High Tech Increases Efficiency in Tough Jobs

This modular automated robotic fixture-plate system competes in general machining markets by increasing machine and labor efficiencies when boring and milling tough and hard materials in high product mix, low volume production runs.

The MMC-R modular automation system from Makino Inc. (Mason, OH) provides robotic fixture-plate distribution in 4- and 5-axis horizontal and vertical machining centers and is perfectly suited for high-product-mix, low-volume production runs, enabling shops to increase spindle utilization up to 95 percent and reduce setup limes through accurate and reliable machine loading, unloading and part storage.

Designed for flexibility, the MMC-R accommodates a wide variety of customized configurations for simple shop-floor integration and improved utilization of capital assets. These systems are typically composed of 4- and/or 5-axis horizontal and vertical machining centers, a 6-axis robot transport, work-setting station(s), fixture-plate storage rack(s) and fixture plates. An optional 7th-axis floor track can be integrated into the MMC-R to support additional machining and storage capacities.

When integrated and installed, the modular automated material handling system links Makino horizontal machining centers, pallet loaders and operators. The servo-controlled vehicle transports material to and from machines with little, if any, operator intervention. Each system is completely flexible and can be designed for a facility using standard components. Its modular flexibility permits future expansion as needed.

The a81M horizontal machining center is a good example of the wide variety of Makino machining centers that can be integrated into this system. It is designed for machining tough and hard materials and is ideally suited for large diameter boring and face milling on such challenging materials as stainless steel, titanium, titanium alloys, Inconel, ductile iron, cast iron and CGI (compacted graphite iron). The unique, high-torque and high-thrust spindle on this machine provides unparalleled productivity and reliability for a system of this type, which helps reduce costs in manufacturing operations. It has a quick tool-to-tool time of only 1.7 sec, with a similarly brisk chip-to-chip time of 4.2 sec.

The a81M has significant application in general machining and production machining. Such specific industries as aerospace, diesel engine, construction equipment, oil field components and pump and compressor manufacturing will all benefit from this machine tool. The a81M is particularly suited for long reach and large diameter boring operations which require a great deal of torque, particularly at low rpm. For applications such as tapping, where a significant amount of spindle stopping, starting and reversal occurs, its high-torque spindle is significantly faster and has less idle time.

The integral drive spindle of the a81 greatly outperforms all other spindles on the market due to the nature of its efficient design, which provides significantly higher torque at a low rpm. This proprietary design combines the optimum blend of speed and superior rigidity necessary to take aggressive cuts. Other high torque spindles utilize a geared-type head that intrinsically causes a loss of significant power and further drops spindle efficiency, which can slow down the spindle performance and adversely affect cycle times. The built-in motor method used in the a81M also provides an advantage against vibration as compared with the gear-type.