The time required to complete an order plays a crucial role in determining overall productivity. Modern navigation systems can significantly cut down on non-productive downtime, helping operators focus more on actual production rather than machine management. As market competition intensifies, manufacturers must adapt quickly to stay ahead. With product diversity increasing, technology evolving rapidly, and product life cycles shortening, companies are under constant pressure to optimize their operations. Longer preparation times and frequent process changes further complicate the situation, making efficiency even more critical.
Stama Machine Tool Co., Ltd. in Schlierbach offers vertical machining centers along with comprehensive "turnkey" solutions. Previously, the "key-in-the-lock" program included not only the creation of jigs and tools but also full process technology support. Moving forward, minimizing downtime will rely on shorter product life cycles, smaller production batches, and advanced equipment. Off-road systems for machine tools can dramatically boost productivity by enabling faster tool changes and smoother transitions between tasks.
Smart clamping tools play a key role in streamlining the setup process. Standardization is essential for efficiently preparing and loading workpieces. Tools like face mills, reamers, and thread drills can be stored in the machine’s tool magazine. However, removing unnecessary tools or adding new ones can take valuable time. A longer engagement time for tools can lead to delays, as even high-performance magazines may struggle to provide the next tool quickly enough. This results in extra, unproductive time that hinders efficiency.
Manually sorting and loading tools into the magazine has its drawbacks. It often requires moving existing tools out of the way, and it's easy to misplace critical tools. The Stama Navigation System solves this by automatically sorting tools based on the program sequence. It uses the first part of the program to allocate storage space, then follows the sequence to ensure the right tools are ready when needed. When a tool reaches the end of its life, the system automatically replaces it with the appropriate backup. If multiple programs need the same tool at once, the system can manage the sequence to minimize setup time. This reduces downtime, which is directly linked to the number of tools being changed.
Modern processing techniques allow the machine to insert the next tool while still performing the current operation. This "fastest" tool magazine doesn’t depend on traditional NC programs and can hold additional tools during the main process (see Figure 1). Even when switching programs or changing fixtures, the machine can still retrieve the necessary tool automatically. This enables quick part family changes and process switches without requiring an operator to be present, ensuring minimal downtime.
The "fastest" magazine also includes statistical software that tracks tool usage frequency. It prioritizes using the least frequently used tools to clear the main magazine, reducing fixture time by up to 70%. In stable manufacturing environments, optimizing tool handling is vital for increasing output, cutting delivery times, and lowering per-unit costs. Reducing the likelihood of part failures and minimizing the time it takes to restart after an interruption are equally important.
Dynamic navigation systems that can return to the system’s starting point are essential for efficient maintenance and error recovery. In the past, machine maintainability and quick component replacement were key, but modern systems must also account for how the machine operates when it starts. If a tool gets stuck or causes interference, production must halt immediately, which can have serious consequences. For example, if a drill bit becomes jammed in a threaded hole, the clamping device must be released, and the machine must be reset in the Z-axis. Manual attempts to remove a stuck tool can damage the spindle, leading to costly downtime.
To prevent such issues, a navigation system that can reset the tool to a safe initial position is crucial. Specialized machines require unique processes and tools, so each NC program must include a retract function. The patented "Stama Initial Position Program (HPP)" ensures the machine navigates safely back to a known position, avoiding collisions and keeping the workspace clear. Operators simply press the "HPP" button (see Figure 2) to initiate a fast, reliable reset. This feature is especially useful during power outages or unexpected stops.
Event monitoring systems help identify and resolve the root causes of production interruptions. While modern CNC systems can log errors, many sporadic issues go unnoticed. For instance, fluctuations in compressed air pressure or minor leaks in the clamping system can cause problems that are hard to detect. The "Slama Event Monitoring" function uses statistical data to trace the source of these issues, helping operators address them before they escalate.
A three-level navigation system guides operators through the troubleshooting process. It maintains a non-erasable memory of the machine’s status from the start-up phase, allowing comparisons between historical and current events. This helps analyze failure patterns over specific periods, enabling proactive maintenance. By identifying potential issues early, companies can reduce unplanned downtime and improve overall efficiency.
Finally, navigation systems help eliminate non-productive auxiliary time. Unlike car navigation, machine tool systems use numerical control to guide the operator automatically. These systems are effective for both tool selection and collision-free idling, preventing costly mistakes and reducing unproductive time without increasing the machine’s load. Overall, intelligent navigation enhances productivity, reduces manual effort, and supports smooth, efficient manufacturing processes.
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