News from John Hart - June 2006

Turn Handle Mill Measure Multi-task

In this issue:>> John Hart news>> New Mazatrol Matrix controller >> Customer stories>> AUSTECH stand map >> Automation & Robotics>> Accessories

...and more

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2006 marks 60 years of John Hart’s involvement in Australian industry, something of which we are all very proud. I would like to take this opportunity to thank all of our customers and staff who over the years have made this outstanding achievement possible. To recognise this milestone we are planning a celebration later in the year.

Over the past 18 months, we have been working

harder than ever to improve all areas of our business, part of which has been an investment in upgrading our facilities.

The recent opening of our new purpose built Technology Centre in Murarrie in Brisbane in early May was a gala affair. This significant expansion in our showroom, service and training areas together with additional staff will increase our local presence significantly. The opening itself was attended by a large number of local and north Queensland customers who dropped by to see live demonstrations on several Mazak machines, a Brown & Sharp CMM display, a functioning Fanuc robotic cell, and selected software and accessory displays. Queensland customers were also the first to see the new Mazatrol Matrix CNC controller while looking through the showroom.

Late last year, we had another facility opening following the completion of our new Automation & Robotics Technology Centre in Melbourne. Again a large number of customers attended to see the new facility, where we displayed 17 robots in a series of active (including full 3D visions system display) and static displays, and to be on hand for the official ribbon cutting ceremony by Mr Hiroyuki Harada, Senior Vice General Manager, Overseas Robot Sales Div Fanuc Ltd.

As part of our longer term program, we are reviewing our other interstate facilities with a view to improving our showroom and training areas throughout Australia.

Reflecting on our activities over the past year, I am happy to report we have enjoyed solid machine tool

>> From the Managing Director’s desk

activity, highlighted by a number of large and complex installations. I am also happy to report a high level of activity in our Automation and Robotics area where many local manufacturers have been seeking to improve their productivity.

Supporting all this activity is our hard working team of service and applications engineers throughout the country. Our front line engineers work tirelessly to ensure your machine is up and running as quickly as possible. To support this effort we are currently reviewing the local and overseas training, test equipment and the in field needs of our engineers.

One important area we are developing is the practical implementation of our new computerised John Hart Service Support System. This system will have detailed machine related information available for our engineers to access via the internet twenty four hours a day, and better factory access which will assist us in providing you with better service. Our commitment to continuous improvement is one of the reasons we believe we remain the leaders in our industry.

We are extremely fortunate to represent a select few world class principals who are all leaders in their fields and who all push the technical frontiers of our industry in new and innovative ways. This allows us to offer our customers the necessary tools to remain internationally competitive.

This is evidenced by the continuing release of new models, entirely new products and even new CNC controllers. In this edition, you will be introduced to the new 6th generation Mazatrol Matrix conversational CNC controller, with over a hundred new features and many advantages for the end user, the Matrix is an integral part of the on going evolutionary development process to deliver production efficiencies on to the shop floor.

As this magazine goes to print, we will be putting the finishing touches on our stand for this year’s Austech Sydney exhibition. We look forward to seeing you all there again this year to discuss your manufacturing needs

Thank you for your valued support over recent times and look forward to working with you to find the best possible solutions to ensure your longer term viability.

Mr Hiroyuki Harada (Fanuc) with Ian Rehfisch at the opening of the John Hart Technology Centre

John Hart Technology Centre, Murrarie, QLD

Managing Director Ian Rehfisch

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Principal and Product news:>> Mazak releases the 6th generation Mazatrol Matrix controller.

>> Mazak announces US$350million to be invested over the next year to update technology in current factories as well as building new facilities to meet increased world demand for Mazak products.

>> Mazak opens new World Technology Centre at Minakamo plant in Japan. The new centre features a 400 seat auditorium and a new showroom area with displays of at least twenty eight of Mazak’s latest CNC and laser processing machines all performing cutting demonstrations.

>> Mazak opens new large machining factory at Minakamo plant. The system features a Palletech system of fourteen large bridge type five face vertical machining centres to process large machine beds.

>> Mazak announces the building of their new Nexus factory which will be used to assemble all Nexus machines by late 2006.

>> Mazak opens new dedicated Laser FabriGear factory increasing manufacturing capacity to meet increased world demand for the popular long tube (up to 12 metres) multi axis laser processing machine.

>> Mazak successfully implements the fully automated ebot 720 cells which utilises a robot and a Mazak e410H multi-tasking machine designed to run unattended for 720 hours.

>> Fanuc releases new R-J3iC controller, which is the most advanced robot controller to date.

>> Fanuc releases the new M710iC/50 robot with the new R-J3iC controller which offers a greater payload and reach than previous models, is water proof and is even more affordable than ever.

>> Recent in field tests confirm that the Brown and Sharpe One CMM is the premier shop floor CMM in Australia due to its’ superior speed and accuracy.

>> Hexagon Metrology releases the new PC-DMIS version 4 metrology software for Brown & Sharpe and DEA CMM"s.

John Hart news:>> A large group of customers and staff were on hand for the opening of the new John Hart

Automation and Robotics Technology Centre in Melbourne.

>> A large group of customers and staff were on hand for the opening of the new John Hart Technology Centre in Queensland.

>> John Hart expands field service capability with the appointment of new service engineers in Branches throughout Australia.

>> John Hart confirmed as the world leaders (outside of Japan) in Fanuc 3D Robotics vision systems. Having successfully installed three systems to date, local companies are able take advantage of this new technology.

>> John Hart Automation and Robotics sets new record for robot installations with continuing strong support for automation systems throughout Australia.

>> John Hart CMM specialist Danny Flude visits Hexagon Metrology in Singapore in preparation for the release of PC-DMIS V4.0 to Australian users.

>> Mazak Integrex Mark IV receives intense market interest following strong sales performance.

>> Resource related manufacturers ride the current boom with increasing interest and strong demand for larger Integrex e Series machines.

>> John Hart hosts successful customer "MIMTA" tours to Japan in December 2005 and April 2006

>> John Hart applications engineer Robbie O’Brien visits Mazak UK for training on new 6th generation Mazak Matrix controller.

>> John Hart installs HyperGear 510 into its Melbourne showroom with a national launch, product seminars, and application demonstrations to follow soon.

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>> Mazatrol Matrix released in Australia

One of the great benefits offered by Mazak is their fully “conversational programming,” system, Mazatrol. This world famous system which runs in the controller’s native language (as apposed to simply outputting G code data) has allowed the fastest and simplest

program changes for tens of thousands of users throughout the world.

In 1981 Mazak released the Mazatrol T-1 controller, which was the first conversational CNC system of its kind. The introduction of the Mazatrol T-1 catapulted the machine tool industry to a level of sophistication never seen previously. Developments continued over many years which saw the introduction of other now famous (and still in service) models including the T/M32, T/M Plus and Fusion 640 controllers.

Over the years Mazak has developed this world class technology with the integration of PC functionality into CNC controllers. This development has proven to be a great step forward in eliminating problems associated with networking, storage capacity and processing speed, experienced with the older style controllers.

The most recent 6th generation controller "Matrix" is

Mazak’s latest offering. The name Matrix refers to the inter-relationships between improved control functions including, conversational shop-floor programming, enhanced off-line office programming, and advanced hardware, with the goals of achieving higher productivity, quality, safety, and ease of operation.

The Matrix controller features many new unique features and functions which will be of great benefit to the operator.

To an operator the new Matrix control provides new features such as:

>> Matrix CAM for full interference checking>> Virtual machining or background simulation while

actually cutting,>> Ease of operation features with rotary dial switches,

pointing device, increased data capacity, larger CNC display, and USB interfaces.

To a programmer the new Matrix control provides new features such as:

>> Mazatrol ramp and helical pocket entry >> 3D graphical help >> Advanced chip breaking turning cycles >> Mill turning Mazatrol cycle >> Conversational language enhancements, (previously

programmed only in EIA/ISO) high speed synchronized tapping cycles, deep hole drilling cycle, radius tool selection for line machining and simultaneous machining on head one and head two.

For more information on the revolutionary Matrix controller speak with the engineers at your local John Hart branch.

>>KH Fox utilises technology for succes

Located in the NSW coastal town of Caves Beach, KH Fox was founded by Kevin Fox in the 1950’s primarily to service the nearby Hunter Valley coal mining region. KH Fox specialises in the manufacture and supply of rotary and core drilling tools, diamond drills and accessories. In 2004, the company was acquired by the service, supply and manufacturing group, SDS Corporation Limited.

KH Fox have utilised Mazak technology for over 25 years. From the purchase of their first M5x1500 CNC lathe in 1979, KH Fox have accumulated a range of vertical machining and CNC turning centres.

To complement their QTN250 which was installed in 2003, KH Fox needed a machine that was going to provide them with even greater turning and machining capabilities on larger parts and at faster speeds. Working with the team at John Hart they selected the Quick Turn Nexus 350M, which offered enhanced turning and machining capacity over their existing machines.

As one of the world’s most widely used turning centres, the versatile QTN350M

features both turning and milling capabilities on the turret, a 30kW main spindle, 7.5kW rotary tool spindle, 102mm bar capacity, a machining length of 603mm and a machining diameter of 420mm, all controlled by the fully conversational Mazatrol Fusion 640 controller.

Talking with Brad Searle, Manager of KH Fox about their decision to purchase the QTN350, he commented “with the Nexus’s large spindle bore, increased power and superior turret construction, we are able to machine a large variety of components efficiently, resulting in improved productivity”.

In addition, Brad noted “we rely heavily on the speed and versatility of the Mazatrol conversational programming system, which ensures reduced setup times”.

KH Fox needed to upgrade their machining capability to meet increased demand and together with the assistance of the experienced team from John Hart and world leading technology from Mazak, they were able to expanded their production capabilities, increase part accuracy and

reduce production times. Ian Plumridge (Operator) and Brad Searle (Manager)

Nicholas Rehfisch and Robert Henson with the Matrix controller

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>>Diemould shapes their success

Originating in Edwardstown South Australia in 1979, and later expanding to include a plant in Michigan USA, Diemould Tooling have established themselves as a market leader for plastic injection mould design and tooling. With an international reputation for making superior quality, competitively priced dies, Diemould manages the complete tool manufacture process from the initial design and manufacture, through to proving and testing moulds before dispatch to the automotive, computer, electrical appliance and packaging industries.

Diemould recently purchased two large double column machining centres, the Mazak FJV 35/60 for their USA operation, and the Mazak FJV 60/120 in Adelaide. The larger Mazak FJV 60/120 was selected to accommodate all facets of Diemould’s machining requirements from high precision finishing to fast metal removal roughing operations. The versatility of the FJV 60/120 sees the work ranging from small work piece machining, up to dies using the 5000kg table capacity.

Another important consideration was selecting the most appropriate spindle, the FJV 60/120 comes with three different configurations; 6,000rpm, 10,000rpm and 15,000rpm spindles. After discussions with John Hart

engineers, the 10,000rpm BT50 spindle was selected, and using a 1mm ball nose cutter at maximum rpm for extended periods of operation, the setup has provided Diemould with a superior surface finish on final operations. In addition the Mazak FJV 60/120 offers excellent torque and rigidity under extreme metal removal conditions.

Diemould’s original Mazak purchase was the AJV 25/405N vertical machining centre, acquired through John Hart in 1991. According to Diemould General Manager Russell Daniel, “the machine is still running strongly and accurately 15 years later”. Russell also noted that utilising the same

high feed cutters used on the Mazak AJV 25/405N, they have witnessed increased feedrates of up to 60% with the new FJV 60/120. Russell remarked that “apart from the specifications of the FJV 60/120, and the excellent on going service provided by John Hart, a major deciding factor in the purchase was the excellent performance and low maintenance costs of the original Mazak AJV 25/405N”. Diemould were able to draw on their previous and long standing experience with Mazak

and John Hart in order help continue their market leading manufacturing.

Daryl Walker (CNC Supervisor) with Dave Lucas (JH)

In July 2002, Yamazaki Mazak Corporation introduced ten different models of the Quick Turn Nexus and Vertical Centre Nexus series to the market. These new machines featured a design concept that combined advanced technology, high performance and exceptional value. Additionally, the manufacturing of all Nexus series was simultaneously started in Mazak’s five Cyber Factories, two in Japan, one in the USA, one in the UK, and one in Singapore.

The initial machines introduced were two axis CNC lathes in four model sizes and three model sizes of vertical machining centres.

Since then, the Nexus series has been expanded to offer faster feed rates, higher accuracy on selected models, and mill and turn multi-tasking capability in order to meet a wide variety of customer requirements. The size range of the Quick Turn Nexus series

has been expanded and two models of Horizontal Centre Nexus have also been introduced.

Some of these newer models were only introduced in 2004 and 2005 and currently, a total of thirty four Nexus machine model variations are produced by Mazak’s Cyber Factories.

The complete Mazak Nexus range has been very well received by customers worldwide and more than 10,000 Nexus machines had been sold up to December 2005 - just three years and five month since their initial introduction. John Hart Pty Ltd sold in excess of 100 Mazak Nexus machines in this period.

Yamazaki Mazak continues to develop the Nexus series in order to meet customer requirements and provide before and after sales service and support through the Mazak global support network and local distributors.

>> 10,000 NEXUS machines installed

Mazak VCN 510C

Mazak QTN 250M

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>> Deer Park has the power

Originally established as a foundry in Sydney in the 1920’s, Bradken today has over 2,600 people throughout Australia, New Zealand and the UK and is a market leading supplier to the industrial engineering, mineral processing, mining and rail freight industries.

At their Ipswich plant in Queensland, Bradken specialises in the production of iron and steel castings, the manufacture, fabrication and refurbishment of mining and other heavy engineering equipment.

Late in 2003 Bradken began reviewing their machining practices in order to understand how they could improve efficiencies, output and quality control. During this process they found that the majority of parts they were processing required multiple operations, a high degree of complexity and long setup times which often led to subsequent quality control issues. As a result, they felt it necessary to make serious and innovative changes in order to stay ahead of the competition.

Working with the team at John Hart, they decided to take their business to the next level by ordering the Mazak Integrex e-1060V8 multi-tasking machine. The Integrex e-1060V8 is world leading and features a 120 tool magazine, 2 pallet changer, vertical turning and full 5 axis simultaneous machining on multiple faces on parts up to 1250mm in diameter. The incredible capability of the Integrex e1060V takes the "Done in One" concept to a new level.

Gary Frost, Manufacturing Manager at Bradken Ipswich, remarked that "Where it was taking multiple set-ups on various machines in the past, there was always the risk that quality would be compromised. We are now able to machine the most complex components in one or two set-ups, and with greater accuracy. Intricate parts such as gear cases, hubs and so on are taking hours, not days. With the Integrex e-1060 we no longer have the scenario where the part has to sit on the floor to get to the next process; we can machine all angles as well as bore just like a vertical turning

lathe and mill like a vertical and horizontal machining centre"

Multi-tasking at Bradken has taken on a whole new meaning, and Gary went on to note "We are conscious every time we look at a job, as to how we can get more operations done in the one setup. Our staff are invigorated with the new Mazak technology that John Hart has installed at Bradken, and we are seeing the benefits in efficiency and quality every day".

Bradken also sought to further their competitive advantage and increase their new found productivity with the recent purchase and installation of their Mazak FH8800 Horizontal Machining centre with 6 pallet changer and a 120 tool magazine. Again Bradken are already seeing similar gains in efficiency, productivity and quality that have been achieved with the e-1060V8.

>> Bradken gets it “Done in One”

Located in Sale, approximately 210 kilometres south-east of Melbourne, is Deer Park Oil Tools Pty Ltd, a subsidiary of Deer Park Engineering in Melbourne. Deer Park Oil Tools specialises in providing manufacturing services and equipment to oilfield companies involved in the exploration and production of oil and natural gas, in Bass Strait, the Otway Basin and other locations around Australia.

Due to the increased activity in the oil and gas industry in recent years, Deer Park needed to increase their machining capability. To meet these requirements, Deer Park installed a new Mazak Model Slant Turn 60N x 3000 Universal CNC lathe in late December 2005.

The ST60N features a 260 mm spindle bore, 710 mm swing, 3000 mm between centres and 45kw turning spindle, with an SMW Autoblok large bore three jaw air chuck at front of the main spindle, and a manual chuck at the rear. The configuration enables the manufacture of various drilling components, casings and drill pipe joints, plus the threading of twelve metre tubing. Some of the benefits of the new machine have been improved productivity through reduced machining time and increased part quality.

Machine shop Services Manager Bruce Steer commented “Deer Park Oil Tools are extremely pleased with the new Slant Turn 60 as well as the very high level of service and support provided from the John Hart team”

In acquiring the latest Mazak technology, together with support from John Hart’s experienced support staff, Deer Park has managed to successfully keep up with the increasing demands of their industry.

Steve Lygris (JH), Bruce Steer (Manager), Greg Dingwall (Operator)

Mark Wenman (JH) with Gary Frost and the e-1060V8

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>> Gearing up for the HyperGear 510

>> New Touch Laser’s 3D advantage

When Brad Drury and James Cao founded New Touch Laser in Bayswater Victoria in 2001, they owned just one laser processing machine, which they operated themselves. New Touch Laser specialised in processing long flat sheet and plate work, jigging, rotary and rectangular hollow section work, and the cutting of thicker plates; 25mm mild steel, 20mm stainless steel and 12 mm aluminium.

By 2003, New Touch needed to gain a competitive edge in the market, so Brad and James sat down with the team at John Hart and discussed the possibilities offered from Mazak’s range of world class technology. Brad and James were impressed with the capabilities and flexibility of the Mazak U44 Space Gear laser, and with three dimensional cubic, pipe and long piece processing abilities, the machine offered New Touch the innovation they were looking for.

Important to New Touch Laser was both the knowledge they could justify the financial, time and personnel commitments required to install a machine of this level of technology, and being able to successfully market this new technology to their customers. Other issues including local support, the machine size and the strategic move from 2D to 3D affected their decision.

Features of their new Mazak U44 Space Gear include:

>> 2D and 3D cutting with 6 simultaneously controlled axes

>> Mazak’s SPACE CAM software allowing automatic programming of work piece fixtures

>> Innovative compact cutting head with 7.5” focal length lens for a wide range of materials and thicknesses

Currently the only one of its kind in Australia, the Mazak U44 gives Brad and James the ability to offer a diverse range of

complex jobs including;

>> Counter sinking of holes and slots on plates and pipe

>> Bevel edging of blades

>> Mitring of plates for weld preparation

>> Creating perfect “monolithic” join points on RHS and tubing

The Mazak U44 eliminates multiple, time consuming steps in job shop processing, and this significantly reduces costs and production times.

New Touch Laser needed to improve their capabilities and increase their profits, and was not afraid of the new technology they required to do so. Brad and James were willing to undertake thorough research before investing in the technology, and with the support and knowledge of the John Hart team, have been successful in implementing the Mazak U44 Space Gear and a new way of thinking. According to Brad, “John Hart was instrumental in the success of the installation; with the training and support we received exceeding all expectations”.

Brad Drury, Simon Chong, Dang Le (JH) and James Cao

3D 5 axis pipe work

Mazak’s latest 2D laser processing machine the HyperGear 510 has caused quite a stir with metal fabricators throughout the world. The new HyperGear 510 uses custom linear motors to deliver rapid traverse rates of 120m/min at a staggering 3g acceleration on all axes. The increased use of sensors, refined programming, read-ahead controls, and new algorithms make the HyperGear up to 20-30% more productive than other machines on the market. The result is higher cutting speeds to process thin, painted galvanized steel sheet 0.2 mm that would otherwise blister or catch fire, all the way up to 25mm steel plate.

The machine is equipped as standard with an automatic torch changer and an automatic nozzle changer. These features, plus automatic focusing and beam adjustments, enable the ideal setup for every cutting application with the lowest possible setup time.

Initial selection of torch, nozzle, assist gas and cutting speed is automatic. All the operator needs to do is select the material type and thickness and the PREview 640 CNC

control does the rest.

The HyperGear 510 has now landed on the floor at John Hart’s Melbourne showroom so to see this technology up close contact your local John Hart branch today.

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Quick Turn Nexus 250MY

Capacity 380mm dia x 504mm longSpindle Power Turn: 26kW, Mill: 5.5kWSpindle Speed Turn: 4,000 RPM, Mill: 4,500 RPMTooling 12 Station Turret VDI Shank

ONE 7.10.7 DCC CMMCapacity X: 700mm, Y: 1,000mm, Z: 650mmVolumetric Error MPE 3.9 + L/250 μmVelocity / Acceleration 520mm/sec, 1752mm/sec2

Measurement Software PC-DMIS CAD++

AUSTECH Stand Sydney

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Vertical Centre Nexus 510C

Capacity X: 1,050mm, Y: 510mm, Z: 510mmTable Size 1,300 x 550mmSpindle Speed/Power 12,000 RPM, 18.5kWTooling MAS BT-40, 30 Tools

•sub micron input(0.0001mm) and nano

control

•16,000,000 pulse encoder

•machined chip break cycle

•matrix CAM

•helical approach to pocket machining

•quadrant spike compensation

•USB interface

•increased data capacity

•virtual machining

•mill turning

Integrex 200S MkIVCapacity 660mm dia x 1,016mm longSpindle Power 1st: 22kW, 2nd: 18.5kW, Mill: 18.5kWSpindle Speeds Turn: 5,000 RPM, Mill: 12,000 RPMTooling KM-63, 40 Tool Magazine

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>> PBR has vision

A third Fanuc robot, utilising Fanuc’s 2D vision system, packs the finished rotors into transport stillages. The Fanuc 2D vision enables the robot to accurately locate the position of the stillage and to verify that the parts and interleave layer dunnage are being handled correctly.

Currently, PBR Australia is utilising John Hart’s unique "one-stop-shop" capability by installing a new line which will manufacture automotive steering knuckles and carriers. This line once again features a very high level of automation with 7 Mazak CNC machine tools, 10 Fanuc robots and a wash machine which utilises a wet area Fanuc wash robot. When this line is commissioned it will meet the customer’s part requirements whilst providing significant the manufacturing benefits of increased outputs, reduced labour costs and elimination of many OH&S issues associated with manual handling of heavy parts.

Following the success of the Fanuc robot cells installed in Melbourne, two additional brake rotor lines are also being installed at PBR in Adelaide, each containing 2 robot cells, in which the transport stillages are capable of being changed without the need to stop the line; another example of how John Hart Automation & Robotics is helping to improve productivity at PBR.

The Fanuc R2000iA/165F robot transferring parts

The Fanuc R2000iA/165F robot complete with gripper.

As this country’s leading manufacturer of automotive braking systems, PBR Australia Pty. Ltd., is constantly seeking ways to improve their manufacturing competitiveness. Some recent examples are the new systems recently installed at their Melbourne and Adelaide sites.

PBR recently installed a new brake rotor machining line in Melbourne. To maximise the efficiency, up time and cycle times for loading and unloading the system, John Hart worked with PBR to design and supply three turnkey Fanuc robot cells, integrated with the existing machining line of vertical CNC lathes.

The first of these cells utilises Fanuc’s state of the art 3D vision system to find rotor castings randomly located within the transport bin as received from the foundry. The robot removes them one at a time from a bin and presents the castings to the machining line.

The machined parts then enter an inspection cell where another Fanuc robot fitted with a double gripper picks up the part and presents it to two automated inspection machines. To ensure continued reliability, the robot is tasked with regularly loading master parts to the inspection machines. Parts which do not successfully pass the inspection are rejected from the cell.

>> Plastic manufacturers utilise technology

Plastic companies throughout Australia are facing the difficulty of keeping up with ever increasing requirements for increased production efficiency and flexibility. To keep pace with these requirements manufacturers are embracing new product handling technologies.

The disadvantages of traditional manual product handling are well known and include higher labour cost, variable productivity and the risk of repetitive-task injuries. In addition the higher priority on production flexibility has highlighted the shortcomings of hard automation and dedicated equipment.

To achieve improved overall production processes the role of handling technology has become a key factor. The solution for many manufacturers has been to implement highly efficient, flexible and reliable product handling systems.

For the plastics industry John Hart Automation and Robotics has the robot technology and installation experience to provide manufacturers with the flexibility to consistently and efficiently handle primary mould extraction processes and secondary applications like trimming, degating, deflashing, drilling, routing and assembly. High or low volume manufacturers alike can realise the benefits of increased flexibility and reliability with a very attractive return on investment timeline.

John Hart Automation and Robotics has a strong track record in the industry with over fifty robots installed into the plastics industry in the last two years alone. So to solve your production problems or to increase the efficiency of your production process, speak with the automation leaders at John Hart Automation and Robotics.

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>> Don’t stop the press!

At John Hart Automation and Robotics (JHA&R) we aim to add extra flexibility to your robot application with our in-house designed and built gantries and floor tracks. Often getting your robot to reach all required positions is not possible when the robot is simply bolted to the floor, but using overhead mounted gantries and floor mounted tracks can eliminate this problem by introducing an additional axis of movement to your robot.

Gantries are ideally suited to applications where floor space is at a premium and placing the robot above the machine still permits maintenance access at ground level. Typical applications would be removal of parts from an injection moulding machine or loading parts to a machine tool.

>> Unique amongst robot manufacturers, Fanuc offer a range of robots designed to operate on overhead gantries including the “Top Mount Robot” range, available in payloads from 6Kg to 200Kg

>> Robots are able to mount on the side or beneath the gantry, and travel along the gantry by means of a Fanuc servo motor and a rack and pinion drive.

>> The Fanuc servo motor is controlled using an additional axis card, located within the robot controller and programmed from the robot’s teach pendant.

>> Flexible power and signal cables are located within a drag chain to the robot, and are available in a range of lengths to suit different gantry sizes.

Floor tracks provide a cost effective means of allowing the robot to access multiple work stations which would normally be outside the reach of the robot.

>> These can be manufactured in a range of lengths, and are designed to meet the length and height requirements of the customer’s application

>> The floor track is bolted to the floor and conventional 4 and 6 axis robots are then mounted on the carriage plate which uses a Fanuc servo motor and rack and pinion drive to travel along the track.

>> Robots running along the floor tracks position using the servo motor and communicate via flexible power and signal cables located within a drag chain.

As part of a recent project to manufacture pressed automotive parts, John Hart Automation & Robotics installed a robotic press loading system at DANA Australia’s Cheltenham plant.

The brief for this project was demanding, with the automation of two existing 500 tonne presses, with a total of 8 parts to be handled and a cycle time of 14

>> Robots on the right track

Two Fanuc R2000iA robots loading a press at DANA.

seconds part to part to be achieved.

The turn key project required four Fanuc robots together with their grippers, accessories, safety fencing and interfacing with the two presses. The system utilised a R2000iA/100P robot with 3,500mm reach for press loading and three R2000iA/165F robots with 2,650mm reach for handling.

With up to five stages of press tooling per part, the design and manufacture of robot tooling was critical. We first modelled the system in 3D and simulated the robot movements using Fanuc’s Roboguide simulation package. This ensured there was sufficient reach and clearance within the presses and that the cycle time required could be achieved. By presenting these simulations to DANA during the project analysis stage, both parties entered the project confident of a successful outcome.

The use of Fanuc robots has assisted DANA to achieve the required project cycle times, whilst eliminating OH&S and safety concerns. The consistent and reliable nature of robot handling also provided DANA with ongoing gains in production reliability and efficiency.

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For more than 20 years John Hart Automation and Robotics has been providing tailored solutions from stand-alone robots to full turnkey systems. When Lang Lang based cutting business Cutting Stuff required such a solution some time ago, they turned to the team at John Hart to help them increase their production productivity and part quality.

Jeff Jansz, Managing Director of Cutting Stuff, chose the Fanuc M16iB/20 robot to automatically water cut a wide variety of parts which were originally cut with a hand diamond saw. The system which has been in production since January 2004, has added flexibility and reliability to the process with the addition of improved part quality.

The Fanuc M16iB/20, which has a 20kg payload capacity and a reach of 1667mm, is widely utilised for various applications throughout industry such as CNC machine loading, de-burring, assembly and sealing. When 55,000psi of abrasive water is added, the cutting power of the Fanuc M16iB/20 robot provides a flexible six-axis cutting machine capable of cutting almost anything up to 50mm steel.

The following materials have been cut on the Fanuc water jet cutting system installed at Cutting Stuff:

Cutting Stuff has also commissioned the Fanuc offline robot-simulation program Roboguide, for use with the M16iB/20. Roboguide allows Cutting Stuff to simulate the cutting process in 3D, prior to starting the actual process.

Roboguide also enables the importation of 2D CAD files in DXF (data exchange format) into the Roboguide simulation

John Hart Automation and Robotics offer regular robot training courses.

The courses introduce attendees to the fundamental principles of robots and their safe operation and programming, covering:

>> Introduction to robots.

>> Safety considerations.

>> Introduction to R-J3 series robot controller.

>> Robot operation, programming, care and maintenance.

>> Application specific operation and programming.

The course length is three days and covers theoretical

>> A cut above the rest

>> Automation and Robotics training

software, allowing the programmer to develop the robot program. This greatly reduces the amount of setup time required for the next job and ensures the job is suitable for the robot’s capabilities.

Talking with Jeff about his system he commented “The Fanuc robot with water cutting attachment was purchased initially for a specific contract to increase manufacturing speed and for staff safety, it improved productivity by 80 percent on this particular process and reduced the environmental impact caused by excessive dust production. The robot has given us scope to pursue other contracts in all fields of industry.”

“Now with the purchase of Roboguide, this has streamlined the process even further as we are able to download programmable files from clients further reducing production time.

“John Hart Automation and Robotics have been overwhelming in their support, being the first 6 axis abrasive water cutter we have purchased this has been a steep learning curve and without the support of JHA&R we could not have achieved our goals.”

The Fanuc M16iB/20 at Cutting Stuff

2006 Course schedule

and ‘hands on’ training. The training can be conducted on site or in John Hart Automation’s training department.

For information on these training courses contact John Hart.

Stainless Steel Aluminium Cast Iron

Foam Composites Copper Brass

Acrylic Sheet Fibre Glass Carbon Fibre

Ceramic Tiles Marble Rubber

Bullet Proof Glass Slate Kevlar

Month Start Finish

June Wed. 28 Fri. 30

July Wed. 26 Fri. 28

August Wed. 30 Fri. 1st September

September Wed. 27 Fri. 29

October Wed. 25 Fri. 27

November Wed. 29 Fri. 1st December

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>> Quick change for success

When we visit various overseas exhibitions and factories on our travels, we are always on the lookout for new and innovative ways of assisting our customers to improve their productivity. For over ten years we have seen an increase in the use of quick jaw change power chucks on CNC lathes and we are of the firm belief that this technology is of great benefit to Australian manufacturers.

One of our principals, SMW-Autoblok, has been at the forefront in the supply of these chucks. In the last two years we have seen a steady increase in the number of manufacturers investing in quick change chucks on CNC and multi-tasking lathes and four and five axis vertical machining centres. The result has been reduced setup times with a typical investment payback of approximately six months. All new users commented that they would not purchase a future machine without a quick jaw change chuck.

SMW-Autoblok supplies a range of alternative quick jaw change chucks suited to a variety of applications ranging from high volume production work to short run and jobbing work. Broadly speaking there are three styles of quick jaw change chucks with the most repeatable being the

monoblok jaw style followed by the quick change base jaws which accept all standard types of top jaws – both of these styles use a safety key for jaw exchange – and "click on" styles.

The most popular chucks are the base jaw style which use standard top jaws. For dedicated high volume applications the base and top jaw combinations use a cross tenon type location for fool proofing, but the majority of customers choose the separate quick change base jaws to accept their existing style of metric or imperial serrated top jaws.

Generally a customer will order two or three sets of base jaws which allow top jaws to be set for the next jobs while the current job is in process. The top jaws can be either existing or machined elsewhere and in most cases the repeatability of exchange means that the jaws do not have to be re-machined once fitted. To exchange a set of three jaws only takes two or three minutes including cleaning – a significant saving in changeover time.

For more information on the various styles of SMW-Autoblok quick jaw change chuck models to suit your application, please contact your local John Hart sales engineer.Type KNCS-N for jobbing applications

Type NT-RC for high volume applications

implementing its own web Service Support system. This local system is tailored specifically to the needs of our engineers and contains information accumulated over a long period from Australian installations. Included in this database are the latest service manuals, detail machine specifications, service bulletins, installation procedures and in field service tips to assist our engineers in being as efficient as possible.

These latest advances in information technology are designed to help our engineers have the best possible in field support as a part of our ongoing commitment to providing the most effective service.

John Hart service engineers in the field often require detailed technical machine information on site. Historically this meant the carrying of large numbers of manuals and support information. With the increasing sophistication and variety of CNC machines in the field, having the right information for the job has become more difficult. As a result John Hart has setup access to Mazak’s secure international support website.

Authorised access with an electronic key to this website allows John Hart engineers to view online service bulletins, service manuals, installation procedures and a whole range of other service related information. This system is being accessed world wide and users have the ability to view the necessary information needed for a particular service job online immediately, reducing their requirement to carry physical documentation.

In addition to this global support tool John Hart is also

>> Information Technology enhances service

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cycle times between the two machines, measuring the same features on identical components:

John Hart is currently installing a major turnkey installation at one of the world’s largest automotive component suppliers. When complete, the cell will enable the fully automated manufacture of two separate suspension components that will be used in a popular locally built car.

As is required during projects of this size, John Hart had to prove the capability of each machine in the cell. This was achieved by running the cell in simulated production, fully manufacturing hundreds of components, half of which were measured on a Coordinate Measuring Machine (CMM). The measured results of each finished component were then collated and analysed, giving a capability index.

In this case the customer supplied their own well known brand of CMM for the run off, however John Hart also temporarily installed their own shop floor CMM, the Brown & Sharpe ONE. Having two CMM’s in the same class on the floor side by side, running the same programs provided a unique opportunity to compare the performance and capability of the two CMM’s.

What was found during the “apples for apples” comparison came from comparing the measurement

>> VITAS measures for success

>> The one and only CMM ONE

When it comes to machining precision parts for the laser equipment, medical, automotive and defence industries, VITAS Engineering in Tullamarine Victoria, doesn’t cut corners. Having been in business for over twenty four years, VITAS has undertaken the manufacture of many intricate and complex parts ranging from prototypes to larger quantity batch sizes. With a strong emphasis on customer satisfaction, VITAS has adopted a policy of embracing the latest and most innovative technology. Included in this program are a number of Mazak CNC machines installed by the team at John Hart.

So when VITAS owner Vitas Lesniauskas, wanted to improve his part inspection process to verify he was producing the highest quality parts, he turned to the experienced team at John Hart to provide a solution. After much analysis he chose the Brown & Sharpe ONE Coordinate Measuring Machine. The ONE offers the latest in inspection technology, it is a high speed shop floor CMM with a small footprint that is easy to use and is great value for money. The ONE was the obvious choice for Vitas Engineering.

After installation in the factory and training by John Hart engineers, Vitas remarked, “The Brown & Sharpe ONE with

PCDMIS software was far simpler to program and operate than we first anticipated. The few programming problems that did arise following the initial training were addressed and resolved promptly by John Hart applications engineers with a simple phone call”.

The results speak for them themselves, with local support VITAS engineering were able to confidently introduce the Brown and Sharpe ONE to their production process, which has brought them greater part inspection capability in their precision work.

Vitas Lesniauskas with his CMM ONE

Brown & Sharpe ONE

These results clearly demonstrate the substantial benefits, not only in time, but in total inspection costs that the Brown & Sharpe ONE delivers by way of the machine’s superior feed rate velocity, acceleration and the Fly Mode feature.

Unique to Brown & Sharpe, the Fly Mode employs a continuous motion system whereby a nominal arc path is automatically applied during machine axis movement, effectively smoothing sharp movements and multiple axis stops to one continuous flowing motion which allows high speed probe movement. In addition to having a measuring accuracy 22% better than their major competitor, the ONE’s measurement efficiency results speak for themselves - the ONE really leaves the others in their wake.

MEASUREMENT CYCLES 1 CYCLE 150 CYCYLES*

Component ’A’ (two components):

Brown & Sharpe ONE 9 minutes 22.5 hours

Other ‘shop floor’ CMM 19 minutes 47.5 hours

Component ‘B’ (two components):

Brown & Sharpe ONE 13 minutes 32.5 hours

Other ‘shop floor’ CMM 29 minutes 72.5 hours

*150 cycles required for capability study

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For your work holding needs

Model ThroughputD600 600m3/hrD1200 1,270m3/hrD2000 1,950m3/hrD3000 3,200m3/hr

Mist Filters

John Hart proudly offers the Sigma Pool range of gear cutting, grinding, forming and measuring equipment.

Making sure you have a quality customer support system in place is as important as ensuring the products you supply customers are of the highest quality to begin with. At John Hart we pride ourselves on our long standing commitment to quality service support and for the last 60 years we have worked hard to deliver on this commitment. One of our key support areas is our Electronic Repair Facility (ERF). Here is a look at some of the features of our facility:

>> Established for over 14 years, we provide quality repairs on all Mazak CNC machines with genuine Mazak and Mitsubishi parts and circuit boards.

>> Service exchange program often provides customers with next day replacement on circuit boards, allowing for minimal machine ‘down time’.

>> A large stock of spare parts enables prompt repairs.

>> We often include replacement of components that are nearing the end of their life span in our repairs.

>> Our expert ERF engineers are able to visit customers for urgent repairs.

>> A 3 month warranty is supplied with our repairs.

>> We are currently expanding our facility to accommodate the next generation of servo and spindle technology.

Electrical Apprentice:

>> We are happy to announce the appointment of Paul Watts to the ERF as a first year electrical apprentice training in repairing, maintaining and testing circuit boards and power supplies.

Mazak Engineer:

>> Tadatoshi (Ted) Fujita: Mechanical Engineer who has worked with Mazak throughout the US and Japan as a service engineer, joined John Hart in August 2005 on our five year exchange program. Ted is a technical engineer who assists our service department and liaises directly with Mazak Japan on more difficult service and support issues.

>> Electronic Repair Facility

ERF engineers Sunny Radic and Paul Watts

Mazak Engineer Ted Fujita

Victoria11 Winterton Rd

Clayton, 3168Tel: 03 9542 6262Fax: 03 9542 6295

New South WalesUnit 11, 3 Packard Ave

Castle Hill, 2154Tel: 02 9634 7011Fax: 02 9634 7066

QueenslandUnit 6, 16 Metroplex Ave

Murarrie, QLD 4172 Tel: 07 3399 6033 Fax: 07 3399 6223

South Australia483 Port RoadCroydon, 5008

Tel: 08 8346 9068Fax: 08 8346 9060

Western Australia17 Belmont AveBelmont, 6104

Tel: 08 9277 6100Fax: 08 9277 3456

www.johnhart.com.au

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