To fully realise the potential of the
technology, and to take it to the level
of precision which would enable Zeeko
truly stand-out above its competitors, the
company needed a CNC partner with a vast
amount of experience across a variety of
different market sectors. Fortunately the UK
headquarters of the world’s leading CNC
systems provider, FANUC, was a mere 26
miles away from Zeeko’s Coalville site, in
Coventry.
Zeeko first trialled FANUC CNC in 2003,
and now uses FANUC’s 30iB control across
its entire portfolio of polishing machines.
The 30iB CNC series has been specifically
developed by FANUC for use across complex,
high-speed and ultra-precise machinery
operating multiple axes and multiple tool
paths, all within an intuitive user interface.
When integrated with Zeeko’s state-of-the-
art software solutions, users are able to
polish concave, freeform and other complex
geometries to within 2-3 Angstrom (the
equivalent of 0.1nm).
While Zeeko leads the field of ultra-precision
polishing machines, one of the main
challenges of holding such a position in a
highly niche industry is the pipeline for work.
“Given a Zeeko machine is a high-capital
purchase, it is not unusual for customers to
undertake extensive R&D testing with us to
prove that the machine is able to meet their
polishing requirements,” says Chris.
“For example, we worked with a customer
for nine months on a prototype optic for a
land satellite survey system. Once they were
satisfied, the machine was installed at their
facility, and produced the next optic in just
four weeks.
However, this approach can result in a
somewhat spikey cashflow, so in order to
grow the business sustainably, we knew
we needed to find other avenues with less
intensive R&D requirements.” With a view to
leveraging the knowledge housed within
the business, the management team took
the decision to expand Zeeko’s position
from solely being an OEM to include systems
integration.
Chris continues: “We realised that the
machines we were manufacturing could
also be put to use in applications where
the polishing requirements were less
demanding, such as making tools for
injection mould parts.
To break into that market, we looked at
what other companies were using and
came across the FANUC RoboDrill. Given our
own polishing machines were controlled
by FANUC CNC, we were confident we
could create an integrated machine tool
and polishing machine offering that could
operate using a common control.”
The first step was for Zeeko to purchase a
FANUC D21 MiB5 RoboDrill, to develop the
software element which would allow the two
machines to work in unison.
While that offering has been available to
customers for five years – and represents
a significant growth opportunity for the
business – Zeeko has retained its original
RoboDrill, which it now uses to manufacture
the tools used on its own range of polishing
machines.
Now the company is not only able to offer
integrated cells direct to new customers, but
it can also provide upgrade kits to existing
FANUC RoboDrill users looking to integrate
polishing in their finishing process.
With one eye on the future, the company
once again turned to FANUC to drive
productivity internally, through the
integration of two robotic arms. “The
RoboDrill is now supported by two FANUC
robots as part of a fully-automated machine
tending and measurement cell. One robot
takes blanks from a rack, loads them onto the
chuck, before the RoboDrill then machines
them to the desired specification,” continues
Chris.
“A second robot then unloads the finished
part, and transfers it to a measurement and
calibration system to ensure it has been
processed to the exact specification required.
Once measured, the second robot will
then transfer it to another rack where the
completed parts can be processed.”
As well as machine tending pick and place
applications, the robotic arms can also
be used to provide initial polishing to
the freshly-machined parts made by the
RoboDrill.
While the fully-integrated cell is still being
fine-tuned at Zeeko’s Coalville factory, it
won’t be long until robots are added to
its turnkey cell integration offering for
customers. Once complete, however, it will
mark the latest in a long line or remarkable
steps which has seen the company
evolve from a dynamic university start-up
into one of the country’s last-remaining
British manufacturers of precision tooling
equipment.
Unlike a number of those left who are
looking over their shoulder at the threat
posed by cheap imports from low-cost
economies, Zeeko has its eyes firmly set on
continuing its sparkling upward trajectory.
www.fanuc.eu
Issue 40 PECM
75