Automated Cell Manufacturing

We at Futuramic have decided to take on the New Millennium with a new approach to machining our products. At the dawn of the 21st Century we have in place our new automated machining cell. This system is unique in the fact that it was not designed to run production parts, yet it can run production parts effortlessly. The system was designed around the concept that small lots, as well as single components, could be run as efficiently as large lot full production. This posed many challenges and caused us to question everything. Another criteria for the system design is to avoid "bleeding edge" technologies. This system brings together the best available proven technologies to give our customers the maximum benefits achievable through efficiency, flexibility, speed, and accuracy.

Efficiency

“Lights Out" machine operation. The machines run from a continuous stream of data supplied from our DNC (direct numerical control) server. The data stream is only interrupted during a pallet change over. No operators are required at the machines. The system contains three loads per machine held in buffers and changers awaiting their turn in the machining center. The system will run long into the night, or weekend, without operator intervention. The change over time between pallets is under 1 minute. This brings machine efficiency up to 95% spindle in part time. The only time the machine is not making chips is during a pallet, or tool change, thereby maximizing use of capital equipment.

Flexibility

The heart of this system is its data control and part locating strategy. The control system is capable of downloading CAD designs of the product to the operator load station. The CAD design will show the part in machining position with the locating points defined. The parts and tooling are then loaded to the pallet in the appropriate location as defined by the point scheme. This is very similar to the child's board game "Battleship," D4, B6, etc. This allows for ease of operation and direct tie in between the pallet locators, part location, and CNC program. Special part fixturing can be supplied to meet what ever your part requires. Each pallet has its own read/write tag that is updated every time a part is loaded. These tags are read in different locations of the system to verify the pallets location, and initiate the CNC, or CMM program from the DNC server.

Speed

The speed of this system comes from maximum utilization of the VMC's (vertical machining centers). Change over times are completed in less than 60 seconds. This allows for chip to chip times under 120 seconds between different parts. Flexible tooling on the pallet reduces load times to less than 180 seconds. This system will support run times as short as 10 minutes across the entire system without experiencing "bottlenecking " conditions.

Accuracy

Continuous monitoring from an in-line CMM (coordinate measuring machine), and pallet positioning repeatability of plus or minus .0005" / .0125mm insure maximum achievable accuracy.

Capacity

This system’s envelope is 60" L X 30" W X 24" H, and up to 2,500 lbs.