MACHINING & MACHINERY DEEP-HOLE DRILLING
UNISIG
Deep-Hole drilling automation is more than part load / unload | Technical Articles
By Anthony Fettig – Unisig Deep Hole Drilling Systems
For deep-hole drilling , part-handling might be the most visible automation element , but it ’ s not necessarily the most impactful . Often , it ’ s internal process automation that yields the most significant results even with a manually loaded drilling machine .
When it comes to automating deep-hole drilling , there are challenges unique to the process itself . These include fixturing complexities — where maintaining alignment requires elements such as guide bushings and tool supports not present in a conventional lathe or milling machine — and part attributes such as length and weight .
Long parts mean a long drilling cycle time , and maintaining production rates often requires multi-spindle , deep-hole drilling systems . Unfortunately , stopping a two- or four-spindle machine means two or four spindles sit idle until the parts are loaded and unloaded . So , in these instances , the more parts in the machine at one time , the more automation can actually inhibit cycle time while the machine is running .
Solving this problem in multi-spindle machines requires internal automation to achieve the objectives of lean manufacturing and one-piece flow . Inmachine loaders singulate processes so that even within a small four-piece batch you maintain one-piece flow . The operator or automation device puts in a part and takes a part out , and the machine does a bit of maneuvering inside to sequence those four parts in such a way as to minimize spindle downtime while maintaining upstream and downstream processes for one-piece flow . For instance , parts could be loaded onto a smart conveyor , indexed , and lifted into chucks for the drilling cycle before robotic unloading on the out-feed side so that there are no bottlenecks to a steady production flow .
Tool life management is another form of internal automation . Getting feedback to the machine enables the deep-hole drilling process to adapt or halt , if necessary , before tools and parts are damaged .
Tool life management is built into a machine ’ s control , and the machine senses torque thrust and coolant . Chip condition is usually the first indicator of wear , which would otherwise require an operator present to detect , so the machine actually monitors the process and can predict tools starting to wear and identify when they need to be changed . A tool life management system also xan count distances drilled and the number of cycles , then prompt a tool change at the appropriate time .
That kind of in-machine automation smooths the path for external automation .
As the process builds , highly standardized options for robot-ready machines such as an automatic door , workpiece-present sensors and programmable workpiece fixturing makes it easier to add a robot at a later date . These robot-ready machines also create efficiencies before they ’ re fully automated . Even with manual loading , the automatic doors and programmable clamping make the process more efficient .
In UNISIG ’ s experience , an embedded reamer tool changer enables manufacturers to manage significant throughput increases , even with an operator . With this technology , operators can maintain the pace of production loading the machine , while eliminating the task of inserting reaming tools for each cycle . This allows the operator to redirect efforts towards tasks such as additional quality checks and off-machine setups .
UNISIG is also exhibiting at the AMB show in Stuttgart , Germany 13 . - 17 . 09 . 2022 . Further information on all machines of the UNI series and the complete UNISIG machine program is available at : www . unisig . com or follow the company on LinkedIn and Twitter (@ UNISIG ).
For further information , please visit www . unisig . com
102 PECM Issue 55