The experience in Mechanics of no. 3 families' generations ( 60 years ) common to the no. 3 well known companies specialized  and  part of the Hi Tech Group ( as per Presentation letter and first idea of Catalogue enclosed ) will bring us to exhibit - at next Xylexpo of 4/8 May in Milan - the below described '' Just in time furniture line to cut, edge and bore/ inserting flexible lots/ batches '' able to guarantee a production up to no. 16 Kitchens per shift.

Macmazza starts this line presenting a brand new patented automation, 'PIERO',  named after the best of our skilled engineers.

It is a flexible loading/parking/unloading warehouse which dispenses with the need of a costly forklift operator in the area where the panel working machine is, or parts of panels to be recycled are.

This robust platform ( 3.500 kg ) will load 5.000  kilos in several, flexible stations and has been designed and patented to solve the real 'bottleneck' of any monoblade machine ( and of all the panel machines inserted in small batches flexible working islands ) where complex handling of loading/parking parts/rejects to be recycled or manual unloading must be carried out by several operators working in close proximity to the machines with the need of a forklift and its driver. 

Nowadays the small batches- and just in time orders depend entirely on the efficiency of machine and forklift operators moving from the panels stockage to the working islands. 

In practice the high performance of the most efficent and modern machines are impeded by handling problems in presence of  small orders. 

Moreover the handling of expensive rejects to be recycled makes the process more complex. 

Often rejects are stockpiled close to the machines, possibly for future recycling, but commonly they remain finally expensive  and  big  rejects which by the year end occupy valuable industrial space, too.

Consequently customers are loosing the will to invest in high performance machines!

The expensive, total automation of  the ' batch one ' cannot be the right solution for companies needing also an acceptable productivity but in their flexible working islands, which could be equipped at lower cost even connected ‘’on line’’ together, but always working  also ‘’stand alone’’ and  in both way very efficiently.

This line working process begins in the office, where the orders are received and with the same speed final parts of furniture to be produced are transmitted just in time to the line .

Both coming from furniture Cad Design  or  Managerial software programs, either collected by simple lists of same parts to be cut, those furniture parts will be informatically inserted simply in an Optimization program saving rejects  as generating results of the best possible cutting patterns, also using the highest thickness/stack capacity available in the beam saw  and  suggesting, case by case, all the most convenient formats of original panels or even of parts to be recycled,  according their presence recorded and up-dated in stock.

The Macmazza beam saw is provided with a double microprocessor, the first controlling all the machine movements as electronic axis, at the same time that the other Personal Computer is only working as interface of the operator ‘s full programming and therefore able also to give the inputs to all the following line, without any cycle interruption .

In fact, labels can be generated on board of the beam saw PC and printed with the same sequence of the parts cut, therefore guiding all same parts at all the following operations of edge-banding first, then automation and turning/ re-feeding devices  and  finally up to the boring/ inserting, granting the possibility of reading the self-programming of the following machines only reading  numbers, letters or even a bar code.

 

Granting the  result of  maximum  manpower  reduction, now we analize the working process:

Once the single panel or stack is loaded over the fork lifter ( even using a simple vacuum crane that Macmazza can supply ) the forklift operator coming from the main panels warehouse, or from the supplier’s truck, can organize the supply in advance, by loading the 'PIERO' flexible stations in masked time (when the operator is working on the machine).

He can also remove the rejects from some stations which are not immediately recyclable and leave - close to the operator - panels with different colour, thickness, size and material required to complete the most urgent flexible orders.

It also allows the operator to change sequences according to demand (for example just in time orders networked to the machine PC ) by selecting one picking station and taking it to the machine loading/unloading height at the right time in a completely independent way.

Macmazza beam saws are also equipped with software for the stockpiling and handling of rejects which can be left in one or more of the stations on the 'PIERO' machine, used in the software programme, so they can be easily identified during the recycling operations.

In addition the dimensions of 'PIERO' can be customized and with its shelves fitted with wheels, it facilitates handling even of the delicate panels.

The extremely heavy duty 'PIERO' was designed to be built entirely, tested and pre-assembled in the Macmazza workshop and then simply placed and used by personnel not necessarily skilled either in mechanics or in electronics.

As you can see in the enclosed picture, 'PIERO' loading/ unloading/ parking area perfectly matches the rotating air flotation table- with Macmazza’s further international patent - removing the only 'bottleneck' that is the front handling, particularly hard in presence of complicated cutting patterns up to no. 5 different cut levels, as generated to optimize the rejects and corresponding to no. 5 different rotations of the same sometimes thick and large stack of panels.

The real needs of modern companies are addressed with the investment in an automation which maximizes the efficiency working with reduced labour, optimum recycling of rejects reduced to a minimum with minimum effort.

Together with the above automation Macmazza inserts on line a super-performance mono-blade beam saw front/ side loaded with grippers, Top Saw, as having resolved the 'bottleneck' of the front handling, consequently all the performance has been improved   and among the upgrades we would like to highlight the following:

- height of cut up to 110 mm – no. 6 panels of 18 mm each – but also best movements and cut of one single panel, maybe in the more and more trendy ‘’ honey comb ’’, up to 80 mm thick  or  of no. 2 of 50 mm each  

-better optimization of all the axes movements according to real panel dimension and thickness, to minimize cycle time

-increase of all the axes speeds, that can be varied by adjustable speed motors according to the different characteristics of material to be cut  or  to the cutting quality required.

-lengthening of the side aligner stroke to combine the simultaneous rotation and the transverse cutting of several strips on a patented whole table, the strips being parallel aligned without any effort of the operator, also thanks to the whole supporting table when unloading 

… in fact, this totally turned table is an important position of the full line to stock cut panels and to divide them for the lables applications, before feeding following machines on line and/ or pre-rollers stations for eventual stock on the floor.

The moving of the panels from the panel sizing machine towards the edge bander takes place thanks to a simple transport system having idle rollers placed on side of the panel sizing machine itself. With consideration to the available room, this first gravitational moving track will also permit the stacking of any panels. The panels will go down by gravity or with the help of the operator towards the introduction roller conveyor linked to the edge bander.

With edge bander Dynamic in its 8.10.A - r.a. one version, aims at bringing concept and technology into small and medium enterprises, with user-friendly systems and top performances, with an excellent quality-price ratio, but above all with those guarantees of accuracy, reliability, and flexibility that has always provide.

All the solutions to insert the Dynamic one product in a panel production system are enclosed in a machine structure slightly exceeding 6 m hence making it possible to perform any required processing.

Controlled-axis systems drive all the groups operating on finishing and  follow all the customer’s specifications so to obtain the required quality.

The diamond tools installed on the Pre-milling, Hogging, Finishing, and Rounder Units guarantee an unchanging finishing for considerable time!!

Our units complete with systems to optimize the tool wear, such as the Pre-milling ones provided with a self-centering system, ensure long life to tools and, consequently, a considerable saving in management costs.

In cooperation with RIEPE, 3 stations have been installed that perform an additional finishing of the panel such as the anti-adhering station at the machine input to spread a liquid over the entire panel length, to easily remove any glue residual (on request, also a anti-adhering station may be installed for the panel end). Moreover, a cooling-antistatic station on the pressure unit output removes the static effect of ABS and PVC materials and ease suction.

Lastly, there is a polishing station installed before the RIEPE DISPANN special brush units to obtain the maximum edge finishing.

The S 7 system easy programming comes with the Bar Code system for the quick retrieval of the operational program required.

Dynamic 8.10.A - r.a. one can process panels ranging from 8 to 60 mm in thickness and with 2 fixed forwarding speeds at 11 m/1' and 18 m/1.

Offers its basic function with this product to then optimize all the possible modifications to be made, based on the customer’s specific requirements: a multi-radius management, a multi-reel management, speeding, etc.

Connection for panels return- panels rotation – drilling machine feeding

The moving and the linked automation on exit of the edge bander will permit to control, accordingly to the cycle needs, either the return of panels to be re-introduced into the edge bander after a 90°-180° rotation, as well as the moving towards the final step of the panel machining. i.e. the drilling operation.

In a way to enable what just described, on the edge bander exit it is linked a system of motorized belts,  properly prepared to move the panels either longitudinally and as well crosswise towards the picking area by means of

the moving device,  which being equipped with a vacuum picking frame will be able to lift the panel and if necessary, to execute the 90° or 180° rotation, accordingly to the requirements and sizing of the same.

The role of this moving device is to move the panel towards the panels return moving system, till the edge banding cycle will be finished; only afterwards the moving operation will take place towards the motorized roller conveyor linked to the drilling machine, in a way to complete the panel working cycle.

The Alberti  machines for the introduction and continuous longitudinal advancing of the panel belonging to the  model range VECTOR/CN, are the result of experience and updated research in the field of automatic applications on drilling and insertion of tooling, on panels typically used in the furniture manufacturing either on “just in time” process and as well for the production of small or middle “lots”. 

All versions of this machine range are distinguished by a patent pending and modern system for the clamping and moving of the panel along X Axes (longitudinal advancing) using a special self-aligning, linear sliding suction cup. 

Extremely performing and profitable is the laser system for the automatic detection of the “zero point” on X coordinate (panel length) permitting in addition to the “reading” of panel front side, a reading of the rear size in this way enabling a real measurement of the panel, recovering the possible present tolerances.

The machine is manufactured on a monolithic high rigidity frame in welded high thickness steel plate, thus enabling the application of precise movement kinematics of the different working units.

The longitudinal movement of the panel on work takes place on a roller table subdivided in three different fields: loading area (motorized), working area (rectified rollers), unloading area (motorized).

Our technology will easily permit us to integrate the VECTOR/Cn machine inside a production cell with logic “lot one”, as well as to position inside an assembly line, or more simply to link it to possible automatic loading and unloading systems for the panel. 

The VECTOR/Cn machines are available in the versions SH (single operating head) and DH (double operating head).

Our Company technical staff is in the position of offering extremely customized solutions, satisfying the most

various and diversified production requirements, thus granting the best price-to-performances ratio.

It is typically possible to execute following operations: vertical and horizontal drilling operations, linear and interpolated routing operations, grooving and insertion of “tooling”, easily passing from one panel to another one without the need of  machine “set-up”. 

The dimensions of the workable panels may pass from a minimal length of 300 mm. to a maximum one of 1200 mm.; while the maximum workable thickness will reach the  60 mm.

The machine is equipped with the exclusive drilling heads fitting out  the patent pending “expansion mechanical block” which is coupled to the spindle selection and de-selection pneumatic system. Thanks to this system and as

well to the mechanical movement of  “Z” axes , it is possible to get the right and constant control of the tool during the several drilling phases, thus granting the quality and precision performances of the operation especially executed during the application with big diameters or the execution of “through-feed” drills.

The VECTOR/Cn machine may be equipped with a minimum of 28 independent, vertical, upper drilling spindles up to a maximum of 50.

In the base versions there are also some horizontal heads which will enable the execution of drilling operations on 4 horizontal sides of the panel.

Wide choice among specific last generation aggregates suitable to execute complementary operations, such as routing (router HSK-F63) with the coupling of tool change magazine, the grooving operation (circular saw group) and the

insertion of tooling (hinge plates, drawer runners, bushings, dowels, and so on.) everything inside the machine technological limits.

Accordingly to specific demands, it is furthermore possible to equip the machine with a lower operating head fitting out independent drilling spindles.

The VECTOR/Cn machine is equipped with a control board fitting out a last generation Personal Computer, used as interface operator/machine.

To obtain the independent control of the axes and the several Inputs/Outputs, it is used a CN able to control a minimal of 3 up to 8 axes.

The preparation of working programs is executed with a powerful “user-friendly” software, WINDOWS-XP integrated.

Programs for the reading and interpolation of “bar code” are available.

The programming system, being based on the use of a standard PC, will make very simple and cheap the connection towards the “company net” typically adopted for the launching and controlling of datas (transmission of production list, sending and research on remote part-program files).