Kidderminster-based Beakbane Ltd, the UK's leading manufacturer
of bellows and machinery protection systems, has invested
£500,000 in a new TruMatic 6000 high performance CNC
punch-laser combination machine from TRUMPF.
Purchased as part of its ongoing investment programme, the new
machine will ensure high accuracy, consistency and reliability of
component production. Furthermore, the large format (3050 x 1550mm)
set-up will provide for improved material utilisation at a time
when steel prices are at a premium, thereby enabling efficiency
gains through a reduction in waste.
"The acquisition of this machine completes a major investment
programme during the past four years to improve the company's metal
cutting, punching and folding capabilities," says Manufacturing
Manager, Roy Legg. "The investment has been targeted to maintain
Beakbane's position as the European leader in the design and
manufacture of machinery protection systems."
Due to be installed in June 2011, the increase in capacity and
efficiency provided by the investment is seen as necessary by
Beakbane in order to offer existing and new customers a high
quality, accurate and cost effective manufacturing capability.
"If you take the strengths of the punch, in terms of accurately
forming material, coupled with the speed of punching holes, and you
take a part that has sweeping contours and irregular shapes where
smooth edges without burrs is important; and you then put those two
types of geometry into one part - that's the perfect combination
machine component," says Mr Legg.
Beakbane has many parts that fall into this category as the very
nature of its business is high variety, low volume specialist
work.
The TRUMPF TruMatic 6000 is a rugged, all-round machine based on
an open C-frame design that is able to process sheet up to 8mm
thick. Intelligent punching, a wear-free ram guidance system and
360° tool rotation are combined with a choice of three lasers
(2, 2.7 or 3.2 kW) and simultaneous (XY) cutting speeds of 108m/min
for optimum efficiency.
Among the many innovative features of the TruMatic 6000 is
Adaptive Stroke Calibration, which automatically monitors and
corrects in real time the depth of forming regardless of material
thickness variations, ensuring perfect parts from the first to the
last piece.
"The TruMatic 6000 will address the costly problem of machine
downtime resulting from tool changes through the use of
standardised tooling on a standard punch machine," adds Mr Legg.
"When a part requires a shape that the standard tooling can't
provide, it can be cut using the laser. This choice of
'combination' provides the opportunity for increased efficiency,
reduced throughput times and agility within the manufacturing
process."
Mr Legg indicates that cycle times will almost certainly reduce
due to fewer handling operations and the ability to complete parts
in one hit. Beakbane will be able to tap, countersink, form and
bend in a single set-up, thus reducing the non-value-added time
associated with secondary operations.
Beakbane has been established since 1954 and is accredited to
ISO9001:2008. Today, more than 120 employees help the company offer
its clients a complete outsourced service from product design
through manufacture to delivery.