Newsletter 5/2005

News 2005News 2005

CMS Technology for

WINDOW ANDDOOR FRAMESWINDOW ANDDOOR FRAMES

CMS at the service of manufacturers.

DOMUS

PROFILER

W1

The production of doors and windows is under-going a technological evolution firmly targetedat the finished product competitiveness. Againstthis new background CMS stands out as aprotagonist by marketing extremely innovatorymachining solutions which combine the well-known quality and reliability with state-of-the-arttechnology and attention to the Customers’request.Manufacturers coping with a growing demandfor competitiveness have a new challenge to takeup, which can be summed up in few words:productivity speed-up without increasing staff orenlarging productive plants. The most suitablemeans for achieving this goal are CMS DOMUSand CMS W1, which offer integration andautomation, combined with the traditionalmachining quality and durability, a well-knownfeature of CMS products.

To this day the productive cycle of many doorand window manufacturing companies includedan angular combined station for tenoning andinternal profiling, a machining centre for carryingout hardware recesses and bend profiling, aclamp for assembly and a double-end tenonerfor external profiling of straight assembled doorsand windows.DOMUS is a mobile bridge machining centreequipped with dual independent operating unitand a special work surface provided with mobilerails and vices, both power-driven.

While taking the room of one single machiningcentre, DOMUS combines the functions of anangular combined station, a double-end tenonerand, of course, a machining centre. Targeted formedium and diversified production volumes, itcan carry out internal and external profiling,straight and curved profiling (in plan also),outside profiling, tenon-, counterprofile- andcomb-shaped joints, and shaped recesses forhardware.The marketing research that lead to the devel-opment of this new CMS machining centre hashighlighted that the critical points in a CNCproductive cycle are represented by idle timesin the machining centre setup phases, due toworkpiece/lot change, to tool change and to timeand quality variables deriving from the operator'sunavoidable manual intervention. As a conse-quence, our designing efforts were aimed at mini-mizing both idle times and human interventions,leading to absolutely outstanding results.

The power-driven mobile rails and vices,controlled by a dedicated software, automaticallyform up in the correct position, by following anideal movement sequence, thought-out for accu-rately positioning and locking the workpieceunder machining. The special vices for lockingthe square large panels where the internalprofiling is to be carried out are covered by design

patent and are equipped with a mobile CNC-controlled reference, especially meant for elim-inating manual adjustments. A further advantage offered by DOMUS withregard to other latest-generation integrated solu-tions is given by the width of the useful worksurface, which enables both to machine large-sized workpieces and to carry out outsideprofiling and accessory machining in alternatingcycles of an extremely wide range of variously-sized workpieces, thus further minimizing idletimes. This is also due to the line of actionespoused for the machining centre kinematics:a mobile bridge instead of a mobile workplane,guaranteeing also greater machining quality incomparison with other solutions.As far as the reduction of tool changing timesis concerned, DOMUS provides a substantialcontribution by adopting two independent oper-ating units, which enables to make up for oneunit’s tool change with the simultaneous oper-ation of the other one. Furthermore, the largedimensions of the work surface (at the top ofthe category) can be exploited by loading moreworkpieces together for machining: this expe-dient reduces the number of tool change oper-ations considerably. Finally, in order to furtherreduce the machining centre stops, DOMUS isequipped with capacious tool change magazines(up to 64 usable tools altogether !), which cancontain all necessary tools for manufacture.

In the linear sliding window and door sector(above all in North Europe and North America)a manufacturing philosophy applies that elimi-nates outside profiling and includes the completemachining of single workpieces, which can beassembled without any further finishing opera-tions. W1 provides this market segment witha high technological content, implying manifestadvantages in terms of space and running costreduction.The two ideas where the W1 project started offare quite simple: having a machining centre withthe functionality of two machines and having italways in operation, minimizing machining idletimes; in other words, this means exploiting thefull productive potential of a CNC machiningcentre by making use of technological evolution,that allows to employ multiple and independentoperating units and workpiece load systems. Thiscan be achieved thanks to the computing speedof electronic devices and the rigidity valuesobtainable from mechanic components: a real-ization in the wake of CMS best tradition ofmechanical and processing excellence.

W1 is a state-of-the-art production line basedon a fixed bridge machining centre, on the sidesof which two groups of independent operatingunits are housed. The former is made up of twopower units for profiling, tenoning, counterpro-filing; the latter can be configured according to

DOMUS e W1. CMS unique solutionsfor door and window manufacturers.

one’s productive needs, along with other powerunits, horizontal electrospindles, drilling assem-blies, etc.; both are equipped with extremelylarge tool magazines (up to 120 tools altogether).The two operating groups are coupled with twoindependent and interpolating carriages thatfasten and handle the machinable workpiecesand with a returning mechanism which enablesthe mechanical reintroduction into themachining area of those workpiece sides thatare usually hidden by the clamping devices, thushelping reduce the line overall dimensions. W1is equipped with special (CMS patented) vicestoo; their reference is power driven and CNCcontrolled, for accurate clamping and automatedintervention under all circumstances. The line comes complete with a loader and anunloader, equipped with a feeding unit and abarcode reader; by acknowledging the workpieceto be machined and by automatically running therelated machining program, they limit theoperator’s intervention to merely introducing theraw piece and picking up the processed piece.Another working mode provided for a fully auto-mated operation of the line is the interface withthe plant management operating system.

Under normal working conditions, W1 machinesthe workpiece handled by a carriage with onegroup of operating units and at the same timemachines another workpiece handled by theother carriage with another group of operatingunits, achieving the goal of combining the func-tionality of two machining centres into one.Similarly to DOMUS, also the multiple operatingunits of W1 enable to mask the tool changesof one unit with the work of the other one, thusminimizing times in which the workpiece is notbeing machined. This results in a considerable productivity raise,combined with total flexibility and small spaces:W1 can produce up to 50 12-piece windowsduring an 8-hour shift in a fully automated mode,even in case of single batches, starting fromthe square large panels and occupying 140square meter space.

Because of its features, W1 can be suitablyemployed also beyond the pre-finished manufac-turing field, in combination with CMS PROFILER(another innovatory fully-automated CMS line thatwas marketed towards the end of 2003), amachine designed for outside profiling.

Together with its new window-oriented products,CMS puts at the Customer’s disposal all of its30-year-old experience and a highly specializedteam of engineers, who are able to assist theCustomer as early as during the business defi-nition phase of the supply, in the choice, config-uration and subsequent management of thesolution that is best suited for reaching theirmanufacturing goals.

Product news

Product news

Product news

An outright rediscover of wood usage for thestructural parts of private and public build-ings has taken place for several years now. The beauty of the material is the main reasonfor this phenomenon: wood offers interestinghints to designers and architects, as it isnatural, alive and ecological. It also has unsuspected qualities of timedurability. Finally, it is more and more suitablefor the industrial machining opportunitiesoffered by numerically controlled machiningcentres.

In the background of a strong developmentof machining centres for the manufacturingof beams, CMS stands out as an old-estab-lished partner for the field operators and isin a position today to put at its Customers’disposal its new SUPREMA machiningcentre. The novelties proposed by thismachinery are maximum machining flexibility,in order to meet the most sophisticatedplanning requirements, and top qualityfinishing, typically a CMS characteristic, thatresults in a superior aesthetic return on thefinished product.

The guidelines determining the designingfeatures of CMS SUPREMA have been :offering maximum freedom in the machiningof workpieces, guaranteeing high tool powerand minimizing both machining idle times andhuman attendance to the machining centre.

CMS SUPREMA is a 5-axis machining centrewith a fixed bridge structure ; it is equippedwith two independent operating units: a TUCU,CMS' traditional double twist head, and aninnovatory RX4, which combines a 5-axis head

flexibility with a tool change speed to be typi-cally found in a revolver system. The extremely wide machining strokes enablethe operating units to machine workpiecesfeaturing sections from 45x45 mm to330x650 mm with the maximum movementfreedom. The double twist operating unit isequipped with a large-sized connection – HSK80/B, the highest offer in today’s market -suitable for transmitting the full 12 kW deliv-ered by an electrospindle at 2000 rpm to aØ 800 mm blade.

A specific tool change magazine has beendesigned for housing another mono-flangeØ 500 mm blade too, to be used for multiplepass end-butting, in order to enable the bladeface opposite the motor to come in fullcontact with the workpiece being machined.

The second independent RX4 operating unitis a double twist head equipped with a4-position revolver which can house 4 elec-trospindles, configurable according to one’sproductive needs and usually devoted tomilling operations. To house the tools neces-sary for other drilling and milling operations,SUPREMA is also equipped with tool changemagazines featuring up to 14 positions alto-gether; they can house 600 mm long bits anda chain aggregate with a 450 mm usefulcutting feature.

Tool changing times, already extremely shortwith the revolver unit, are further minimizedby alternatively using two operating units,which enables to mask one unit's tool changewith the other unit’s simultaneous operation.This technique is made possible by the inde-

CMS novelties for themachining of linear beams.

pendent operating units and maximizes themachining centre productivity, while mini-mizing idle times.

The operating units are supported by anextremely sturdy crosspiece, featuringsection dimensions that are unparalleledamong the machining centres in this marketsector. The same can be claimed also for theother structural parts of the machining centre,to the advantage of machining speed andquality as well as of reliability and durabilityof the machinery, which is designed for day-to-day heavy-duty removal operations. Finally,a perimetric cab around the work area anda mat for removing chips and trimmingscontribute to the abatement of dust and noiseand to the keeping of the machining and envi-ronmental cleanliness.

The workpiece movement is guaranteed bymeans of 4 clamping devices on independentand interpolating carriages, driven by apowerful motor – capable of reaching a speedof 100 m/1' with full load rapid mode oper-ations – which helps to ensure high qualitymachining. A lateral overturning system in theloading area has been designed foravoiding any possible damage to the work-piece and guarantees the machinability of allthe beam faces. The clamping force exertedby the system – about 250 kg at 6 bar –enables to operate on the workpiece with ahigh power and at the same time to coun-teract the effects of warping – to be oftenfound with long beams - thanks also to thespecial designing geometry.

Mainly designed for linear beam machining,SUPREMA proves also a very versatilemachining centre : in fact it is possible toassemble a series of vacuum suction tableson the clamping device carriages for a totalsurface of 12x3 m in order to be able tomachine prefabricated house walls andcurved laminated wood joists.

The maximum overall dimensions of machin-able workpieces are sizeable: SUPREMA canmanufacture beams as long as 12 m withoutworkpiece recovery, or up to 18 m withrecovery cycle. The workpiece load/unloadmanagement is completely automated bymeans of systems installed on the machinesides, with the possibility to carry out a lasercontrol of the machinable workpiece lengthduring the load phase.

SUPREMA comes with a software applicationthat imports and processes programs fromthe main CADs for the design of marketableroofs and beams, thus controlling the wholemachining process ideally.

Product news

CMS Technology for

DOORSDOORS

CMS at the service of manufacturers.

CMS Technology for

STAIRCASESSTAIRCASES

CMS at the service of manufacturers.

CMS – an Italian manufacturer of CNC machiningcentres – has recently disclosed to the press thatit has reached an agreement with the French groupBénéteau-Jeanneau – word leader in the produc-tion of pleasure boating – for the supply of large-sized Poseidon series machining centres to beemployed in the finishing of fibreglass hulls, decks,accessories and components.

The boating industry has gone through a periodof technological innovation in these years, due tothe industrial restructuring of complete productivecycles, which were once carried out manually andare now performed by CNC machining centres. Thisleads to a considerable reduction of productiontimes, along with the substantial qualitativeimprovement of products and work environment.

CMS stands out as a promoter and an activeprotagonist of this industrial renovation: it manu-factures machining centres that combine hugemachinable volumes with absolutely outstandingrepeatability and accuracy standards, consideringthe dimensions of such machinery; CMS is alsoengaged in a constant effort of technologicalresearch, by running machining tests in collabo-ration with the best-known manufacturers of indus-trial materials; finally, CMS boasts a first-ratecustomer service, in a position to offer itsCustomers the whole body of technical expertisein the field built up in over thirty years’ outstandingactivity, aimed at optimizing the use of machiningcentres and facilitating the transition from tradi-tional manufacturing methods to mechanizedmanufacturing.

In collaboration with CMS, world-wide famous ship-yards such as Azimut, Ferretti, Intermarine(Rodriguez Group) and Numarine have started outon this innovatory course, which proves absolutelynecessary today for the preservation of excellencewithin a globalized market.

In these years CMS has already been supplyingthe Bénéteau-Jeanneau group with machiningcentres for the nesting cut of structural parts andmarine multilayer panels for interior fittings: theFrench group’s direct experience of the commit-ment and the spirit lavished by CMS on theCustomers’ service was just one of the manyimportant factors that prompted their decision tostart this new collaboration.

The technical specifications of CMS productscomplete the picture: a mobile bridge structureand a machinable cube of 18x6x3 m, so as toenable the easy positioning and the uninterruptedmachining of large-sized workpieces; a telescopicZ carriage, that guarantees great rigidity also inthe presence of wide axis strokes and minimizesthe overall height dimensions of the machiningcentre; a 5-axis operating unit equipped with acontinuous duty 12 kW electrospindle, in order toprovide power and freedom of space movementas required by the workpiece materials and geome-tries; magazines that can house up to 40 tools,with possibility of tool extraction outside themachining area, in order to minimize machine stopsdue to retooling or tool sharpening. Fibreglass boat parts to be machined are char-acterized by large dimensions and irregular highthickness, owing to prior manual rolling. Machining

CMS and Bénéteau-Jeanneau group:a partnership for the technologicalinnovation of the boating industry.

consists of finishing outer edges and drilling holesand windows into other parts before assembly.A 5-axis quality cut requires accuracy and repeata-bility, which can be obtained thanks to the rigidityof the machining centre structural parts, combinedwith spindle power, which must be available overa wide rotation speed range, in order to optimizethe use of blades and small-diameter tools. Wecan proudly state that CMS Poseidon – a 5-axismachining centre especially designed for HighSpeed Cutting of large-sized workpieces – fullysatisfies all necessary requirements.

An unforeseeable variable, that the system mustbe able to cope with, is represented by the randomdeformation of workpieces due to the materialdimensions and nature, which make the actualgeometry of the machinable workpiece differentfrom the nominal geometry. The solution adoptedby CMS – decisive for achieving the highest levelof plant productivity – considers a laser examina-tion of the workpiece, therefore involving the useof intelligent algorithms for the recognition of thegeometric variations and the ensuing self-adjust-ment of machining programs. Finally, for ensuringthe best utilization of the software – realized incollaboration with DELCAM, an English multina-tional corporation – and the optimization of thewhole process,CMS has provided instructions andsupport in order to perfect the ideal systems forlocking and centering the workpieces on themachining carriages.

The astounding mix of technology, skills and expe-rience offered by CMS has turned out to be winningonce again, while the partnership with Bénéteau-Jeanneau is bound to go a long way: the consign-ment of other large-sized machining centres to theFrench group is under consideration for themachining of boat hulls, decks and accessories.

Case history

Case history

CMS Technology for

CHAIRS ANDBENT PARTSCHAIRS ANDBENT PARTS

CMS at the service of manufacturers.

Present-day companies operating in the auto-motive field are constantly searching for grea-ter efficiency and fewer unit costs per pro-duct, along with higher aesthetic and functio-nal qualities, as they are strongly urged by aworldwide competition that compels car-ma-kers to continuously fine-tune and updatetheir development plans.

The automotive market is certainly a maturemarket, characterized by almost standardizedand well-established corporate processes,where technological solutions seem to be gi-ven for granted at first glance. However, the-re is an urgent need to overcome current sta-te-of-the-art performance levels, expressedabove all by European manufacturers, whoare engaged in a daily competition with newproductive realities from Eastern Europe andthe Far East, which appear invincible from thelabour cost viewpoint. At the same time, Eu-ropean manufacturers must cope with thegrowing demand for fewer unit costs per pro-duct together with higher and higher qualitylevel requirements from the end-users.

The technological update of a well-establis-hed process requires strong collaborationbetween leading companies who are stronglymotivated to dispute their own policies andto invest resources in the stubborn pursuit ofsuccess. This is exactly the path taken byCMS – a Bergamasque manufacturer emplo-ying more than 400 workers, operating in thefield of numerically controlled machining cen-tres and world-wide known for its thirty-year-long production of advanced solutions – andan important supplier of a well-know Italiancar-maker. Together they have examined thecurrent production of foamed PVC car dash-boards and have successfully elaborated ahighly innovatory solution for the cutting andtrimming phase.

This is how CMS THESIS 2 TU2 was desi-gned, a numerically controlled machiningcentre equipped with two 5-axis fully inde-pendent operating units, able to machine thesame workpiece simultaneously. THESIS 2TU2 can guarantee an extremely high finis-hing quality as well as offer maximum toolingflexibility; at the same time, it can also mini-mize machining times, idle times and humanattendance to the machine. Moreover, fur-ther advantages are to be emphasized. Theycan be summed up by stating that, thanks toits unique features, this machining centrepractically replaces and improves the func-tionality of two co-ordinated cutting systems,with astounding results in terms of reductionof productive spaces, containment of semi-fi-nished warehousing and less need of work-piece handling.

Present-day dashboards, as typically seen in-side our cars, are car components characte-rized by a high technology content, conside-ring both the component materials and fromthe processes involved in the manufacturingof these finished products.

The state of the art in the machining of cardashboards currently involves a combinedprocess of shearing/punching and millingoperations. Indeed, in order to break up ope-nings for dashboards, air nozzles and car ra-dio/navigator, very stiff mechanical shearsare to be used, especially dedicated to thecar model involved ; for geometric and di-mensional reasons, such operations cannotbe completed by shearing machines, whichtherefore must be integrated by anthropomor-phic robots to be employed for final cuttingand trimming operations.It is a two- or multi-step process then, impl-ying workpiece repositioning on different jigfixtures, different machinery, handling logi-stics and finally an unavoidable operationalcomplexity.

Greater problems are connected with techno-logy itself though. A shearing machine, evenif offering undeniable simplicity and sturdi-ness factors, is an expensive equipment, asit is rigid and specifically dedicated, thus dif-ficult to be reconverted to new product mo-dels. Anthropomorphic robots, that aremeant for controlling the system, positioning,assembling and varnishing – when used forcarrying out cutting operations reveal a se-ries of remarkable structural limits : themany joint points and the arm length noti-ceably decrease the comprehensive system

New CMS technology for thefinishing of car dashboards.

rigidity, that is to say, the ability to operate onthe workpiece with a given cutting strength,while keeping the preset trajectory withoutdeviations. This implies negative consequen-ces on the quality of the finished product,which almost invariably must be recoveredand hand-finished by the operator, if not re-jected.

The logical solution that the market could of-fer for overcoming the current technologicallimits is perhaps a CNC machining centreequipped with a 5-axis operating unit. Thissolution entails another series of problemsthough: even by taking performance to extre-mes, this machining centre could not ensurethe productivity levels that car makers intendto achieve. Just think of speed, which cannotbe exceeded for quality cuts when operatingwith one only tool on foam materials.

Hence the idea of a machining centre equip-ped with two independent operating units, atechnological solution adopted and managedby CMS for years, that can make full use ofthe computing speed and capacities offeredby present-day electronics.

The mechanical structure of THESIS 2 TU2consists of a mobile bridge with a dual inde-pendent crosspiece, which can effortlesslyhold the weight of the twin operating units. Its« full digital » axes provide the two twin-cams-haft electrospindles, equipped with 2 toolseach and a maximum revolution speed of40,000 rpm, with absolutely outstanding acce-leration values ( 5 m/s2). In combination witha dynamic control system of the tool stress,obtained by automatically setting the optimum

Case history

Case history

feed speed in real time, it is thus possible tocarry out very quick, accurate and high-qualitymachining operations at any one time.

An outstanding characteristic of THESIS 2TU2 is given by the overturning table loadsystem, which enables to carry out the work-piece load/unload operations while the ma-chining centre is still operating, with a consi-derable advantage for the system productivityand in total safety conditions for the opera-tor, thanks to the complete isolation of thework area from the load/unload area.

Special attention has been dedicated to ma-king this machining centre as user-friendly aspossible : programming takes place by digiti-zing a 3D model, a very simple and naturalsystem indeed, and can be carried out di-rectly onboard or outboard the machiningcentre, by using an ad hoc measuring arm,especially designed by CMS for this type ofapplications, with the further advantage ofoptimizing the plant productive time. Pro-gramming simplicity turns out in a reduced ti-me-to-market, thanks also to the greater in-trinsic flexibility of the machining centre withrespect to the traditional system.

After being put into production, THESIS 2 TU2exceeded our best expectations : it was pos-sible to verify that one single system is ableto accomplish all opening/cutting/trimmingoperations that until nowadays have reque-sted the combined use of a shearing machi-ne and anthropomorphic robots, offering aclearly superior cutting quality, comparable tothe cutting quality of a single shearing machi-ne, but taking less time and simplifying theproduction logistics.

The project success is witnessed by the deli-very of a third installation that CMS is carr-ying out as of April 2005.

CMS Technology for

GUNSTOCKS ANDCARVED PARTS

GUNSTOCKS ANDCARVED PARTS

Along with its products, CMS puts at the Customers’ disposal all its more than thirty-year-old experience and a highly qualified technical staff, in a position to help theCustomer to make the right choice, configure and then manage the machining solutionthat proves more suitable for reaching one's productive targets, right from the supplysettlement phase.

Case history

Case history

CMS at the service of manufacturers.

CMS Technology for

NESTED PANELSNESTED PANELS

CMS at the service of manufacturers.

C.M.S. SpA - Wood Division 24019 Zogno (Bg) Italy - via A. Locatelli 49

Tel. +39 0345 64 270 - Fax +39 0345 64 280www.cms.it - wood@cms.it

C.M.S. SpA - Wood Division 24019 Zogno (Bg) Italy - via A. Locatelli 49

Tel. +39 0345 64 270 - Fax +39 0345 64 280www.cms.it - wood@cms.it

CMS has been at theCustomer's service since 1969.

CMS has been at theCustomer's service since 1969.

The first CNC Machining Centreproduced by CMS, still working.