Issue n. 10 - October 2008Download pdf

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6-03-2009
8:23
Pagina 1
No. 10 - 2009
BLM 10 ENG.qxp:BLM intero ITA imp
INSPIRED for
TUBE
ENG
www.blmgroup.com
6-03-2009
8:23
Pagina 2
Contents
www.blmgroup.com
pdf version and other news can be found in:
INSPIRED FOR TUBE
Contents
INSPIRED FOR TUBE
4
JOBSHOP
8
EVENT
Small companies grow
A more complete range
10
AUTOMOTIVE
14
JOBSHOP
18
TECHNOLOGY
20
HEALTHCARE
22
JOBSHOP
Each project has its own “cell”
As added value ... The lasertube
LT8 the new frontier
in lasertube systems
Strong, stable and light
“Doing something others don’t”
INSPIRED FOR TUBE
2
Inspired for tube By
Communication
BLM GROUP
Antonio Farese
Emanuela Colombo
Giovanni Zacco
Cristina Guzzetti
e-mail: [email protected]
tel. +39 031 7070 200
Produced by
BLM GROUP
Via Selvaregina 30
22063 Cantù (CO) Italy
www.blmgroup.com
Number
INSPIRED FOR TUBE
Nr. 10 - 3/2009
Design and Graphics by
Studio Grafico Page
Vincenzo De Rosa
Fabrizio Santini
Printed by
Intergrafica Verona S.r.l.
Verona
Fotografie
Fabrizio Santini
Aeffe
Reproduction, even only in
part, of the articles and illustrations published in this
newsletter is strictly prohibited unless otherwise
authorised.
6-03-2009
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Pagina 3
INSPIRED FOR TUBE
OPINION
Emanuela Colombo, Anna Mascheroni, Pietro Colombo, Paolo Colombo
Where Innovation Delivers Real Value
From 16 to 27 March 2009 BLMGROUP will be
holding INTUBE09, the Group’s Open House, an event that usually occurs every two years
open to all customers. The theme of this event
is “Where Innovation Delivers Real Value”.
The most complete and innovative range of
tube, wire and section manipulation technology in the world will be exhibited on 7,000 sqm
floor space..
Each solution on display shows how it is possible to deliver real value using the BLM
GROUP’s machines and systems in order to:
• reduce manufacturing costs
• develop new products
• integrate multiple operation into a single process
• assure all the required flexibility to win new business in changing environment.
Other reasons why you should not miss this appointment are :
• first time that all seven models of the Lasertube family are exhibited altogether
• live laser cutting demo of tubes from 10 to 508 mm and combined tube-sheet metal
• the première of the latest generation of LT8 lasertube cutting system for tubes up
to 220 mm
• the complete line of all-electric tube bending and tube end forming machines
• the new on-line Web Remote Teleservice (WRT), e-Learning, e-Support and Webinar
• new applications to cut tubes made of high-reflecting material by means of fibre
laser source
• last but not least it is the first time that the Open House is being held at the Levico’s
premises of BLM GROUP, still unknown to many customers involved in tube forming only.
Pietro Colombo
President & CEO
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At AL.PI Srl, Italy, 80% of the stainless steel tubes used in the production
process is worked by laser on three lasertube systems.
INSPIRED FOR TUBE
Jobshop
Small companies
grow
AL.PI Srl, located in Rosà in the province of Vicenza has been in the precision metal fabrication and stainless steel, iron and aluminium tube
processing business since 1985. The family-run
company with 15 employees is managed directly
by the owners Mrs. Luciana Meneghetti, Managing Director and her daughters Daniela and
Sara Alberton, head of the administration and
personnel departments respectively and by Davide Moresco and Lago Simone, production and
technical manager.
The activity is substantially divided into two production lines: the traditional one that gave ori-
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gin to the company in the processing of hydraulic
tubular components for industrial cleaning systems used in restaurants, bars and community
centres; and the most recent division relating to
the service sector for furniture, solar and photovoltaic panel supports, automobile and farm
equipment components.
Lasertube planning
The extensive know-how that has been grown
from the processing of stainless steel for washing machine components using materials such
as AISI 304 and 316 that are not easy to cut,
punch, lathe or weld has been a launching pad
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INSPIRED FOR TUBE
Jobshop
Alberton Sara,
Meneghetti Luciana,
Alberton Daniela.
al even where hollow sections are not required.
“Since the first Lasertube LT652 system that was
installed in 2001, we have come a long way as
far as technology is concerned” recalls Davide
Moresco. “Customers have understood the potential of using tubes and are now able to design
components for laser cutting”.
“Turnkey” oriented
A development that has not been easy with a lot
of imagination and DIY. Daniela Alberton tells us
of “how in 2002 AL.PI Srl exhibited at the first trade
fair, inventing samples and displays ad hoc.
Nowadays, we still exhibit proselytising the laser-
Number 10 - March 2009
for the introduction of lasertube processing and
for the development of the service centre.
80% of the tubes currently used are laser
processed according to the specifications using
three ADIGE systems. Other operations include
fabrication of structural steelworks, end machining, forming and TIG/MIG welding with associated tightness tests.
“Even in our specific field - explains Davide Moresco
- stainless steel tubes are replacing sheet metal because of the benefits: greater savings in raw materials thanks to thinner walls and greater structural
resistance of the tubes. The use of open profiles
(flat, C and L sections) now can replace sheet met-
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INSPIRED FOR TUBE
Jobshop
tube processes that continue to be valid systems
and make us stand out”. To see the level of imagination come to life all you have to do is take a look
at the chairs and benches that furnish the office
entrance, which are made entirely of stainless
steel tube.
“Thanks to the service centre, our most varied
clientele can benefit from all the know-how we
can provide not only as far as cutting is concerned, but also complete ready to be assembled pieces. Our strength” continues Davide
Moresco “is to be “turnkey” oriented as much
as possible. We follow everything through starting from the design stage”.
These are not impulsive words, even
if they are said with the typical boldness of a young person. When you
know how to process stainless steel
and you have three lasertube systems
of three different generations (LT652,
LT712D and LT722D), you can quite
safely say that you know how to run the
machines. In addition there is also the
new potential of the ArTube program-
6
ming software, the latest ADIGE development for
its lasertube systems.
Meticulous craftsmanship
and top technology
The new facilities that AL.PI Srl moved to a few
months ago seems to be more like a laboratory
than a mechanical workshop. Even the components produced in small and medium batches
give the meticulous characteristics of craftsmanship combined with top technology of the machining processes. It is sufficient to take a look at
the wide range of samples to understand how a
broad range of technologies can be gathered
combining the “cut & bend” feature on a round
tube to achieve tight bends from a single piece,
or creating a tank by using 150 mm diameter
tubes, cut and testing them for water tightness.
The company is currently in the process of ISO
9001 certification, but has been working in compliance with the standards for some time now; an
acknowledgement that has already been confirmed by the market that day after day makes
AL.PI Srl a successful small company.
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INSPIRED FOR TUBE
Jobshop
AL.PI S.R.L.
Via dell’Artigianato, 24
Zona Ind. San Pietro
36027 Rosà (VI) - Italy
Tel (+39) 0424.89.85.89
Fax (+39) 0424.89.85.90
[email protected]
Moresco Davide, Alberton Daniela, Lago Simone,
Meneghetti Luciana and Sgarbossa Laura.
www.alpilaser.it
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With the acquisition of Officina Meccanica Montorfano Sas the BLM GROUP
now adds high-tech wire and tube bending systems to its production range
Event
A more complete range
INSPIRED FOR TUBE
tion, sales and technical personnel has been
incorporated in the BLM SPA headquarters at
Cantù.
Full-speed ahead!!
With the acquisition of Officina Meccanica Montorfano Sas Cantù (CO), a company specialised
in the manufacture of patented double-head
wire and tube bending systems, BLM SPA
broadens its range of technological systems
even further.
As of 13 January 2009 all the design, produc-
8
Officina Meccanica Montorfano Sas has been
in the business for over 40 years and is a completion to the range of high-tech tube bending
systems with its high-production bending solutions for wire, bar, flat sections and for reinforced
electrical heaters.
The patented double-head automatic bending
machines of the DH2000 series double the productivity and complete complex processes on
wire and/or tube from precut bars or coils in a
single cycle without any need for setup or adjustments.
The advantages are many, but to name but a
few:
• High productivity thanks to the bending operation of the two heads at the same time
• Left-hand/right-hand and variable radius bending on the same head using the same tool
• Central locking of the piece to make closed
and/or folded shapes and better control of
piece deflection
• Bending of twin pieces with automatic cutting
to separate them after being bent
• Suitable for pieces with prewelded or flexible
parts and for bending reinforced electrical
heaters
José Alexio Santiago
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INSPIRED FOR TUBE
Event
BLM SPA
Via Selvaregina, 30
tel. +39 031 7070200
fax +39 031 715911
The main applications of the wire bending machines are:
Domestic appliances
Internal-external furnishing
Shop equipment
Industrial building
Hospital equipment
Children and toys
Seating components, brake - wiper - steering column tubes even preassembled
with hose, jack lever reinforcements, torsion and anti-break-in bars
Wire racks and grids for ovens, dishwashers, refrigerators and gas hobs, tubular
serpentine, reinforced electrical heaters
Bathroom fittings, wire and tube chairs, kitchen components and accessories
Trolleys, baskets and display stands
Bar structures, reinforced concrete bars, structural grids, industrial heaters
Bed components and healthcare equipment, drip stand
Pushchair and pram frames and frames for toys, such as handles, pedals, etc.
Automotive
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6-03-2009
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Pagina 10
The production philosophy at Caparo
Tube Components Ltd, UK is based
Each project
has its own “cell”
produce a varied range of bespoke assemblies, fabrications and components.
In its role as a first and second tier supplier CTC offers
customers what Simon Baxter, Sales Manager, describes
as “full support throughout the product design and development cycles and on to the delivery of the finished
component”. To achieve its stringent quality and traceability objectives, the ISO 9001/ISO 14001 accredited
company has put in place a manufacturing sequence
than extends from the supply of steel strip and steel tube
production in the adjacent Caparo Precision Tubes, to
tube bending, forming, laser profiling, welding, press
work, machining, finishing and assembly within CTC. In
this way full traceability can be assured, and accreditation to the TS 16949 automotive industry standard means
that components can be delivered straight to line.
INSPIRED FOR TUBE
Automotive
on dedicated automatic cells supplied by the BLM GROUP
Each cell is a dedicated cell
According to Caparo Tube Components Ltd’s Managing
Director, Phil Begley, two major orders were secured during 2007 because BLM GROUP UK Ltd undertook to
supply the necessary production equipment within extremely acute delivery targets. The total investment
amounted to £1.4 million, with 90% of the equipment and
tooling being ordered from BLM. “I was confident that
Paul Lake and his team would deliver and install to plan,”
says Phil Begley. “Both the CTC and BLM engineering
teams worked extremely hard to deliver numerous projects/parts within a timescale of weeks, which was an
amazing achievement and why we have continued to
work with BLM.”
10
Caparo Tube Components Ltd (CTC), part of the £1 billion turnover Caparo Group, manufactures a range of tubular components and assemblies, predominantly for
the European automotive sector. Although the West Midlands site’s history extends back to 1927, it houses a manufacturing facility that uses 21st century technology to
The majority of CTC’s output is delivered through manufacturing cells dedicated to specific customer projects.
One example is fuel filler pipe assemblies. The main pipe
cell comprises of a BLM E-TURN 40 all-electric left- and
right-hand CNC tube bending machine and two BLM
AST100NC CNC tube end forming machines. The 35
mm diameter main fuel filler pipe is given a double bead
form (hose connection) on the first AST100 and then bent
to shape on the E-TURN 40 tube bender. The other end
of the tube, which will become the main filler neck, is
expanded on the second AST100 using three punches
and rotary trimmed, using a unique ‘swarfless’ capability and/or rotary facing tool to remove the required 10 to
15 mm trim length, before the tube end is curled over to
form the cap lip.
The use of multi-station end formers minimises, or in
this case eliminates, changeover times and allows the
use of more than one punch to produce high quality, highly accurate end forms. This single set-up approach has
the added benefit of eliminating the compounded errors
that inevitably result from the traditional multi-machine approach.
A second manufacturing cell comprising of a BLM
AST25N multi-station tube end forming machine and a
BLM Dynamo MR100E five-axis tube bending machine,
produces the 15 mm diameter breather pipe, with the first
operation again producing a double bead form on one
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Simon Baxter
Right first time
Dean Newey, CTC’s Operations and Engineering Manager, believes that the all-electric drive technology featured in BLM’s E-TURN and E-BEND CNC tube benders
has revolutionised the tube bending process. “The accuracy and repeatability that we can achieve using BLM’s
technology in our tubular components is far superior to
anything else we have seen before and changeovers
take just a few minutes. As such, we are confident that
we are offering our customers the best possible quality
products on top of considerable production efficiencies”,
he says. “Our bends are ‘right first time’ and the process
of tube bending is no longer a ‘black art’.”
As an example, he instances a high volume order placed
with CTC because a competitor had experienced seri-
ous quality and supply issues. The downside was that
the deadline to begin production seemed impossible
to meet. “Following on from our initial contact with BLM,
we had off-tool samples within four weeks and the new
E-BEND 90 installed and working at full rate within six
weeks. From day one we produced what we knew was
going to be a demanding job within a tolerance of ±0.5
mm with no problems whatsoever and running the machine 24/7. The component involved was a 70 mm diameter by 3 mm wall thickness steel tube component
with three tight radius bends. Even more remarkable was
that we never had to change the bending parameters,
even though the material specification varied slightly from
batch to batch.”
The choice of the E-BEND 90 was made because of the
requirement to produce left- and right-hand suspension cross member components. As it is a multi-stack
machine, left- and right-hand tooling can be mounted
in a single set-up. As well as eliminating costly tool
changeovers, CTC was able to bend left-hand and righthand parts in sequence, which improved the process
flow and provided better control of subsequent manufacturing operations.
The bending cycle time was also an important consideration. This was kept to the absolute minimum as the E-
CAPARO TUBE
COMPONENTS
PO Box 14
Rood End Road Oldbury
West Midlands B69 4NN
+44 (0)121 543 2100
[email protected]
www.caparotubecomponents.com
end of the tube prior to bending. End forming tools for
other diameters and forms of breather pipe can be premounted if required, thereby eliminating non-productive
changeover time, while the mounting of different diameter tooling on the Dynamo tube bender also eliminates
downtime when changing from one size of tube to another. With a cycle time typically of 1.5 seconds per bend,
CTC is confident that it has now achieved the highest
possible output while maintaining optimum repeatability.
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INSPIRED FOR TUBE
Automotive
BEND 90’s VGP 3D software could simultaneously
move and control each of the machine’s 13 axes individually. For example, the clamp position on a traditional hydraulic bending machine is either open or
closed, and the distance between these two positions can be as much as 150 mm. This means that
after each bend the clamp has to retract and, in
some cases, the bend arm cannot return to zero
until the clamp has reached its open position.
This can take up to 1.5 seconds, which does
not seem much, but on volumes of, say,
150,000 components this wasted time
soon adds up.
However, on the all-electric E-BEND 90, and any other
of BLM’s all-electric tube benders, the clamp movement
on or off can be controlled infinitely. This means that a
‘clamp off’ distance of 150 mm does not need to be made
on every bend. Instead, it may be as little as 5 or 10 mm,
thus contributing significant cycle time savings.
Targeted investments
12
Typical tube products manufactured by CTC for automotive applications include fuel filler pipes, steering rack
tubes, car seat frames, suspension components, car
cross beams, oil and water pipes, chassis components,
and side impact door beams. The preferred tube manipulation route, according to Simon Baxter, is to set up
a new stand-alone cell that is either specific to a product
(as with the suspension arm cell) or to a family of products (as with the fuel filler pipe cells). This, he says, provides an ideal opportunity to evaluate current methods
and, when appropriate, to invest in new technology. “We
installed the fuel filler main pipe cell because, although
we could do the work on existing equipment, the projected volumes meant working a three-shift system and
excessive overtime as well as leaving no room for customer’s schedule variations. The new cell has also given
CTC the additional capability needed to attract similar
work from other customers.”
This has proved to be perceptive as the automotive industry is currently reducing its output. However, the decline has been countered by an increase in aerospace
work and orders gained from other industry sectors. Investment continues because many automotive and aerospace projects have long lead times and CTC quotes for
new business on the premise that, according to Simon
Baxter, “if we don’t have the capacity now, we will make
sure that it is in place before the project is ready to run”.
He says that the choice of machine tool is influenced
by price but points out that CTC also takes account of
the performance of existing machines and the service
and support provided to keep them running. “We cannot afford for a machine to be down, not least because
there may be penalty clauses involved,” he says. “It is
better to have some overcapacity, although we don’t want
machines standing idle for long periods of time.”
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INSPIRED FOR TUBE
Automotive
CTC has a total of 17 BLM machine tools, 12 of which
have been installed in the last two years, including a BLM
LT 712D CNC tube laser installed in 2007. This is a significant indication of Caparo’s commitment to investment
in modern day, high technology equipment to provide
customers with high quality products at the lowest possible price per part. One job, a rectangular hollow section radiator support beam, would previously have required tube to be cut to length on a production saw,
deburred, manipulated on a tube bender, the holes drilled
or punched, each end trimmed to 45 degrees, and a final deburring operation.
This component is now completely laser profiled - all
the holes cut and both ends mitred - in a single hit
on a fully automatic basis before being completed
by the final bending operation. In addition to cycle
time savings, several operations have been taken
out of the process and this has eliminated the re-
quirement for dedicated hard tooling and fixturing.
“As there is no tooling involved with the laser it is very
quick and inexpensive to make changes to any component and to produce prototypes,” says Simon Baxter. “The laser can also etch a component, whether for
identification proposes or to act as a positioning guide
for a subsequent bending operation or to provide a
guide to correct assembly.”
Caparo Tube Components Ltd shares its Oldbury site
with Caparo Accles & Pollock Ltd, which manufactures high integrity, thin wall, stainless steel and titanium tubular assemblies for the aerospace, medical, automotive and power generation sectors.
Caparo Accles & Pollock is now planning to expand
its advanced bending, welding and forming capability and, says Phil Begley, “BLM is the obvious
choice to supply the two additional tube bending machines that will be needed in 2009”.
“As a supplier, BLM GROUP ticks all the boxes,” says
Dean Newey. “What really appeals is the flexibility and
reliability of these machines, which is a ‘must have’ given the demanding and fast changing nature of the automotive business. With thousands of machine installations world-wide BLM has shown that it can provide
a total solution, whether it is for tube bending, end forming, sawing or laser tube cutting, and as individual machines, dedicated cells or integrated manufacturing
solutions.”
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INSPIRED FOR TUBE
Jobshop
At Danieli Laser Cut s.r.l., Italy, the lasertube system is the real added value.
It was fundamental to have believed in its potential before others.
As added value ...
The lasertube
Danieli Laser Cut s.r.l., a family-run business,
located in Castelgoberto, in the province of Vicenza, has grown over the years to turn into one
of the most far-sighted examples of laser job
shops in Italy for processing sheet metal and
tubes.
“Sheet metal” and “tube” are two distinct divisions as far as the internal logistics are concerned even though one is the natural complement of the other. The need to provide the
best layout and the most rational production
flow made it necessary to organise the work in
well-dedicated areas.
thanks to Dino Danieli, a constant promoter of
the process.
“Work is not only technology, but it is also the
result of close relations with customers and the
service that one is able to guarantee” says Mr.
Danieli. “However, it is necessary to invest and
keep updated on the technologies so that you
can become versatile and respond punctually
to the market requirements that are increasingly demanding and changing, trying to perceive
the potential requirements ahead of time in order to buy targeted machines and solutions and
not make the wrong choices”.
Experience makes
a difference
Both decisions, first to invest in sheet metal cutting and then in tube laser cutting technology
follow this direction; but the second investment
made in February 2004 was the real added value. Having believed in the potential of lasertube
systems before anyone else was fundamental.
“Demands are now almost exclusively for the
Danieli Laser Cut was among the first Italian
companies to install a lasertube cutting system
and since 1996 its role has evolved from being
a pure “OEM supplier” to become a partner,
working closely and alongside the customer,
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Pagina 15
supply of finished and complete products, which
means that tube processing cannot disregard
sheet metal and vice versa” states Dino. “The
two technologies are complementary and interact to create an inseparable union, which led
us to choose flat cutting with the first laser system specifically for tube cutting. The choice
turned out to be a winner as the Adige LT702D
lasertube system distinguished the company
because at the time (and we’re only talking
about five years ago) there were only a few competitors who could process both elements with
good quality.
Those who, like us, foresaw the possibilities of
the lasertube system are a step ahead. The gap
of experience gained and the know-how acquired from the beginning certainly make a difference”.
Conceived, created and
achieved With tube
Dino Danieli
considerable precision with which the parts are
coupled, and the cost reductions. The implementation and production cycle is shorter and
more economical compared to a structure made
of sheet metal. At that point, we were looking
for tube cutter with bigger O.D. capacity in order to widen our range”.
The market immediately highlighted the importance of being able to process sections even
greater than 150 mm that could be cut on the
LT702D so that more complex applications
Nowadays, there are not many job shops who
are convinced and have the right tools to
process tube; but those who, like Danieli, invested a long time ago represent the ultimate
expression in technological terms of engineering and skills to provide new solutions to their
customers, who use tube as an innovative design concept and the most economical component.
“Since we have been using the lasertube system - explains Dino - almost all the structures
we produce have been conceived, created and
made with laser cut tubular components. The
advantages are undeniable both in terms of the
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Pagina 16
INSPIRED FOR TUBE
Jobshop
could be approached. For example, we are talking about artistic coverings of buildings, where
Dino’s inspiration and his origin and skill as a
surveyor have found a fundamental ally in the
new LT8 lasertube installed towards the end
of last year.
Growing by diversifying
the sectors
Today, Danieli Laser Cut’s shop offers two flat
bed laser cutting systems, one of which has a
high production capacity with linear motors, a
combined punching and laser cutting machine
and two Adige lasertube cutting systems that
cover a working range from 12 to 220 mm tube
diameter.This means that there are five different laser systems, each one designed for a specific use and job, which further confirms Dino’s
far-sightedness.
“I find it restrictive and wrong to invest in systems and solutions that are the same. This is
why I never purchase the same machines as I
believe that the purpose of any investment is
not only to respond to an effective requirement,
but also to give the possibility for the company to grow in different business sectors. However, notwithstanding the difficult economic situation, diversifying allows us to face the crisis
without any problem.
The LT8 lasertube, for example, has been operating in the company for eight months and I
don’t think we have ever cut the same profile for
two days in a row”.
Both Adige machines work continuously for nine
hours a day and, of course, we try to deviate all
the cutting that exceeds the working capacity
of the LT702D onto the LT8. In fact, considering
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INSPIRED FOR TUBE
Jobshop
18 km of tube
From the applications point of view, one of the
first jobs carried out in the tube/sheet metal processing field was the implementation of 500 automatic ticketing machines installed throughout
the metro network of Milan. “Each of these units
consists of a stainless steel tubular structure and
stainless steel panels” says Danieli. “This was a
standard product that enclosed all our processing skills: cutting, bending, assembly work,
welding and painting.
But the furniture sector proved to be the real
launching pad. Here the lasertube system allows us to implement processes that had never
been possible before and this “authorises” designers, even the most innovative and adventurous, to let go their imagination. Nowadays, I
do not think there is any industry that we are not
already in, from electronics, electro-mechanical,
bycicle and motorcycle, automotive, agricultural and earth moving field, that would be potentially interested in lasertube”. Danieli Laser Cut
is doing a great job in implementing fume damping structures in electric power stations or supporting structures for photovoltaic panels. Needless to say that there are also examples of simpler
applications, but even here Dino still manages
to surprise. In fact, he states “recently we
processed 18 km of tube for a customer who
had to make simple holes on 6m bars”.
DANIELI LASER CUT S.R.L
via dell’industria, 6
36070 Castelgomberto (VI)
Tel. +39 0445 940067
web: www.danielilasercut.com
the new concepts of the LT8, it has certainly
turned out to perform better.
At times we are tempted to reroute almost all
the work on the LT8, particularly when there are
tubes that have numerous holes and cuts. In
this case, if we compare the LT8 to a classical
lasertube, using the same section, over 40% reduction in the cutting time is guaranteed. Moreover, it is also extremely easy to programme
thanks to the new ArTube software.
“Notwithstanding this - points out Danieli - I am
personally pleased to have both systems. The
first lasertube allowed us to gain experience
that has served in using the LT8 in the best possible way and to sound out and examine the
market to understand the right direction and
technology to invest in”.
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Pagina 18
The LT8 consolidates ADIGE’s leadership in the lasertube
Technology
cutting increasing the gap with other existing systems
LT8 the new frontier
in lasertube systems
INSPIRED FOR TUBE
Performance
The LT8 combines the
utmost flexibility and
excellent performance in a
single system. The vast
dimensional range of tubes
that can be worked (from 12
to 225 mm O.D. and up to
8,5m in length) makes it
possible to cover a wide
spectrum of services. At the
same time, the
performances that can be
achieved are currently
unmatched even on small
size tubes.
Innovative machine
software
The LT8 programming
software has been
designed using innovative
criteria. Working cycles
have been optimised to
achieve excellent
performance and an
“intelligent” on-board
operator user-friendly
interface guides the
operator.
ADIGE S.P.A.
Via per Barco, 11
38056 Levico Terme (TN) Italy
tel. +39 0461 729000
fax +39 0461 701410
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INSPIRED FOR TUBE
Unloading from a
lasertube system is a
delicate phase, which LT8
handles extremely well
thanks to various options
that consider the variability
of tube sizes and
geometry to be processed.
A special centring feature
allows superior
consistency on long
pieces while a separate
conveyor belt guarantees
maximum productivity.
Technology
Unloading system
3D head
With the increase in size
and thickness of tubes
that can be processed,
the need for a 3D cutting
head often becomes an
indispensable tool to fully
meet the user’s
requirements.
The LT8 is equipped with
a fast moving “3D” head,
which is extremely
effective and precise in
cutting a considerable
thickness.
Loading systems
The idea was to provide
the LT8 with several
distinct loading stations –
front and rear. They allow
to follow the need of the
operator either by
interrupting a bulky
production temporarily so
that a small number of
tubes can be cut urgently
or so that a production
batch can be prepared
while the previous one is
still being processed.
19
6-03-2009
8:25
Pagina 20
At Sidhil Ltd, UK community care bed design benefits from
laser processing resource
Healthcare
Strong, stable and light
INSPIRED FOR TUBE
estimated as 30 months and there have been significant other benefits.
Better use of the material
Healthcare equipment manufacturer Sidhil Ltd’s
initial venture into CNC laser tube cutting and profiling has proved so successful that all three variants of the Halifax, West Yorkshire company’s electrically-operated community care bed are
designated Solite laser. This new design - whether
it is the Vari-Height, 2-Section or 4-Section variant - features a series of interlocking joints and
such is the accuracy and consistency of parts
processed on the BLM ADIGE LT 712D Lasertube that these joints require the minimum of welding. The result is that the Solite laser bed is strong
and stable yet light and aesthetically pleasing.
James Ibbotson is the person responsible for implementing change within the manufacturing environment. He joined the company in 1998 as a
management trainee, working in various departments before eventually becoming Sidhil’s Operations Director. A decade later he describes the
decision to invest in laser machining as a direct
response to increasing competition from overseas and the need to drive down costs here in
the UK. This objective has been achieved following the tube laser’s commissioning, with the
LT 712D matching the annual output of previous
highly labour-intensive methods within a few
months. Several people have been redeployed
from the tube manipulation section, payback is
20
“We now have consistent quality with no defects,
because once programmed, parts are always to
specification,” says James Ibbotson, “and relevant production information can be called up at
any time. This contributes to improved material
utilisation because the machine will cut and profile several equal length parts before moving on
to another program to cut a shorter part from the
remaining tube length, leaving just a stub of waste
material in the machine’s chuck.
“Laser cut parts slot together exactly without the
need for deburring prior to welding, while the laser
produces perfectly round holes that avoid problems when the four component sections of the
Solite laser, the heaviest weighing just 22 kg, are
bolted together. This is crucial because the bed
is designed to be easily assembled or disassembled by one person working alone without
the need for special hand tools. There are no
longer gaps between parts that need to be filled
when welding, so the process is much faster with
6-03-2009
8:25
Pagina 21
no wastage of welding gas or wire and the improved surface finish of each joint contributes to
more efficient powder coating.”
A “gentle” transition
This BLM ADIGE LT 712D is equipped with
Siemens Sinumerik 840D CNC and can process
round, square, rectangular and flat-sided oval
section tube up to 152 mm diameter, courtesy of
a 2500 W laser source. The Siemens control allows the operator to manage all the main functions, including program downloads, while fast
set-up and change-over times - around three minutes - means small batches can be managed as
cost-effectively as longer production runs. Because Sidhil wanted a smooth transition from its
previous manufacturing methods, it sent four people to the ADIGE factory in Italy for on-the-machine training. “From day one they were able to
operate the new machine,” says James Ibbotson,
“and while there was a continuing learning curve,
production in Halifax was never affected.”
SIDHIL LIMITED
The reward for Sidhil’s £½ million investment in
laser tube cutting and profiling has been steady
growth, with the company selling more community care beds than its competitors, and a net
increase in the number of people employed. “We
believe the underlying reason for our success is
that Sidhil is consistently meeting customers’ expectations,” says James Ibbotson. “Long gone
are the days when a four to five week delivery
schedule was acceptable: customers want their
bed, cot, bedside table, chair or trolley delivered
within two to three days of ordering, and this is so
much easier to achieve now we have the flexibility and capability to manufacture tube components for any of these products at any time.
“We do source some products from overseas and
we do keep a three-day buffer stock to be on the
safe side, but the Lasertube is a very reliable and
consistent machine and is clear evidence that we
haven’t made the mistake of turning our UK factory into a warehouse. In fact, we have not stopped
production here in Halifax, night and day, six days
a week, with a single shift on Sundays, in the two
years since the BLM laser machine was commissioned.”
Sidhil Business Park, Holmfield,
Halifax, West Yorkshire HX2 9TN
Ph +44 (0)1422 233030
[email protected]
www.sidhil.com
Prior to installing the BLM ADIGE Lasertube, Sidhil, one of several companies within the familyowned £60 million turnover Siddall & Hilton group
founded 110 years ago, had decided it was more
cost-effective to buy in specific lengths of tube
for its high-volume product ranges rather than cut
all its tube material in-house on several CNC saws.
Now, however, Sidhil has standardised on less
expensive random lengths for all its production
requirements because, as James Ibbotson explains, “the laser machine can sort and cut random lengths with very little waste and much faster
than the auto saws we used in the past”.
21
6-03-2009
8:25
Pagina 22
PROFILAS, in the Czech Republic, has made lasertube its cornerstone in
supplying not only finished pieces, but various beneficial solutions
INSPIRED FOR TUBE
Jobshop
“Doing something others don’t”
On a snowy winter evening near Prague, Mr. Jan
Beran owner of PROFILAS shows us the business
facilities that he set up about three years ago for
job shop machining.
From outside the view is a little spectral, but very
charming: the company is located in an area that
was once a large steel mill and is now an infinite
array of semi-deserted buildings that are taken
one by one and restructured by new businesses
like PROFILAS.
ting systems should be considered a winner.
With great pride, Mr. Beran tells us of the great
leap compared to his previous experience
where everything was done manually as the
processes had extremely little automation. The
new business immediately started with the installation of an LT120 ADIGE lasertube system,
but only a few months later the company unexpectedly found itself in a condition to have to
purchase a second one.
Mr. Beran used to be division director of a large
building company and handled mostly structural steel constructions. He tells us fondly of his experience, of his great interest in the mechanical
field and how he came to a turning point and set
up his own business.
“At first, it wasn’t at all easy”, he says, and it’s not
hard to believe him, “but there were several signs
that I had done the right thing at the right time”.
Of course, the idea of innovation, in the sense of
“doing something that others don’t” that guided
Mr. Beran through the whole development stage
to become a sort of corporate mission was right.
In fact, the advantages deriving from the use of
lasertube systems were immediately evident: a
considerable reduction in production times and
costs compared to traditional technologies;
great production versatility to give the possibility of penetrating new market sectors and the
possibility of supplying its customers not only
with finished pieces, but a varied range of solutions and benefits compared to traditional technologies, which is what Mr. Beran considers the
most important. “I don’t like doing routine work”
he says, without hiding the satisfaction of supplying his customers with something different
and certainly interesting.
Using the system’s 3D programming software
Two lasertube systems,
in only a few months
The choice of automating the production
process with the installation of CNC laser cut-
22
6-03-2009
8:25
Pagina 23
INSPIRED FOR TUBE
Jobshop
Jan Beran
Innovation
In conclusion, perhaps it was pointless asking his
opinion on the right strategy to overcome this world
crisis. In fact, his comment was consistent with
everything he said up to now: innovation.
PROFILAS
Halkova 2972
272 01 Kladno
Czech Republic
Tel/Fax +420 312 645057
[email protected]
One must “do something that others don’t”. But
not only that. The secret is to “satisfy the customer
in terms of delivery times, costs and quality. If I
make a mistake, I try to put it right before the customer even so much as notices it and if the customer makes a mistake I do everything possible
to find the best solution to put it right”.
shows how in the construction solutions of elements that needed pipe joining, new types
of joints can be suggested thanks to the laser
system that immediately fascinated customers.
“Start-up of the system was not critical as I was
already familiar with plasma systems and systems for sheet processing.
Of course, tube processing is rather different,
but I wanted to learn about the product thoroughly so that I could programme it and operate it myself. I have a good relationship with the
technicians of the service centre who guarantee an effective service”.
23
6-03-2009
8:22
Pagina 24
INSPIRED FOR TUBE
TUBE BENDING
ENDFORMING
CUTTING, DEBURRING AND WASHING
CUTTING AND END MACHINING
LASERTUBE
COMBINED LASER CUTTING OF TUBE AND SHEET METAL
HANDLING
3D MEASURING
MANUFACTURING CELLS
NON TOUCH MEASURING SYSTEMS
SOFTWARE FOR PROCESS CONTROL
Via Selvaregina, 30
tel. +39 031 7070200
fax +39 031 715911
Via per Barco, 11
tel. +39 0461 729000
fax +39 0461 701410
Viale Venezia, 84B
tel. +39 0461 720007
fax +39 0461 720214
Also available in pdf format on:
www.blmgroup.com

Issue n. 10 - October 2008Download pdf

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