KV Automation
Triag clamping system at the heart of pneumatic Kanban manufacturing philosophy
As an established manufacturer of pneumatic components, KV Automation Systems ensures that all products are manufactured to the highest quality. At the heart of manufacture is a cell-based production environment that utilises the reliability and repeatability of the Triag workholding system.
'Having implemented TQM in December 1996, we are constantly striving to improve the working relationships with our customers, working with them to find a personalised solution to every Pneumatic problem. This requires a flexible, mixed batch production system.' Stated Senior Production Engineer, Steve Brown.
'We operate a modern Kanban manufacturing method,' added Brown, 'with well organised working areas improving efficiency and lowering costs. We also utilise a roll-over production method on four twin-pallet HG Series Hitachi Vertical Machining Centres(VMC), and three Bridgeport VMCs, all fitted with the Triag modular workholding system, condensing six operations into a single set-up by eliminating tool change times, set-up times etc.'
'Having put our faith in the Triag system, we have never found a system that can rival it,' added Brown. 'The majority of core products are manufactured here at the company headquarters in Milton Keynes, and the Triag system has been instrumental in reducing lead times. In principle, with a unit of six parts, if you put in a raw billet you get out a finished unit. If the 'chaser' needs a quantity of finished units to suit the customers' needs then at the end of every cycle, that's exactly what you get. As opposed to operations of 10 -, 20-, 30-, 40-, 50-, 60-off where you have set-up times of each individual operation which could see a unit produced in three weeks time against a set-up time plus a cycle time run of 12 hours giving you two finished units, with subsequent units in two's produced every twenty minutes.'
A typical machining operation for a manifold and sub-base will see selected designs in 3D CAD files received and tool paths calculated, downloaded at the machine - full DNC linking is planned. Aluminium manifolds & sub-bases need to accommodate an infinite number of valves, and carry mounting via through-holes in the body. A pneumatic unit set-up on a Hitachi twin pallet VMC will see the machining of round, square, rectangular and a variety of other shapes and sizes held in Triag units. 'It is critical that the components, regardless of shape and size, are clamped tight in order to ensure repeatable accuracy.' added Brown 'A Hitachi probe will calculate tool lengths and set the workpiece offsets by referencing the Triag rail before drilling, tapping, interpolating, milling, thread-milling, boring & counterboring to tolerances as tight as 20 microns but typically +/- 0.5mm
The Triag rail systems, available in a variety of widths from 19mm to 100mm, allow flexibility in all three axes and offers the highest workpiece density per given machine envelope. High precision component location is based on the vernier effect allowing positioning increments of 2.5mm. Every vice module has a double function. The front side clamps the workpiece by means of a downward force being exacted by the moving jaw, giving a clamping force of two tonnes. The rear side of the vice module provides a datum face for the next workpiece with exact reference to program zero. Consequently workpiece's never have to be clamped in a mirror image as is necessary on double vice systems with fixed jaws.'
'Having seen the benefits of the Triag system, I am looking to adapt other machining operations to embrace it. Smaller runs of fewer components are run on both the Bridgeport's and some ageing Hartford VMCs without failing to achieve the required repeatable accuracy. However, on our longer runs I am looking to set the Triag system up on an Erowa UPC pallet which will carry a known reference and allow us to simply place the job up on the Hitachi High Speed VMC when needs dictate, and run the stored program..' concluded Steve Brown
Dec 2003
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