|
|
 Major developments
in machine, tooling and CAM technology are making High Speed Routing
(HSR) a reality for manufacturers.
With
HSR technology it's possible to route considerably faster, and
produce highly accurate contours with an excellent surface finish.
This new machining approach will reduce lead times, optimal batch
sizes, and stock.
|
Experience
Heians' 50+ years of experience in CNC
Routers has been crucial in realizing the benefits of high speed
manufacturing.
High tech
design solutions are created and tested at the Miyakoda
Research Institute, opened by Heian in 1996, where new machine designs
undergo dynamic analysis to achieve the greatest degree of balance,
rigidity, and long-term high performance.
High Speed Machine Options
EG, ER,
SR, NC, HR, ZR and UR models are capable of rapid feeds of 60 and 100
m/min respectively, and 40+ m/min maximum cutting feeds without loss of
definition or surface finish.
Customers
have the choice of single or twin table models, with table sizes from
1500 x 800 mm, to the popular 2600 x 1600 mm or 3,100 mm and upwards!
Maximum efficiency
One
example of a high volume machine for kitchen Doors, features five ATC
spindles, 30,000 rpm ceramic bearings, independent Z axes and tool
change functions, eight tool positions, and twin tables each 3,100 x
2,100 mm with a staggering 1,440 cu.m/hr suction, enabling the smallest parts to be
clamped instantly, without problem, at the start of the machining
cycle.
Cycle
times for a kitchen door with a single tool path are under 40 seconds,
and complex 3 tool Shaker doors can be produced in two minutes.
Non-stop production
The twin
table model machines five components simultaneously on each table, or
five sets of parts, within each 620 x 2100 mm zone. One table can be
charged while the other is mid-cycle.
Fixtures
can be eliminated by the use of vacuum pads, again reducing down-time.
ATC
spindles can also change while another is mid-cycle.
Output of
the Shaker doors on this machine is realistically about 1000 doors per
shift, or 1500 traditional doors.
Safety
Noise and
dust is minimal. The machines are enclosed with the operator some metres away. The acoustic enclosure, isolating the
machining zone, includes Key interlocked access doors, providing
effective protection, and full accessibility for the occasional setting
and maintenance procedures, satisfying both the European Safety
Directive, and Users demands for good accessibility. Visibility is also
excellent.
Quality
In
addition to complying with CE standards, Heian are also ISO 9001
quality certified.
IT Compatibility
The new
large twin table UR, features the Fanuc 160i controller, complete with
a large 14" touch screen type colour
LCD, with graphic simulation, dual processing independent NC and PC
boards, complete with a Microsoft Windows PC, Ethernet communications
and an optional Modem if desired.
Heian
confirm many variations on the above configuration are available,
affordable, and tailored to your requirements!
Lower product costs
High
speed routing is one of the main areas of interest in CNC Routing
today, resulting in cycle times and product costs both being cut. The
high speed router will typically operate up to four times faster in
terms of actual cycle times, compared to conventional machines. Add to that
the increased up-time with Heian's renowned reliability, and you have a
winning combination.
Greater Design potential
With High
Speed Routing, more design details can be incorporated (eg., sharp corners, smaller radii, carved effects)
which would otherwise be uneconomic to produce.
However,
while HSR obviously offers the opportunity to manufacture furniture
components quicker, there is much more to this technology than just
buying a new machine and operating at higher spindle and feed speeds.
Efficient Control
As well
as the need for specially developed CNC Routers or Machining Centres, (designed for efficiently operating at
high spindle speeds, feed rates, rapid traverse, rapid spindle
selection, quick tool changing, etc.,) consideration also has to be
paid to the CNC Controls, tooling, and cutting strategies.
CAM & DNC
An
essential key for a successful high speed routing operation is an
equally powerful CAM and DNC system.
Without this, the investment may fail to produce the benefits.
Cutting tools
The
capability of cutters can restrict machining speed. However, a variety
of cost effective high speed cutters are now available, (including
special carbide, PCD, multi flute spiral tools, etc., with stronger
bodies, sharper tips, greater stock removal at higher feed rates and
with lower wear rates) which are highly recommended to facilitate the
application of HSR.
Spindle
and tool holder accuracy are important, since any inaccuracy will
result in radial eccentricity as the tool rotates. This causes
vibration, noise, heat, a poorer surface finish, and reduced tool life.
Investment Adopting
HSR
requires a higher investment compared to conventional Routers. However,
as a growing number of Heian's high speed router customers have found,
HSR lives up to its claims, significantly reducing manufacturing costs
and lead times, improving quality, added value, and increased
competitiveness with higher margins.
To ensure
the investment produces the returns expected, a thorough understanding
of the technology is recommended. Heian provide the training and
technical know-how, not just in specifying the right machine, but also
in tooling, and CAM software.
Heian
have developed expert partnerships, to provide the complete
professional solution.
We hope
you can benefit from Heian's products and service too. We would be
delighted to discuss your requirements and invite you to contact us, or
any of our partners worldwide, today.
Please do not hesitate to request a quotation for a
specific model, or a customized proposal according to your specific
requirements.
|
