On the Radar

Versatile Floor-Type Horizontal Boring Mill
The MAG FTR 3500 floor-type horizontal boring mill (HBM) is a versatile, mid-sized job-shop machine, capable of a full 2m reach inside parts with a ram-supported spindle. The machine tool is ideal for heavy metal milling, as well as precision multi-axis contouring, boring, drilling, and tapping on large parts.

The FTR 3500 is available in column heights of 2.0m to 5.0m (6.6ft to 16.4ft) in half-meter increments. A traveling-column design allows virtually unlimited X-axis travel for processing of large and long workpieces or multiple batch parts, while 20mpm (787ipm) rapid traverse rates reduce cycle times. The choice of spindle power trains includes two four-speed versions available with spindle diameters of 130mm and 155mm (5" and 6").

Linear positioning accuracy is 0.015mm (0.0006") and repeatability is 0.008mm (0.0003"). Precision roller packs on X, Y, and W axis provide stability, low friction, durability, and maintainability for high-performance machining. The Y-axis has a 100mm (3.94") preloaded, anti-friction ballscrew, while the Z and W axis use a 63.00mm (2.50") diameter ballscrew. The X-axis is driven by an electrically-preloaded rack and pinion system.

MAG-IAS
Erlanger, KY
mag-ias.com

Multi-Axis Laser System
The Laserdyne 430 is a 3-axis system designed for precision cutting, welding, and drilling 2D and 3D components. The 430 system is currently available with a fourth rotary/circular axis option, with a fifth tilt axis available later in 2011.

The Laserdyne 430 operates at speeds up to 800ipm in the X, Y, and Z axis (0 to 20mpm) with bi-directional accuracy of 0.0005" (12.7μ). This accuracy is throughout the system’s 600mm x 400mm x 500mm work envelope, making it ideal for processing a broad range of components such as precision drilled fuel filters, electronic assemblies, and transition components at the highest rates with precision quality.

The Laserdyne 430 system features the latest and most powerful system controller, the S94P, and includes the full complement of Laserdyne hardware/software features where required, such as BreakThrough Detection (BTD) and Automatic Focus Control (AFC).

Laserdyne Systems
Champlin, MN
prima-na.com

Custom Engineered Systems
Machining process designers looking to increase their market advantage will find the answer with Kurt’s integrated custom engineered systems. Consisting of automated workholding, fixturing, part conveying, and gaging, these systems greatly expand productivity while reducing labor content.

A typical Kurt custom engineered system maximizes the productive capacity of today’s machining centers. They include high density clamping fixtures with integrated robot arms for automation. This allows for automated part loading, machining on all sides of parts, and unloading and stacking of finished machined parts. The custom engineered system also includes automated part gaging for quality and real time process control with complete part traceability. These systems can be designed to automate a single machining center or an entire cell of machining centers and support systems.

Kurt will partner on a project from start to finish, drawing on more than 25 years experience designing and building these systems for all types of manufacturing applications. In just weeks, Kurt will research design, develop, and build fixtures, workholding, automation, gaging, and data collection.

Kurt Manufacturing Co.
Minneapolis, MN
kurtworkholding.com

Stay-Flat Vacuum Table
During all precision manufacturing operations materials must be handled with care and held in exact position while undergoing drilling, cutting, laminating, or other processes. Graphic Parts International Inc., through its vacuumtables.com division, concentrates on building customized airflow systems, and the proprietary fabrication process used to produce the Stay-Flat Vacuum Table results in a non-warping, non-oxidizing flatbed that outperforms its rivals.

Vacuum tables are useful for rapid prototyping, CNC routing, and a host of manufacturing applications wherever holddown is required. Available with cutouts, inserts, disappearing registration guides, lift pins, and more, the company’s vacuum tables are easily customized to suit almost any need. A variety of sizes up to 10ft x 25ft, as well as configurations and surfaces including anodized aluminum and stainless steel, are among the many options available. For non-conductive and sensitive material applications, phenolic tabletops are also available. Hidden camera wells used for critical registration are another option.

Tables are built around an all-aluminum honeycomb core, and the sandwich design yields a excellent strength-to-weight ratio and the flattest tables in the industry. For added durability, all vacuum tables come standard with extra-thick top and bottom plates. Brushless, maintenance-free vacuum motors are ultra-quiet and emit no sparks, providing a safe and low-noise means of powering the system. Blowback devices enable gentle but precise removal of components or substrates, using the exact amount of flotation required for successful material handling.
All tables are made to order and designed to exact customer specifications.

Graphic Parts International Inc.
Chicago, IL
vacuumtables.com

Compact Integrated Motion Controller
A 22mm innovation extends the portfolio of the BX4 range of four pole brushless DC servomotors from Faulhaber. The series 2232/2250-BX4 CSD/CCD is the world’s most compact drive with an integrated motion controller. This series combines all the advantages of the BX4 four pole brushless technology with a single axis motion controller. High reliability, high torque, a compact slotless design with no cogging torque, and robust construction without the use of adhesives make this series ideal for complex applications such as robotics, automation, laboratory technology, specialty machinery, and aerospace.

The  flexible and easy to use drives are available with a RS-232 serial or CAN interface. Configuring the drives is simple using the complimentary Faulhaber Motion Manager 4.4 software. The drives are based on the flexible and easy to use Faulhaber motion control platform. The compact motion controller, which fits within the diameter of the motor – combined with the motor and a full range of gearhead combinations – provides a versatile modular platform for a variety of applications. The drives have a wide operational temperature range from -25°C to 85°C and provide a continuous current up to 0.69A with a peak of up to 3A. The speed can be precisely controlled from 5rpm up to 8,000rpm.

Custom firmware and software are available on request. All of the drives have factory preset current limits to protect the motor and electronics during normal operation.

Micromo
Clearwater, FL
micromo.com

3D Online Modeling Tool
An advanced online modeling tool, from ITT Interconnect Solutions, enables design engineers to create virtual 3D connector models, even for designs that have yet to be manufactured. This capability builds on ITT Interconnect Solutions’ existing web-based configuration technology and single field search, which allows users to utilize a single interface to search for commercial, industrial, medical, military, aerospace, and hi-reliability interconnect products.

With the 3D modeling tool, design engineers can select from various output model formats – such as STEP, Pro/E, Shrinkwrap, STL, and IGES – provided the requested product represents a standard configured item. The new 3D modeling capability is currently available for ITT’s 38999 Series III connectors.

The 3D web-based modeling allows design engineers to quickly and easily import different fully-assembled connector solutions directly into prototype designs, giving them the flexibility to try different solutions.

ITT Interconnect Solutions
Santa Ana, CA
ittcannon.com

Lapping Plate Device machines plates flat to within microns
FastLap Facing Device is an optional upgrade for Engis Corp.’s FastLap series of lapping and polishing machines.
Lapping plates conditioned with the FastLap Facing Device produce a more consistent surface finish with a more predictable removal rate, helping manufacturers achieve quality goals, lower reject rates, and lower overall production costs.

The FastLap Facing Device uses a diamond tool bit to remove the top (worn) layer of the lapping plate, machining it flat to within microns. To produce a controlled surface geometry and texture, the device then makes a second pass, which machines a groove pattern that serves as the basis for structured embedding of abrasive particles. Plates reconditioned with a facing device show excellent batch-to-batch surface consistency.

The costs of raw materials in lapping operations, such as sapphire for optical components or gallium nitride for semi-conductors, tend to be expensive. Further, lapping occurs at the end of the manufacturing process. A rejected part loses not just the value of the material, but all of the value-added manufacturing steps as well. As such, the predictable, repeatable and controlled results from the FastLap Facing Device can reduce total cost of operation while providing an additional quality assurance.

Engis Corp.
Wheeling, IL
engis.com