Quantum leap in edging – laserTec for CNC processing centres
Laser edging is evolving as an all-round success, as HOMAG once again provides irrefutable evidence of its technological leadership: by equipping its CNC processing centres with laserTec, HOMAG is consistently transferring the quantum leap it has already achieved in edging joint quality for straight-edged components also to shaped parts.
Over recent months, several processing centres equipped with laserTec have been sold and an optimum degree of process reliability achieved. No matter whether stationary or throughfeed technology is involved, now almost any material can be simply and reliably processed with a zero joint. This innovation has allowed all kinds of workpieces to be produced with the same attractive appearance and outstanding edge quality – no matter what their shape. Whether table tops or shop fronts, work tops or kitchen cupboard doors, whether roller shutter cabinet side elements or shelves for caravans – HOMAG offers its customers cohesively perfect edges across the board.
The appearance and quality of furniture items boasting the “zero joint” is recommendation enough – but these are not their only benefits: Process reliability, machine availability, the reduced complexity of cleaning work and energy consumption are all factors which have benefited significantly as a result of the laserTec method. Edge banding using stationary technology is being perfected all the time, and manual intervention to reset the gluing unit is no longer required. The work once involved in monitoring, maintaining and cleaning the glue tank and the application unit is now a thing of the past. And the elimination of glue means no more time wasted waiting for glue to heat up. As a solution, the laserTec method is not only smart but also efficient. Compared to traditional methods, it reduces energy consumption by around 20%.
Not just the gluing technology but also the machine platform is new. With laserTec, this is the first time that HOMAG has exhibited the use of gluing technology on the BMG 500 machine series. The moving gantry design and the vibration-damping base material SORB TECH provide the ideal basis for perfect edge preparation and finish processing – an essential prerequisite for achieving optimum quality with laserTec.
Independently operating Y axes ensure high output. While the trimming spindle is operating, for instance, the gluing unit is already inserting the next edge. But the moving gantry design has another important benefit to offer: Because the edging magazine and gluing unit are mounted at the front on the operator side, edge changeover and monitoring can be performed with maximum efficiency and minimum strain for operating staff.
KBE 100 – self-produced pre-coated edges for laserTec
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Producers with ambitions to get involved in edge pre-coating will appreciate the benefits of the new HOMAG KBE 100. This machine ideally prepares edging material for subsequent processing using the laserTec process, coating conventional edges using a specially developed function layer. This allows even thin edging materials to be prepared for processing with laserTec. The machine is ideal for use in the entry level range for edging quantities of up to 2000 metres, as the availability of laser edges is not yet extensively guaranteed throughout the world market. |
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And in the field of edging materials for processing, HOMAG provided still further proof of the importance it attaches to technology and progress. Practically all materials can now be processed with zero joints for an outstanding joint quality. This innovation lends every workpiece the same exemplary standard of edge quality: No matter what the edging material used, HOMAG offers perfect quality across the board for its customers.
THROUGHFEED TECHNOLOGY
K 350 series – entry into a whole new world of flexible production
One of the highlights at this year’s Ligna was the K 350 series, designed to open up flexible production right down to batch size one, primarily with the entry level users in mind. An outstanding workpiece transport system engineered for optimum running noise and workpiece guidance ensures the best possible standard of processing quality. The series combines all the important features of the high-tech machine series and is ideally suited as stepping stone into the world of flexible production. Just like its bigger sister, the K 600 series, the K 350 series comes complete with a rolling block link chain designed to minimize chain running noise. An additional polygon compensation function reinforces the effect of the smooth running chain, substantially reducing wear. The machines of the K 350 series are also fitted with workpiece guides which guarantee precise dimensional and angular positioning. Scope for free equipment with processing units and a durable, torsion-resistant machine frame offer a range of additional benefits. Workpieces are transported with pinpoint precision and absolute dimensional and repeat accuracy. The improved chip and waste piece disposal facility in the sizing section makes for improved machine availability and a longer service life.
flexTrim & powerTrim: Productivity increases of up to 50 %
flexTrim – flexible profile changeover for two profiles
The principle is a simple one: Few profiles, short resetting times, increased productivity – from the woodworking shop through to the industrial manufacturer. Maximum flexibility and a minimal error quota for trimming operations – these are only two of the benefits provided by HOMAG’s new flexTrim development.
With its new flexTrim processing unit, HOMAG has laid another major milestone in the field of batch size 1 production. The operating error quota is substantially lower than when using comparable products. Primarily responsible for this is the facility for rapid tool displacement in the unit, and the structure of the trimming head. The head is fitted with two differently sized profiles (such as R2 and R3). These are arranged one inside the other, with the larger radius or profile trimming tool permanently fixed in place. The smaller trimming tool is set back and can be automatically pushed forwards as required. This means that automatic resetting between the two radii and different chamfers is possible within a workpiece gap of just 400 mm.
flexTrim is suitable both for use in 4-motor contour trimming units and also for 2-motor contour and profile trimming units. The new technology represents a number of major milestones in terms of precision, time savings and flexibility. Used in combination with the new profile scraper blade flexBlade for faster exchange between two profiles during trimming and profile processing operations, the flexTrim offers unbeatable benefits – particularly for batch size 1 production.
powerTrim contour trimming – around 50 % faster for flexible furniture production
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powerTrim (three profiles) represents a consistent further development of the flexTrim (two profiles), and will be showcased at this year’s LIGNA in conjunction with the new K350 using the following units:
- Multi trimming unit with servo adjusting motors for trimming work from above and below
- Profile trimming unit powerTrim for corner rounding
- Multi scraper blade with servo adjusting motor for workpiece finish processing
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When using these three units on machines of the K350 series, flexible production can be achieved with three different profiles and chamfers at an infeed of 30 m/min alongside profile changing within a resetting gap of 400 mm. When the units are used on other machines it is possible to realize infeeds of 50 m/min leading to a productivity increase of 50% in comparison to solutions usual in the market.
Using these 3 units in combination, flexible production can be achieved with three different profiles and chamfer at an output of 30 m/min, alongside profile changing within a resetting gap of just 400 mm. All these benefits add up to a productivity increase of around 50% compared to conventional solutions available on the market.
KFL 520 combination machine
The KFL 520 combination machine sets the performance standard in edge processing, with feed rates of 50 m/min for longitudinal and 30 m/min for transverse processing. With these performance levels, HOMAG covers every conceivable series production requirement, as well as demonstrating exemplary energy efficiency, with energy cost cuttings of up to 30% possible in series operation. At the show, the KFL 520 was demonstrated operating in tandem with a WEEKE BST 800 for high-speed drilling technology and transverse throughfeed.
New KAL 211 edition series – edge banding machines for cabinet shops and industry
HOMAG developed its new KAL 211 edition range specifically for the woodworking shop sector and also as an entry level machine for industrial producers. At the LIGNA, there were three different models from the series on show – all working in conjunction with the gantry return conveyor ZHR 500 from LIGMATECH.
With a seamless portfolio from the smallest edge bander to the high-performance edge banding machine with extreme technical flexibility and fully automatic resetting, this series covers the entire spectrum from the woodworking shop to the industrial manufacturer. Fitted with units taken from the industrial sector, this machine promises the guarantee of a long service life coupled with a consistently high standard of quality – and all with a highly affordable price tag of below 100,000 EURO. One of the highlights of this machine is the newly developed QA 65 gluing unit from HOMAG, which represents the culmination of 50 years of expertise in edge banding with added new features such as a short heating-up time and a high melting output.
The PC22 powerControl system also permits user-oriented, graphically supported touchscreen machine operation. laserTec technology can also be used or retrofitted without problems on almost all the machines.
Flooring production: RANDOM LENGTH
Working in association with TORWEGGE, a jointly developed double-end tenoner line with the name RANDOM LENGTH has been produced for the transverse processing of multiple layer parquet. In a similar way to solid parquet, this machine concept allows all the workpieces to have random different lengths. This development allows even small-scale suppliers to cost-effectively produce multiple-layer parquet with click profiles and random lengths while ensuring optimum material utilization. The machine was developed on the basis of the 260 series, and so closes a still remaining gap in the broad HOMAG Group double-end tenoner range. The plant is capable of processing up to 100 workpieces per minute using up to 8 motor units. Because of the single-sided concept with integrated offsetting station, no losses whatever are incurred during resetting when changing between dimensions.
STATIONARY TECHNOLOGY
World premiere Venture 316: 5-axis technology for all
HOMAG unveiled a totally new machine based on the BMG 300 platform at the show. Destined to be a “smash hit for all”, the VENTURE 316 presented at the Ligna promised visitors a whole new world of stability and precision in this machine category.
With this new development, HOMAG is nudging high-quality, highly flexible 5-axis processing ever closer towards the 100,000 Euro threshold. Here, it is the customer who sets the standard: The new Venture 316 has everything it takes to address practically any customer requirement in the furniture and door production and interior fittings sectors. |
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A small number of standard tools permits practically every type of processing requirement to be covered without the need to use non-standard units or tools. This is the ideal work horse for all those who cannot be sure what it is their customers are likely to want tomorrow or the day after.
The Venture 316 sets whole new standards in its category: The weight alone – around 30% higher than that of comparable products – and the generously dimensioned, stable moving gantry clearly mark this out as an industry standard machine with a woodworking shop price tag. The machine also provides a wide range of features as standard equipment, such as a pneumatic interface at the spindle, rack and pinion drives in X and Y, vibration sensor for spindle protection or an effective part height of 250 mm from the console, which can be used complete with all units.
The machine is also equipped with a safety system using not the customary tread mats, but instead bumper contact cushions which bring the machine to a stop on first contact of the machine by the machine operator.
The benefit: Unobstructed access to the machine and dynamically changeable field size for alternating processing: While a short component is being processed on one side, a long one can be positioned on the other side and vice versa.
With this array of features, the Venture 316 raises the bar in this sector: This machine offers the optimum selection of components for woodworking shops and for industrial non-standard element production.
BMG 600 gantry processing centre
The BMG 600 moving gantry processing centre follows in the footsteps of its predecessor, the highly successful BMG 500. The BMG 600 is capable of heavy-duty 5-axis processing operations up to 500 mm in height (including clamps). The main fields of application for the BMG 600 include vehicle and staircase construction, model building and shopfitting, as well as the processing of plastic and composite materials. This machine also benefits from the patented mineral material SORB TECH© , whose high mass and optimum vibration absorption properties make for excellent processing quality and tool service life increases of up to 20 per cent. Instead of using tread mats and light barriers, the patent-registered safety system safeScan provides a no-contact safety guard of the work area. The benefit of this system: if a machine operator approaches the safety area, first of all the feed rate is reduced and the employee is given a warning. The machine is not actually blocked until the safety area itself has been penetrated. During alternating processing, the operator is able to make a dynamic selection of the work area, and the floor directly in front of the machine is freely accessible. Unlike the bumper system, this option does not compromise traversing speed.
Providing an ideal complement to this safety feature, particularly for 5-axis processing operations, is the software module collisionControl. This monitors the processing operation online and helps prevent machine damage resulting from collisions caused by programming errors.
powerProfiler BMB 900 – a whole new class in window processing
One of the major highlights in the field of stationary technology this year is the new powerProfiler BMB 900, a true multitalent that comes equipped with up to 432 tools. The challenge to produce "40 windows per shift" was what prompted HOMAG to launch the development of automated processing centres capable of executing the whole range of tasks required for complete individual part processing in CNC precision – in other words the achievement of a degree of ready-to-assemble fitting accuracy requiring no finishing or reworking processes. This applies not only to standard straight window components. Also exceptionally small cross-sections under 50 mm and short lengths of below 170 mm for windows used in restoration projects, as well as for sash bars, large cross-sections up to 300 mm and long components up to 3,500 mm for upright and transom constructs can all be processed. The concept also offers scope for processing parts up to 6,000 mm by means of re-gripping and displacement.
The spectrum even includes the production of round arch components and front door panels. For this, the powerBeam gripper table is fitted with consoles which are compatible for the entire highly flexible HOMAG clamp range.
By combining up to four processing units, tool changing systems with up to 432 slots which permit several spindles to access the same common storage system, and a wide range of drilling head and exchange units, output can be ideally adjusted to requirements. chipGuide elements can be connected to ensure the most efficient possible capture of even large volumes of chips.
Flexible product design using five-axis technology and automatic workpiece handling leave plenty of space for additional processing scope. All the processing centres are designed to allow integration in existing product lines and link-up to trade-specific software.
Cell with robot feed facility for door processing
| Automation made easy: The example of a customer plant for unmanned processing of door leaves demonstrates the benefits of intelligent automation for a 5-axis CNC processing centre. Feed, stacking and flipping with a high degree of freedom and fast changeover times are linked to the flexibility of complete CNC processing. |
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The lateral arrangement of the robot ensures that full flexibility is retained, as the BMG processing centre can be optionally loaded manually from the front or automatically by the robot.
Gripper technology with a system: The suction beam at the end of the robot arm is designed to allow the entire part spectrum to be securely gripped – from heavy doors to finish processed doors with ornamental mouldings and glazing cut-outs. Sensors ensure that the parts are correctly engaged, helping to eliminate faults due to adhering parts.
But efficient operation using this type of system is unthinkable without a cell control system to coordinate the various processing possibilities. To address this need, HOMAG is now offering a simple new intuitively operated user interface for visualization and control of the processing centre and the robot. This means that the machine operator only requires a command of just a single system.
SOFTWARE
Extreme programming simplicity with woodWOP 6.0
woodWOP 6.0, the latest generation of the Workshop-Oriented Programming system installed already in over 25,000 HOMAG Group applications, makes for significantly simplified CNC programming. Visitors to the Ligna stand had the opportunity to experience this first hand with a series of live demos. The new three-dimensional workpiece view provides greater safety and clarity in the production engineering process, as all the processing operations are graphically displayed. The help function integrated in the user interface provides an illustrative graphic for each parameter and supports the daily work of the programmer. The free adjustability of window sizes and information boxes which can be hidden or shown as required permits programmers to configure the interface to suit their specific requirements. An update is also available for existing users.
woodWOP 6.0 – now with CAD functionality
In the software sector, the new woodWOP CAD plug-in can be counted one of the highlights of the LIGNA 2011. This plug-in extension module allows contours to be generated with far greater speed and convenience. It allows lines, arcs, circles, ellipses and splines to be interactively drawn. In addition, a large number of editing functions such as cropping, flipping and stretching are also possible. A smart search algorithm converts generated drawing elements into a contour, recognizing and displaying crossing points. The further direction is indicated by a click of the mouse. The CAD plug-in is fully integrated into woodWOP, allowing users to quickly attain the operating skills needed to generate a finished CNC program from the drawing using the familiar woodWOP functions.
MMR - Machine Monitoring & Reporting
Optimum machine and plant utilization is decisive when it comes to determining successful production. HOMAG has developed a new software solution which goes by the name MMR (Machine Monitoring & Reporting) in time for the Ligna 2011, whose function is to optimize resource efficiency in the field of machine utilization: The key to higher output!
One of the fundamental benefits of MMR is its ability to centrally log and display all error messages. The produced evaluation dialogue clearly shows the most frequent root causes of faults at a glance. This is particularly effective in networked plants which generally comprise several individual machines. In the past it was often difficult to obtain a meaningful diagnosis of production bottlenecks. Using a range of sorting and filtering functions, the MMR now allows all faults to be simply determined and eliminated, taking into consideration not only technical faults but also errors caused by operators or by environmental factors such as missing material.
The capability of MMR goes far beyond the functional scope of classical machine data acquisition tools. The intelligent acquisition logic records optimization potential and illustrates it in the form of graphic analyses.
Alongside this optimization function, MMR also displays all important key indicators of a machine such as output and main utilization rate. Using the Office module, all evaluations across several machines can be generated centrally from the office workstation.