and their usage in final assemblies under real conditions. For that purpose ESI Group has developed a new open collaborative engineering environment allowing process customization and automation.

The ProCAST solution includes automatic mesh generation, thermal analysis with radiation effects, flow analysis for mold-filling, fully coupled thermal, flow, and stress analysis, and advanced metallurgical options. This software provides state-of-the-art simulation capabilities to the casting industry allowing complex processes to be simulated and provides foundries with the capability to test more mold designs in less time. In 2006, the ProCAST solution received the European Technology Leadership of the Year Award from Frost & Sullivan.

QuikCAST, the fast and efficient solution for casting process evaluation, is a streamlined and user-friendly casting simulation tool which provides a complete industrial solution to foundries and delivers realistic predictions at each step of the casting process. Based on robust solvers and efficient self-correction features, this technology yields comprehensive and realistic results with high mesh independence.

"Almost 20 years ago we had to explain the purpose of our work and even CAD software was in its infancy," says Marco Gremaud, ESI Casting Solutions product manager. Ten years later, towards the end of the 20th century, simulation was well understood but user requirements shifted the focus towards validating the numerical results with experimental work. Today the main challenges are found in the integration of simulation results within the global product life cycle and the capability to rapidly predict better results with additional specific casting functionalities in a friendly user environment. In fact this is exactly what ESI Group casting solutions propose because of its fast developments, strategic acquisitions, and rapid expansion all over the world. As the casting simulation veterans of the GIFA foundry trade show, we will be honored to welcome you in our booth in 2007 to show our recent developments and to explain our strategy," he explains.

DC Micromotor with Graphite Commutation

Micro-Drives announces the expansion of its DC Micromotor product line with the addition of its Series M2232U. The low-cog DC micromotor has an external motor-diameter of 22 mm and a length of 32 mm. The low-cog rotation is achieved through a combination of skewed laminations and a tapered permanent magnet system. The DC micromotor can achieve a stall torque of 25.62 mNm and speeds of up to 10,000 rpm. The DC micromotor comes in 2 different versions each with graphite commutation which ensures long-life even under overload conditions. The Series M2232U GS has a cantilevered brush system while the Series M2232U CS has a cartridge brush system for even longer life applications. The 2.0 mm diameter motor shaft ensures high rotational stability.

The Series M2232U DC Micromotor can be combined with a gearhead, encoder, and linear actuator for a complete miniature DC drive system. Plastic and metal planetary gearheads are available in 22 mm diameter with various reduction ratios allowing an output torque up to 600 mNm. The 2 channel magnetic encoders allow for precise control of speed and direction of rotation as well as the positioning of the drive shaft.

Series M2232U motors with 6, 12, and 24 volt windings are immediately available from stock with a 24 - 48 hour turnaround.

Efficiency for Small Bottle Blow Molding

As production requirements for a single type package can reach 100, 200, or even 400 million containers per year, processors are looking for the best, least complex, and the most economical machinery that can handle these extreme production rates.

Some blow molding machinery manufacturers have begun promoting tandem blow, the process of blow molding two bottles per parison that have been configured in a neck-to-neck or base- to-base arrangement in the mold. Their rationale is not necessarily that this technique produces better bottles, but that it is the only way to increase output without incurring the additional cost of multiple machines.

However, producing two identical bottles in tandem blow process is a problematic challenge, especially with free falling parisons typically used by shuttle and reciprocating blow molding machines.

Why?

Because the parison shape is never identical from the top to bottom in the mold and achieving an identical material distribution in the top and bottom containers can be next to impossible. Additional variation is added by trying to balance and set up four, six, eight or more parisons to be identical. Even with wheel machines the physical variations in bottles blown in tandem process can never be totally eliminated.

Innovative Processing Equipment Manufacturers Are Developing Technology To Solve The Challenges Of High Speed Small Container Blow Molding:

Wilmington Machinery, Wilmington, North Carolina, is one example of an experienced blow molding processing system manufacturer that has turned its attention to overcoming challenges in blow molding small containers at high speeds.

Wilmington Machinery has designed a new system for producing small bottles that utilize a single parison and individual cavities, instead of tandem, in order to produce the highest quality bottles with the least variation in material distribution bottle-to-bottle, and with the smallest weight variation.

The result?

Processing speed, efficiency --- plus cost savings to the customer.

Wilmington Machinery's focus is on very high output applications requiring a minimum of 250,000 bottles per day or 75 million per year. As its prime objective, the company aimed to eliminate the problems associated with high speed bottle handling and to make their new system extremely simple to set up, operate and maintain.

The result is the Wilmington High Speed Small Bottle (SB) rotary blow molding wheel system. The Wilmington SB process blow molds small bottles in a single cavity mold and uses a proprietary method of guiding the containers from under the blow molder through the trimmer at extremely high speeds with maximum efficiency. The Wilmington SB system's success is made possible by miniaturization of Wilmington's proven mechanical clamping systems --- a technology originally perfected in their larger wheel machines --- combined with a proven technique for accurately positioning the clamps and molds relative to each other.

The Wilmington SB Series is designed specifically for high speed, high volume single serve dairy, food, juice and liquid yogurt applications for containers 200 to 500 ml. A smaller clamp has been added to handle bottles sizes as small as 80 ml. These machines are economical, extremely simple and can be built with up to 60 cavities at speeds up to 30,000 bottles per hour depending upon the container. Like their larger machines, the extrusion rates and layer configuration can be designed to match any application such as white-black-white or barrier bottles.

The Results:

Technical breakthroughs such as Wilmington Machinery's High Speed Small Bottle Series now gives processors the ability to blow each bottle in individual molds while totally eliminating the need for high maintenance bottle knockout systems, complicated bottle takeout devices and cut off knives or shear steels.

Customers have reported they were amazed at the easy-start up and operating of Wilmington's 24 station demonstration wheel at speeds up 240 BPM. Bottles literally fall out of the molds on their own and because Wilmington Machinery developed the technique to blow 100 percent of the entire parison, bottles and flash never stick together. This process works as well for polypropylene, including multilayer, as it does for HDPE.

Perfects Line Finishing on Stainless Steel

CT - J. Walter Inc. offers the LINE-MATE(TM) finishing system to expertly match or impart a perfect line grain finish every time on stainless steel. At the heart of the system is the LINE-MATE(TM) II finishing tool. This electronic angle grinder is specifically designed to provide just the right speed and to maintain that speed electronically. When combined with the extra wide inflatable drum and a selection of drum belts the LINE-MATE(TM) quickly removes welds, imparts direction of the grain, removes scratches and matches many grained finishes. You can also refine the line finish with one of many LINE-MATE(TM) finishing drums available in Coarse, Medium, Fine, Two-in-One or other available grits. Using the handrail attachment you can even refinish tubing after it has been welded. Also available are a selection of polishing felt belts and drums to give a perfect mirror finish when used with WALTER's white and blue polishing compounds. We offer the industry's largest staff of trained representatives able to teach and train your fabricators the art of line finishing.

Manufacturing Service offers line-ready custom die castings

ustom manufactured die cast parts, precision machined and assembled for hydraulic, engine and electrical end product applications are available from Fivestar Die Casting.

Providing custom high-pressure/high integrity aluminum and zinc die castings with full machining and component assembly capabilities. Fivestar Die Casting is a reliable domestic source delivering line-ready die cast assemblies to meet just-in-time program requirements. High integrity processes include squeeze casting and the capability of semi-liquid casting.

Die casting press capabilities in zinc range to 400 tons clamp force, and in aluminum to 800 tons clamp force. Precision machining capabilities include CNC turning, milling, drilling and tapping. Finishing capabilities include deburring, painting/plating, assembly, packaging and appropriate ISO documentation.

Unlike most die casters with limited or no precision machining capabilities, Fivestar has fully integrated machining facilities that provide a total quality management approach, ISO 9001: 2000 certification, and statistical process control. Equipment includes CNC vertical and horizontal machining and turning centers, CNC Swiss screw machines, wire EDM, CNC chuckers, drilling, reaming and tapping centers, cutoff saws, punch, stamp and bend presses and more.

"Fivestar Die Casting gives OEM manufacturers a more responsive, higher quality sourcing option to fulfill their finish-machined die casting needs," reports Alan Koch, general manager. "Consolidating vendors saves time and handling, and provides better inventory control."

Software eliminates misplaced documents

Kyocera Mita America, Inc., one of the world's leading document solutions companies, today unveiled iTag version 2.0 at its National Dealer Meeting in Las Vegas. iTag is an intuitive, user-friendly document management solution ideal for small businesses or departmental environments. By simply enabling end users to capture, store, share and retrieve scanned document and electronic files, iTag eliminates misplaced or mismanaged documents, greatly reducing office downtime for increased workflow efficiency. iTag seamlessly integrates with select Kyocera multifunctional products (MFPs) and comes standard with a DELL(TM) server, Microsoft Windows SharePoint Services 3.0 document repository, one Kyocera MFP device connection, a server kiosk and touch screen validation station.

The latest version of iTag offers a comprehensive array of new features that have simplified operation and expanded its capabilities. iTag can now store and share a greater volume of documents and image files due to a doubling in storage capacity. Further enhancing the storage capacity, iTag utilizes auto-color detection when scanning documents with both black and white and color pages. Available on select Kyocera MFPs, this competitive feature ensures optimal file size for all scanned documents while maintaining document integrity. With a new full-color touch screen validation station, end users can review scanned images, complete basic editing functions - including deleting and rotating individual pages - edit index data and reorder pages from a multi-page file, all with the touch of a button.

ITag is a fully scalable, "out of the box" solution that offers all of the document storage and indexing capabilities necessary for a small business or department to start a document management initiative. With iTag end-users can effectively keep track of an organization's documents and share them efficiently over the network. Additionally, it comes equipped with security and privacy capabilities that allow network administrators to manage document accessibility to ensure only authorized users view files.

"iTag is an ideal solution for smaller companies or departments that require an intuitive, scalable, easy-to-use document management solution to manage their daily document workflow," said Peter Hendrick, vice president of marketing, Kyocera Mita America. "We're confident iTag will enhance the way a typical department manages the filing, indexing, sharing and securing of critical documents, leading to a more organized and streamlined work environment."

In February, Kyocera achieved Microsoft Gold Certified Partner status. iTag, along with KYOcapture Powered by AutoStore - Kyocera's award-winning server-based document capture workflow solution - were key components to this accomplishment. By utilizing Microsoft Windows' SharePoint technology in their development, Kyocera demonstrated it understands that end-users require solutions that are built on familiar platforms - specifically the Microsoft Office environment.

Designed as a fully scalable document management solution, iTag users can add additional MFP device connections as workflow volume increases, or can upgrade to KYOcapture as their document management needs grow to enterprise level.

iTag is available through authorized Kyocera dealers at an MSRP of $15,000. To find the nearest dealer, or for more information about Kyocera's award-winning line of monochrome and color MFPs and printers visit Kyocera Mita America's dealer locator at www.kyoceramita.com/us.

Handling Module permits mechanical movements up to 120 cpm

Precision Detroit Company (PDC) introduces the Weiss HP pick and place handling module. Freely programmable in both horizontal and vertical axes, the HP is directly driven by highly dynamic linear motors. The direct drive components permit fast mechanical movements up to 120 cpm.

The HP's linear guidance system uses recirculating, linear ball bearings which are quiet and efficient compared to pneumatic units. The HP includes integrated overload protection and an integrated lubrication system.

Weiss Application Software (WAS) is available for easy startup. The HP is also reusable for different applications. Precision Detroit Company is the exclusive North American Partner for Weiss Automation Products. Download CAD drawings and view a video of the HP pick and place at www.pdc-inc.com.