Thermographically controlled lathe - Type MONOBLOC

Model shown: Monobloc 92 / Revolving tool holder (3 tools) / Double burner support, motorized chucks, automatic blowing system / Thermo-dimensionnal camera

 

Other products:

• Semi-calibrated tubes and profiles
• Thermographic controlled lathe - Type MINIBLOC
• Thermographic controlled lathe accessories
• Pneumatic chuck model 2008 for MBS 42 series

Overview:

The thermographically controlled lathes manufactured by Sadems are high technology production machines which are fully automated producing a wide range of glass and quartz products by hot forming operations.

From tubes or rods, these machines can shape by using any combination of forming, pushing, pulling, blowing, sealing, collapsing or centrifugal operations, providing a very high dimensional accuracy.

Thanks to a teaching system, programming of the equipment is quick, simple and user-friendly. Another advantage is the flexibility. As no mechanical setup is required, only a few minutes are required to switch from a production to another, making this equipment cost efficient, even for small production batches. It is available in various sizes and includes a set of accessories to fit the widest range of applications.

 

Main technical features

Frame	3 in 1 self-supporting cast iron bench
Dimensions	L 2000 mm x l 1480 mm x H 1400 mm.
Spindle bore	92 mm and 112mm.
Swing over bed	800 mm
Distance between flanges	1450 mm
Number of NC axes	From 8 to 11
Number of tools	1 to 3 (revolving system) – water cooled
Number of burners	1 to 3 (revolving system)
Programming	By remote control (teaching)

Main options :

Inside and edge forming tool holder (to shape the end of a tube) Robots and feeders for automatic loading and  unloading operations Protective water-cooled shields Automatic blowing system

 

More information?	Tel.: 00 32 4240 2212
	Contact Sadems Industrie

 

Principle of working

The principle of working of these machines is based on two unique features which make them both efficient and easy to use :

1. The programming system.
2. The thermographic and dimensionnal regulation system.

 

The programming system

In glass or quartz hot forming applications, one of the main problems is in describing the process in a formal sequence of operations. Indeed, manual working is a skilled job resulting from a combination of training, feeling and of course experience. Unfortunately, there not a full theory about glass hot forming operations, but any automatic machine, as sophisticated it is, requires instructions to operate.

To solve that problem, Sadems has developed a unique programming tool : the remote control. Using joysticks, potentiometers and other controls, the glassblower can produce a reference piece on the automatic machine. During this operation, called « Acquisition », the machine is recording all actions made by the glassblower (movement of tools, burners, tailstock, spindle speed, gas flows, blowing pressure, etc.) also the thermographic and dimensional maps.

Once the acquisition is completed, the software analyses all the information recorded during the acquisition, finds correlations between the actions made by the glassblower and the thermographic and dimensional information and finally automatically generates a production programme. This compilation phase is called « The conversion ». In practice, it means that the machine not only knows about glassblower's actions but also the sequence in which these actions have to be performed.

As a third and last step, the programme can be executed and the automatic process observed and analysed by the glassblower. Then corrections can be made directly in the programme to improve either the quality or the production speed. This step is called « The refining ».

This programming method provides very good results within a very short period, typically a few hours for one application.

 

The thermographic and dimensionnal regulation

As a glassblower works on a manual lathe, he is actually working in closed loop. He carries out an operation, looks at the effect of this operation on the glass and consequently decides about his next action. The effect analysed can be linked to the viscosity of the glass (fct of temperature) or its shape (fct of dimensions).

This method allows the glassblower to adapt to variations in his working environment (dimensions of tubing, flame power) in order to produce the same final result from various working conditions.

Sadems thermographically controlled lathes are roughly working on the same principle. The embedded thermographic camera continuously measures the temperature profile and the dimensions of the working glass at locations defined by the programme (auto-generated by the teaching) and adapt the programmed actions according to the result of these measurements. Taking into account that the machine is able to perform these measurement with a far greater accuracy than a glass blower, the final result is also more accurate and repetitive. We can expect tolerances up to ±0.05 mm.

Switch over programme

Another impressive characteristic of these machines is the time required to switch from a product to another one. Indeed, the machine is designed so that no mechanical setup or manual setup is required during a change-over. The tasks are limited to the change of burner heads, forming tools and possibly the blowing connections. Then, the programme has to be selected in the library. In pratice, no more than 10 to 15 minutes is required to change over production, making these machines flexible and cost-efficient even for small productions.

Software

Although the hardware includes an axes controller and a CAN bus I/O terminal, the user interface has been concentrated in a single software programme running under Windows XP, making the use of the equipment simple and user-friendly.

The software manages all « low level » interfaces, leaving the user with a well known Windows interface. No specific knowledge is required to use this machine in production, other than a knowledge of Windows XP and the Sadems training session. Also, all applications share the same common architecture, making programmes easy to read and modify.