>> John Hart news

>> New Mazak products

>> New agencies

>> AUSTECH stand map

>> The Fanuc LR Mate 200iC Robot

>> Customer stories

...and more

News from John Hart

In this issue

2007 Vol.1

From the General Manager’s desk

I would firstly like to welcome you to this year’s AUSTECH show edition of Hart Beat. As always the Melbourne show provides a great opportunity to see and evaluate in one place, the latest technologies from all over the world.

As manufacturers face ever increasing competition, the need to embrace the advantages of technology is now more vital than ever. The “Done in One” concept of combining processes into a single machine to increase part quality, improve production efficiency and reduce idle stock is now common practice worldwide.

To this end, our stand features machine tools, robotics, software and accessories, all demonstrating the capability and versatility of our technology. On hand will be local and overseas experts who will be available to assist you and I am sure after visiting us you will come away with fresh ideas on how technology can assist your business.

I would especially like to draw your attention to the advantages offered by Mazak’s new 6th Generation Mazatrol Matrix conversational controller, which will be demonstrated both on our Mazak machines and in our software presentation area.

Since our last issue we have seen continued strong support for our products and services as customers continue to embrace the advantages of new technology, especially multi-tasking. Mazak has been at the forefront of multi-tasking technology for over twenty years now and is the largest supplier of multi-tasking technology in the world. So if you are looking for multi-tasking technology, you can’t go past Mazak.

In other news, we are pleased to announce that we recently signed agency agreements to represent Zoller GmbH and Citizen Machinery in Australia. Zoller are market leaders in tool presetters and Citizen are market

leaders in small sliding head lathes. These two new products will be of great interest to manufacturers Australia wide, as they offer new opportunities to increase your production efficiency.

In the customer support area training has been a top priority in the first half of this year. We have had specialist factory engineers from Mazak, Zoller and Citizen visit us to perform over five weeks of training for our engineers. In addition we have also planned advanced factory service training overseas later in the year.

In other areas, we have seen strong demand for our automation solutions as more manufacturers benefit from the flexibility and affordability of Fanuc robotic solutions. If you have not yet considered the options available through process automation, I strongly encourage you to contact the engineers in our JHA&R team.

Finally I would like take this opportunity to thank our loyal customers for their continued support. Our goal remains to provide the best available technology at affordable prices, supported by a professional service and technical organisation to help our customers be more successful.

In March of this year, John Hart conducted another successful customer tour to Mazak’s manufacturing plants in Japan. For the tour members there was special significance to the trip, as it was the first time an Australian group has visited the newly opened Minokamo Number 2 factory.

The new facility is Mazak’s 8th major production factory in the world. This purpose built 33,400m2 state of the art manufacture and assembly centre, is the new location for the production and assembly of the Nexus Mark II series of CNC lathes and machining centres.

The tour was also highlighted by visits to Mazak’s other main Japanese factories where visitors can walk through the production and assembly areas and view various machines in all stages of assembly. Integrex, Integrex-e

and Variaxis series were all on show as were a wide variety of other vertical and horizontal machining centres.

Mazak engineers were on hand to answer questions and discuss the ideas and concepts behind Mazak’s products. The goal is always to find ways of applying Mazak’s world class technology on a local scale to improve manufacturing efficiency and flexibility.

Impressive to the group was the way Mazak utilised their own machinery, the cohesiveness of their whole production system, the flexibility of their build to order factories and the real benefits of utilising multi-tasking technology.

Mazak Tour 2007

A Mazak e--Bot cell

Nagoya Castle visit

Nicholas RehfischGeneral Manager

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>> Mazak opens the newly constructed 33,400m2 Minokamo Plant Number 2, Mazak’s 8th manufacturing plant in the world. This plant features state of the art environmental features and manufactures QTN-II, VCN-II, Multiplex and IVS series.

>> Mazak releases the new QTN Mark II 400/450 size lathes. These new lathes offer 305mm/400mm/450mm ø chucks, 30kW spindle with bores from 132mm to 185mm, 580mm part machining ø and up to 2075mm maximum machining length.

>> Mazak releases the new Mark II series for the Quick Turn Nexus, the Vertical Centre Nexus and the Horizontal Nexus.

>> Mazak releases the new Matrix Cam offline programming system.

>> Mazak releases the new Hyper Turbo-X laser for flat plate and sheet materials with up to 4.0kW and auto torch changer options.

>> Mazak releases the new Super Turbo-X Champion cost effective laser for flat plate and sheet.

>> Mazak releases the new Integrex e-420H-ST II with lower turret.

>> Mazak releases the updated Variaxis 630-5X-II T with turning table capabilities.

>> Mazak releases new the Horizontal Centre Nexus 4000-II and HCN-6800-II machining centres with high power, high rigidity and high speed.

>> Mazak releases the new Cybertech Turn 5500 MT, a larger version of the very successful CT400 series.

>> Mazak releases the new IVS 400 inverted spindle high volume lathes to compliment the existing IVS-200 and IVS-300 series.

>> Fanuc releases the new LR Mate iC series robot which offers greater reach and motion range as well as being lighter and more affordable than previous models.

>> Fanuc releases the new M430i high speed picking and placing robot.

Other Principals>> John Hart Directors visit world leading Swiss-type turning centre manufacturer Citizen Machinery in

Japan. >> John Hart signs exclusive agency agreement to represent the Citizen Cincom range of small CNC lathes

in Australia. >> Christoph Zoller, General Manager of the world renowned tool presetting equipment company Zoller

visits John Hart.>> John Hart signs exclusive agency agreement with Zoller GmbH to represent them in Australia.

>> John Hart WA moved into their new branch office in Belmont in May 2007. The official opening ceremony is scheduled for later in the year.

>> Glenn Evans is appointed as NSW State Manager in January 2007.

>> Kym Browning is appointed as SA State Manager in April 2007.

>> John Hart hosts another successful customer tour to Japan in March 2007.

>> John Hart expands the Electronic Repair Facility investing in new test equipment to be able to repair the MDS range of electronic boards.

>> John Hart service and application engineers were recently trained by principal factory specialists to add to the company’s customer support capability.

>> John Hart Victoria recently hosted a large number of customers to witness the launch in Australia of Mazak’s state of the art, high speed 2D laser HyperGear. Manager of Mazak Optonics Corp, Japan Mr. Hideo Awa was the event’s guest speaker.

>> John Hart Automation and Robotics recently expanded their team to meet the increasing market demand for automation systems.

>> John Hart representatives visited the JIMTOF 2006 show in Tokyo and Mazak in Nagoya to view Mazak’s newest products and facilities.

>> John Hart re-signs Technology Partnership with the Holden Racing Team for the current season.

News update

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The Variaxis 630-5X II-T with turning is the latest addition to the recently released Variaxis II series of 5 axis simultaneous vertical machining centres from Mazak. The first of its kind to feature a separate turning spindle, and controlled by the industry’s most powerful CNC, Mazatrol Matrix, this already powerful multi-surface machine tool with high-precision tilting rotary table, is now more versatile than ever.

The inclusion of a turning spindle built in to the C Axis table demonstrates a continued ingenuity in machine tool technology, yet more importantly it offers the manufacturer a greater ability to machine large, complex parts in just a single setup.

The Variaxis 630-5X II-T features a 30kW integrated main milling spindle with 18,000 rpm. The compact nose on the main spindle is designed to maximise the machining envelope to accommodate a wider variety of parts for processing. With the introduction of the turning spindle, turning can be accomplished on the tilting rotary table at 0-degree or 90-degree positions with an 18.5 kW motor and speeds of up to 1100 rpm.

High-speed processing of the large amounts of data

that high-precision simultaneous 5 axis machining requires is readily accomplished by the new Mazatrol Matrix CNC. Software and hardware advances in the Mazatrol Matrix include powerful internal computing speed from a new 64-bit twin-engine CPU, feedrates for machining complex curved surfaces are two times faster than the previous CNC and new servo control technology minimises vibration.

More importantly, new software capabilities make the Mazatrol Matrix

easier and safer to program and operate. A unique Voice Advisor verbally informs

operators of machine alarms and switch settings in manual operation to allow simpler part setups.

Enhanced visual 3D simulations allow the operator to identify and correct any interference conditions prior to machining, as well as part program simulations can be run while the machine is operating.

Already the Variaxis 630-5X II is the strongest, most versatile and powerful 5 axis vertical machining centre in its class, now the Variaxis 630-5X II-T with turning offers even greater machining capabilities on the one machine, reduced set up times, and more value to your business.

The new Mazak Variaxis 630-5X II-T

The new Mazak Variaxis 630-5X II T

Quickturn has the speed

Located south of Newcastle in the town Cardiff is Quickturn Pty Ltd. Established over 22 years ago Quickturn manufactures strata control gear, hydraulic hose connectors, gas turbine engines and other products primarily for the mining industry.

Owner Richard Rhodes originally started out 38 years ago in a tool room on a manual centre lathe and manual mill, but it wasn’t until he purchased his first Mazak QT10N in 1985 that he realised CNC machines were the way to remain competitive. Since this first investment Quickturn has continued with this philosophy, and utilising Mazak technology has been able to help improve both part quality and production levels.

Employing eight staff, Quickturn recently purchased their ninth Mazak CNC machine, a Mazak Super Velocity Centre 2000L/120. This high speed vertical machining centre features 120m/min rapid traverse speed on the x axis, a 3.4m long table and a 12,000rpm / 22kW spindle.

Due to the long table the machine also features a central partition which acts as a two pallet changer allowing work to be performed on one side of the table while the next job is simultaneously being setup on the other side. The large machine capacity also allows Quickturn to extend their machining capabilities to include a larger more diverse range of products.

Talking with Richard, he noted “the SVC has allowed for the faster machining of products, with greater accuracy and improved surface finishes”, going on to say “by being able to satisfy customer’s demand for quality products, in the fastest possible time frame, constant annual growth is being achieved”.

Richard had the last word when he said “choosing a suitable machine tool for my business is a simple task based on past experience with John Hart and Mazak. I need to make parts quickly, accurately and reliably, and the combination of John Hart and Mazak makes this possible."

Travel X/Y/Z axis 3048mm / 510mm / 510mm

Table Size 3400 x 510mm

Table Load Capacity 2400kg (evenly distributed)

Spindle (30 min. rating) 12000 rpm, 22kW [30HP]

Tool storage capacity 30Richard Rhodes (Owner) and the SVC2000L/120

As you would expect from the pioneers of conversational programming, Mazak’s latest 6th Generation Matrix CNC controller delivers elements that take machine control and machining to new levels of efficiency.

The new Matrix controller is run by two 64 bit risc processors which deliver vastly increased processing speed. The program system also uses sub micron input of 0.0001mm which delivers high accuracy and high speed machining.

Within Matrix are five additional elements that set it apart from other control systems. These are:

1 Intelligent Safety Shield provides the user with active collision monitoring, when the machine is in manual or set up modes, resulting in the virtual elimination of collisions and the consequent downtime and costs associated with them.

2 Virtual Machining monitors potential collision points during the creation of the NC program, and as a result the time required to complete the programming operation is greatly reduced.

3 Active Vibration Control uses fine resolution encoders and more powerful servo drives, combined with rigid and stiff machine structures to virtually eliminate the effects of machine vibration and axis settling on component quality. Matrix is able to do this by monitoring and modifying axis movements ‘on the fly’. 4 Matrix’s Intelligent Thermal Shield reduces the effects of heat dissipation by monitoring, identifying and compensating for thermal variations and also eliminating any potential areas of heat build up, by channeling heat away from the machine area.

5 Over 100 new programming functions have been created to assist in the programming of the machines by simplifying the process and improving cycle time. They include the Mazatrol Mill-Turn cycle, the Machined Chip Break cycle and the addition of the ability to machine on two spindles and two stations simultaneously

Matrix is featured on the Mazak Quick Turn NEXUS II series, Vertical Centre NEXUS II series,

Horizontal Centre NEXUS II series, Integrex IV series, Integrex e-H series, Integrex e-V series and

Variaxis II series machines.

hyperMILL®

Machined chip breaking cycle

Virtual machining

OPEN MIND Technologies AG is a leading developer of CAD/CAM solutions for designing and manufacturing complex moulds and parts. They offer an extensive range of products from feature-oriented solutions for milling standard parts through to software for 5 axis simultaneous machining.The well-known CAM solution hyperMILL® is an extremely dynamic programming system with 2D, 3D, HSC and 5 axis modules that are simple and easy to use. Thanks to its flexible production strategies and the forward-looking feature technology, it is ideal for the tool and mould making industries.

hyperMILL® boasts a fully developed feature technology. Using this technology, geometry information from surface and solid models can be recognised and processed. Feature recognition takes place on the whole model and recognises holes as well as other geometries including pockets and plane levels.

The innovative 5 axis cycles offer an alternative to conventional production strategies and significantly reduce production times. Shorter, more rigid tools can be used for 5 axis movements thanks to reliable collision control and avoidance. The result: ideal interfaces, less wear on tools, and a high degree of contour accuracy.

The integration of the CAM system with the CAD interface offers frequent advantages. For example, a uniform data model is used for the entire process. The CAD and CAM systems both use the same database. In addition, programmers can use one of the most modern CAM environments and continue to work with their familiar CAD interface.

John Hart can supply you with a tailored hyperMILL® package to suit your needs, and this latest release software from OPEN MIND is the most accurate and cost effective way of modelling your parts before they go into production. Hartbeat 5

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10,000rpm BT40 spindle and a table load capacity of 1000kg. In addition, a 300mm 4th axis rotary table is permanently fixed onto one end of the main table, and this is fully integrated into the system and programmable via the Mazatrol conversational controller.

With the long fixed table design the VTC200C has an easily removable centre partition that divides the work space into two separate areas. Heath can machine one job on the left side of the table with the door closed, while changing out another job on the right side, effectively making the VTC200C two machines in one.

For short part runs and quick changeovers, the Mazatrol conversational controller’s simplicity and ease to program is essential, and was an important factor in the decision process. Complete with full colour graphics, Heath found that it is almost "impossible to make a mistake before you take the first cut, while machining the work piece in the shortest possible time".

Thanks to the VTC200C, CQPE’s production rates have risen

dramatically, work piece handling has been reduced and profitability has increased.

In just five years of operation, Central Queensland Production & Engineering (CQPE) in Mackay has grown significantly with the installation of seven Mazak CNC machines. As a small business specialising in the production of smaller repetition parts such as nuts, bolts, pins, gears, splines and one off parts for the coal and other industries, CQPE has invested in a variety of machining centres with differing capabilities.

As the business has progressed there has been a need for faster, more rigid and efficient machines, prompting CQPE owner Heath Buckeridge to recently pay a visit to John Hart’s Queensland branch in Murrarie, Brisbane. Sitting down and discussing CQPE’s requirements with the Queensland team, Heath viewed a VTC200C vertical machining centre in the field and decided this was the right technology for his company.

The VTC200C features a fixed 2000 x 510mm table with travelling column, removable centre partition, 15kW

Getting to the centre of production

of new Mazak multi-tasking technology, National Hydraulics has been able to increase production efficiency, reduce average job setup time, reduce cycle times, minimise stock in process and reduce job changeover time. The versatility of the Variaxis and its multi tasking capability were stand out factors in Noel’s decision.

Noel commented on the Variaxis "we are now able to machine jobs on five faces in the one setup. The versatility of the machine’s five axes has in some cases cut cycle times in half. Part accuracy has been improved and labour costs have been reduced due to the elimination of the need for loading and unloading between setups. We are also able to continually machine on the separate pallets with the two pallet changer feature."

Noel has also found "the Matrix Controller very user friendly with a larger range of programming options than previously allowed. This has given us much more flexibility in the way we machine our parts. The monitoring options of general running conditions together with the larger display screen certainly make life easier for the operator."

The assistance and ongoing support offered by John Hart was also an important factor in making the investment.

When Noel Bradley took over at National Hydraulics in 1993 he found that there was a lack of locally manufactured hydraulic equipment and saw an opportunity to become a specialised manufacturer in the field.

Located in Nunawading in Melbourne’s east, National Hydraulics was founded with the goal of providing customers with high quality and affordable hydraulic components. The result has been steady growth and the building of a strong reputation for quality and value with customers throughout Australia.

Recently Noel looked at expanding his operations as well as improving his production efficiency. After talking with John Hart engineers about his requirements and viewing machines in the field, Noel decided to invest in a Mazak Variaxis 500-5X-II, fully simultaneous five axis vertical machining centre with Mazatrol Matrix CNC controller.

Utilising a full cradle design that is built into the machine’s structure, the table in the Variaxis 500-5X-II can move 150 degrees in the A axis (movement in the cradle) and 360 degrees in the C axis (table rotation). The machine’s

rigid construction and a 22kW spindle motor also means the Variaxis 500 has plenty of muscle for heavy duty cutting operations.

With the introduction

National Hydraulics has all the angles covered

Shyam Das (JH) and Noel Bradley (Owner) with the VRX 500-5X II

Heath Buckeridge and the VTC200C

Last October saw Mazak unveil an extensive range of new technology at the annual JIMTOF 2006 trade show. One such addition to the Mazak laser range was the new Super Turbo-X Champion hybrid laser cutting system.

Building on the proven capabilities and success of the Super Turbo-X family, the Champion is designed for the affordable, high-speed and high-precision cutting of a wide variety of materials with the ease of set-up and operation that we have come to expect from Mazak.

The machine’s constant beam length allows it to uniformly and accurately cut sheets up to: •11.75mm mild steel •4mm stainless steel •4mm aluminium •2mm brass without changing optics, thus eliminating set-up and downtime.

The revolutionary Takumi closed-box frame is designed to provide outstanding vibration dampening to ensure high accuracy, high-speed cutting with excellent edge quality. High-precision ball screws in all axis of motion create smooth acceleration to assure smooth cutting and high quality finished parts.

A 1200mm x 2400mm work table moves smoothly along the X axis while the patented constant beam length system moves the torch in the Y axis for the optimum cutting with no beam divergence.

Mazak’s PREview 640 CNC, featured on the HyperGear 510 laser drives the Champion through a powerful 64-bit processor featuring "look-ahead" capability to predict and prevent cutting problems.

The Champion offers time and money saving technology to manufacturers through its intelligent controls, modular design, sheer cutting power and affordable price tag.

The new Mazak Super Turbo-X Champion

Laser Central Pty Ltd is a family owned and operated contract laser cutting facility located in the Brisbane suburb of Richlands. Established in 1998, Laser Central’s key capabilities and

activities include flat bed laser processing

of sheet material, metal folding and more recently tubular laser processing of large pipe, structural and long product materials including mild steel, stainless steel and aluminium.

In almost their tenth year of operation, Laser Central’s father and son team of Bob and Rob Newton have enjoyed continual business growth by providing a wide variety of accurate and cost effective job shop solutions to a large customer base.

Broadening their horizons, they travelled to the Euroblech tradeshow in Hanover Germany in 2006 where they witnessed first hand the impressive Mazak FabriGear 300 laser processing machine. They also visited another Mazak FabriGear user in Chicago, as well as Calgary and Saskatoon in Canada prior to making the final decision to purchase the Mazak.

With its unique 5 axis head, 4kW continuous laser output, 300mm cutting diameter with a maximum cutting thickness of 22mm, 12 metre material length capability with auto load and unload, the FabriGear offered the greatest range of processing opportunities on the market. No other laser processing machine offers true 5 axis cutting with a total of 24 controlled axes as the FabriGear does, and with its huge cutting area, Laser Central has a sharp edge on its competition.

The only one of its kind in Australia, Laser Central are now capable of cutting bevelled edges, pipe joints and intersections, true mitre cutting and weld preparations with previously unparalleled accuracy and flexibility. The accuracy with which the FabriGear can process parts and weld preparations has also greatly reduced the time required for further operations such as welding and assembly, and significantly reduced the need for welding jigs due to its ability to process interlocking families of parts that make up an assembly.

The FabriGear also has the ability to directly import solid modelled part files and create cutting programs using the Mazak FG-CAD/CAM software package, giving Laser Central another competitive edge.

The FabriGear 300 was a significant investment for Bob and Rob Newton to make, yet with the assistance and support of John Hart and Mazak, and the proven performance, flexibility and opportunities offered by the Mazak FabriGear 300, the decision now seems easy.

Parts produced on the FG300

Tha Fabri Gear 300 at Laser Central

5 axis cutting head

Big things are happening at Laser Central

Introducing the Super Turbo-X Champion

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Technology on display

AUSTECH Stands - K20 & L20

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Accessories

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Welcome to John Hart’s Austech 2007 stand This year’s stand features:

• 5 latest model Mazak machines demonstrating ‘live’ metal cutting

• Mazatrol Matrix demonstrations on all Mazak machines

• 3 robot demonstrations featuring vision systems and machine tool loading

• New tool measurement and presetting technology from Zoller

• New small Swiss style lathe technology from Citizen

• Accessories from Losma, Renishaw and SMW Autoblok

Features

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Citizen joins John Hart

In April of this year it was announced that John Hart Pty Ltd would be the exclusive agent for Citizen’s Cincom products in Australia. The coming together of these two companies offers customers the advantages of John Hart’s Australia wide network of technical and service support.

Citizen Machinery was founded in 1982 and is a subsidiary of the well known global company Citizen Watch. Based in Nagano Japan, Citizen Machinery produces a comprehensive range of sliding head (Swiss type) lathes ranging in work piece diameter from 10mm up to 42mm.

Designed primarily for high speed and high productivity applications, Cincom machines are world leaders in repetition machinery equipment. For increased capability there is a wide variety of integration and application options available to suite customers needs.

The addition of the Citizen Machinery range complements John Hart’s other world leading brands and offers another manufacturing solution to customers.

Improved productivity can be achieved with the Cincom A20 - ø20mm sliding headstock CNC lathe, which features the latest NC unit along with Citizen’s unique control technique “Streamline Control”. This revolutionary software reduces idle time and part cycle times greatly. The new generation CNC lathe also provides unrivalled cost performance, and real productivity advantages to manufacturers.

The A20 features:

• Heavy duty bed construction• Rigid sleeve holders • Rigid spindle construction • Roller guides on all axes• Convenient control panel layout• PC card slot• Large capacity coolant tank • Coolant tank design that restricts heat

emissions • Left/right symmetrical bed design to handle

thermal expansion• Optional left or right side machine

configuration• Coolant nozzles • Chip compartment • In machine lighting

Cincom A20 right spindle machine

Cincom A20 tool layout John Hart and Cincom partnership signing Cincom L32 VII tool layout

L32 VIIThe Cincom L32 Type VII sliding headstock lathe utilises a “Full servo system” to reduce idle time, power consumption and operating costs. High speed program check functions, threading functions and high speed rigid tapping also reduce cycle times.

The L32 VII is equipped with a higher performance CPU than previous Windows based machines and the user friendly interface makes for easy operation. The modular design of the L32 allows for greater tooling flexibility and for the simultaneous machining on the front and back of the machine due to the separate spindles.

The L32 features:

• Main spindle (1 degree indexing/C indexing control/through hole 36mm)

• Back spindle (1 degree indexing/C indexing control)

• High power live tool motor (1.0KW)

• Maximum no. mountable tools: 20*

• 5 turning tools

• 4 live tool spindles

• 6 ID tools: 6 (3-Front/3-Back)

• 5 back ID tools

*22 is available by mounting the optional 4-ID sleeve

Cincom L32 VII

A20

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Roboguide - Simulation Software

Fixturing for success

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One of our most active areas in JHA&R is in the design, manufacture and commissioning of machine tool fixturing. With an experienced team of specialist designers, project managers and engineers, JHA&R has a strong track record of implementing high quality fixture and process solutions to customers throughout the world.

The reasons for our success:

1. The initial consultation is with the experienced engineers.

2. We study and understand customer’s part holding requirements, including viewing the casting process and identifying key location points.

3. We ensure the chosen tooling supplier “buys in” to the project..

4. We review cutting forces and ensure all selected clamps exceed the minimum required forces.

5. We consider future proofing the design so that the fixture can in future accommodate improved tooling and machines.

6. We model the entire machine envelope and all tooling in 3D CAD.

7. We model the complete fixture in 3D CAD including all hydraulic pipes, air pipes and fittings.

8. We design for easy maintenance including ensuring common screws and fixture accessibility.

9. Where possible all hydraulics are internally ported for ease of assembly and greater swarf control.

10. All aspects of the fixture design including part loading, pre-location, part handling are reviewed by the customer prior to manufacture.

11. We simulate in 3D the part and tool clearances.

12. We simulate all CNC programs, check for collisions and form base programs for commissioning.

13. Our commissioning is performed by experienced machine tool engineers who specialise in part machining, part measurement and project commissioning.

14. We deliver on time and on budget.

As the Australian market continues to suffer from skilled labour shortages and the focus on OH&S grows, customers are coming to John Hart Automation and Robotics to discuss new and more productive Fanuc robot solutions.

A valuable tool that greatly assists the development and demonstration of these solutions is the Fanuc 3D robot simulation package Roboguide. Roboguide is a cost effective software package that enables our engineers to design, prove and program robot systems in real time, either concurrently in a new product design or for making modifications to existing equipment or programs.

Roboguide provides John Hart engineers with the tools needed to develop and test a complete robotic application in a 3D environment without the time and costs associated with developing a prototype work cell.

For customers who are considering automation, Roboguide can quickly and easily provide reliable and accurate information about a given application. This helps in reducing the amount of time taken to design and test a solution, and speeds up the assessment of a project’s viability.

Roboguide can import unique CAD models of process parts and create a virtual work cell which includes machinery, part transfer devices and factory obstacles. Roboguide will then teach robot paths to simulate the operation and performance of the robotic application taking into account the physical obstacles.

Also simulated in Roboguide’s 3D environment is reach verification, collision detection, accurate cycle time estimates and other visual system operations. These functions can be used to produce a simulation video to help evaluate and approve a project.

Whether it is to assist design, simulate, install or commission a robotic system, JHA&R apply these technologies to a wide range of applications in areas such as material handling, machine tending, picking, packing, palletising and material removal.

A complete cell simulated in Roboguide

The components of the above cell simulated in Roboguide

QMN embraces automation for success

The new Fanuc LR Mate 200iC

The latest addition to the Fanuc robot range is the new LR Mate 200iC multi-purpose mini intelligent robot. More than just an upgrade on its predecessor, the LR Mate 200iC features significant enhancements in robot motion performance, size, weight and power supply.

FEATURES:

• A 152% improvement in its cumulative 6 axes motion speed over the former model brings about the best motion performance in its class.

• A 39% reduction in its arm diameter enables the robot to move without interference in a

narrow space.

• The mechanical unit weighs 27kg, 60% lighter than the former model, and the lightest

weight in its class, enabling the robot to be installed inside a machine or easily mounted on the ceiling.

• Robot rigidity essential for quick motion has been increased.

• The slim and highly rigid arm, combined with FANUC’s latest servo technology, results the best motion performance in its class while eliminating vibration.

• The dust and drip proof option (IP67) can be added to protect the robot from water infiltration at a depth of 1 meter for 30 minutes and the robot controller can be sealed and equipped with a dustproof mechanism to prevent the infiltration from outside air.

• The robot’s compact controller R-J3iC Mate offers a wide variety of intelligent capabilities including: Robot link to coordinate motion of multiple robots and collision detection to minimize damage caused by interference.

• The 200iC is now powered by a 220 volt single phase power supply.

Suitable for a wide-range of applications, such as machine tool handling, bin picking, assembly and insertion, the faster, lighter, smaller, and more agile/versatile LR Mate 200iC marks another significant development in intelligent robot technology from Fanuc.

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Historically many people believed that implementing automation systems and particularly robotic solutions was only possible at large organisations. This view has however been disproved by a number of medium sized companies such QMN

Manufacturing.

QMN Manufacturing which is located in

Ayr (QLD) manufactures a wide range of hydraulic cylinders on a number of Mazak CNC machines. In 2004, Managing Director Charlie Quagliata approached John Hart Automation & Robotics (JHA&R) to talk about how robots could be utilised to improve his manufacturing operations.

With a shortage of local labour and the objective of reducing his manufacture costs, JHA&R sat down and worked with Charlie to identify which operations in his factory could be automated.

Since these initial discussions QMN has been able to successfully automate many of their operations. Their first project involved a Fanuc R2000iA/165F which automatically loads blank clevis parts into a Mazak lathe. This use of the robot removed any OH&S issues, achieved consistent up time and was able to work longer hours than previously achieved.

After this initial success QMN looked to their welding

operations where they were able to implement a Fanuc Arc mate 100i to weld cylinders to end caps. Again this installation proved successful with an increase in process productivity and improved part quality.

Their third project utilised a Fanuc R2000iA/165F robot to load a Mazak machine with lengths of tube which are machined into cylinders. Prior to machining the robot measured the tube length and honed the bore. Again this cell proved very successful by increasing process reliability and part quality.

Currently in progress is QMN’s fourth project which utilises a Fanuc R2000iB/165F robot to handle polished bar which is loaded into a Mazak Quick Turn Nexus 250-II machine. The part is measured prior to loading and as polished bar is being used the robot gripper was fitted with special soft jaws to prevent damage during handling.

All four projects at QMN have been designed and installed by JHA&R and have produced significant improvements in product quality and process productivity.

As we all now compete on the world stage, companies like QMN lead the way by embracing the latest technology to help them achieve greater success.

Dimensional comparison between 200iC and 200iB

models (mm)

The Fanuc R2000iB/165F and the Mazak QTN 250-II

Loading the polished bar into the Mazak

In February of this year it was announced that John Hart Pty Ltd will be the exclusive agents for the Zoller range of tool presetters in Australia. Based in Germany, Zoller is the world leader in tool presetter technology. Offering a broad range of tool measurement and integration options, manufacturers can achieve increased machine up time utilising Zoller’s precision products.

Christoph Zoller (General Manager Zoller) and Ian Rehfisch (Managing Director JH) signing

the new partnership

Zoller joins John Hart

ZOLLER - “Venturion”Zoller Venturion is the high-precision presetting and measuring machine that is universally applicable for measuring tooling for CNC production. Ensuring that your CNC tooling is extremely accurate is a cost effective and efficient way of increasing your CNC performance.

Offering significant boosts in productivity, great ease of handling and measurement results to the µm, the Venturion range removes the uncertainty in the accuracy of your CNC tooling.

The Venturion series achieves consistent production through:

• Less time required for training machine operators.• Reduction in work piece scrap as the parts are in

tolerance from the start. • Fewer machine crashes due to automatic zero

point selection.

Other design elements of the Venturion include:• One-handed control button.• Mouse free operation.• Photo-realistic input dialog box . • Graphical user interface.

ZOLLER - “Smile”The Smile series of presetting and measuring machines from Zoller offer an easy, quick and accurate method of measuring a variety of CNC tooling. Based on the larger Venturion range, the compact and versatile base unit and easy to use software makes the Smile especially suited for use in small to medium sized manufacturers as either a bench top device, or standalone unit with base.

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The high precision accuracy of the device offers many benefits to your manufacturing, both in terms of efficiency, production levels, and financial savings.

• Featuring automatic tool cutter recognition, the Smile can measure and test all your tools regardless of whether you are using standardised cutter shapes or special stepped tools.

• The QuickTouch user interface allows for operation without mouse or keyboard.

• Tool management software available on the Smile series allows for measured data to be uploaded onto your machine controller directly.

Technical data: smile 400 smile 500 smile 600Travel distance Z-axis 400 mm 500 mm 600 mmTravel distance X-axis 160 mm 200 mm 200 mm Measuring diameter 320 mm 400 mm 400 mmRepeat accuracy ± 0.002 mm ± 0.002 mm ± 0.002 mmSetting accuracy <5µ <5µ <5µDisplay accuracy 0.001 mm 0.001 mm 0.001 mmConcentric precision 0.005 mm 0.002 mm 0.002 mm Machine weight 800 N 1500 N 1600 N

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Technical data: venturion 400/500 venturion 600...1400Travel distance Z-axis 400/500/600 mm 600/800/1000/1200/1400 mmTravel distance X-axis 160/200 mm 300/460/500 mmMeasuring diameter 320/400 mm 600/920/1000 mm *Repeat accuracy ± 0.002 mm ± 0.002 mmSetting accuracy < 2 µ < 2 µDisplay accuracy 0.001 mm 0.001 mmPositioning accuracy (saturn 2) ± 0.001 mm (saturn 2) ± 0.001 mmConcentric precision 0.002 mm 0.002 mmMachine weight 3500/4800 N 5500-7000 N

*optional also 1400 mm diameter

14 Hartbeat

The John Hart service team has been very active recently with strong investment in service equipment and factory training. As the complexity of machine tool technology increases so does the requirement for our engineers to be up to date with the latest technology. For this reason all of our engineers have received Mazak factory and in-house training.

The goal of John Hart service is to provide value to our customers. If your machine has a problem then our ability to respond in a timely manner to resolve your problem is paramount in maximising your machine up time.

Currently there are some new initiatives being implemented at John Hart to ensure we are continually adding value to the services we offer customers, these include:

• Implementing a new branch customer call log system which tracks when a customer calls and our response time ensuring that timely service is provided.

• A new spare parts stock/restock system has been implemented to prevent part stock outs.

• A new spare parts system has been implemented

to allow us to source parts from any Mazak factory in the world via our Mazak on-line parts system link. This helps minimise the chance of a spare part not being available.

• A new training schedule has been implemented to ensure all service engineers receive Mazak factory training. This ensures a uniform high standard of service throughout Australia.

• We are updating our Electronic Repair Facility capability by investing in new repair equipment to enable us to repair the MDS series of servo and spindle controllers. This new capability will help reduce machine downtime, as repairs will now be performed locally instead of overseas.

• We are investing in a spindle repair facility upgrade to handle Integrex e series spindles, ensuring the larger multi tasking machines have local spindle repair support.

The service relationship between John Hart and Mazak goes back over 44 years and their backing continues to underpin our service capabilities. With a full time onsite Mazak engineer and their continuous support on service and warranty issues, we continue to offer one of the most comprehensive and best trained nationwide service organisations in the country.

Service Training with

ERF testing unit

Mazak service training

Kym Browning – SA State ManagerIt is also with great pleasure that we announce the appointment of one of our long standing employees Kym Browning, to the position of SA State Manager.

Kym has been with John Hart since 1997 where drawing on his background in tool making and CNC operation he began as a mechanical and electrical service engineer, later moving into the applications area.

Kym’s highly regarded technical expertise and professionalism equips him well for his new role.

Glenn Evans – NSW State ManagerIt is with great pleasure that we announce the appointment of Glenn Evans to the position of NSW State Manager.

Glenn is a qualified fitter machinist who has worked in the areas of machine programming, servicing and applications. In the late 1990’s Glenn moved into machine tool sales where has developed a proven track record in the NSW market.

Glenn is well known in the NSW market and brings to the role a real focus, energy and industry experience.

WA Office OpeningWe are excited to announce that our WA office has moved to a new and upgraded Technology Centre in Belmont, Perth. The new facility feature’s a large in-house office area, new showroom area and a service and training facility. The official opening of the new centre is scheduled for later in the year.

Whats new at John Hart

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.

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Victoria11 Winterton Rd

Clayton, 3168Tel: 03 9542 6262Fax: 03 9542 6299

New South WalesUnit 11, 3 Packard Ave

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

QueenslandUnit 6, 16 Metroplex Ave

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

South Australia483 Port RoadCroydon, 5008

Tel: 08 8346 9068Fax: 08 8346 9060

Western AustraliaUnit 2, 32 Robinson Ave

Belmont, 6104Tel: 08 9277 6100Fax: 08 9277 3456

www.johnhart.com.au

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