EXTENSIVE CUSTOM DRIVE CAPABILITY

The Framo Morat range of drive systems from R. A. Rodriguez includes compact slip-on geared motors, linear actuators and push-pull linear chains, all based on modular design principles and customised to suit each application. 

Custom capabilities extend way beyond these standard product ranges however.    R. A. Rodriguez has 40 years of applications knowledge and Framo, 140 years experience in the manufacture of gears, transmissions and actuation devices.  This rich heritage puts the partnership in a unique position to design, develop and manufacture special custom drive assemblies to suit specific application needs.

At its 15,000 m2 manufacturing plant in Eisenbach, Germany, Framo has every facility for cost-effective design, prototyping and production. Drive systems can be manufactured in virtually any material required, both metallic and non-metallic.  The company also provides heat treatment of metals to specification.

Examples of successful custom drive projects are many and various.  They include lawn mower gearboxes, gear train drives for floor polishing machines, actuator units for tractor implements, caravan manoeuvring devices and complete drive systems for stairlifts.

AWARD FOR CONSISTENT, HIGH-QUALITY BEARING SUPPLY

In recognition of its quality products, processes and supply the KAYDON® Bearings Division has just received the prestigious Bell Helicopter Premier Supplier Award.   Only AS9100 certified suppliers can qualify for this award and the winner must have maintained the consistent delivery of quality-assured products at a minimum frequency rate of 98%. 

The helicopter sector is a prime market for the KAYDON® custom-engineering and performance critical bearings.   In the UK these products are supplied by R. A. Rodriguez; typical examples are rotor mast and swashplate bearings.  The swashplate is a device that translates the pilot's commands via the helicopter flight controls into motion of the main rotor blades.

For more than 30 years, R. A. Rodriguez worldwide has been providing full engineering support to aircraft companies.  Indeed its aircraft products are fitted to a large number of military and civil aircraft in the Western World including many spacecraft.  They are also used in many other leading edge technologies such as optical sighting systems and laser range finding.

R. A. Rodriguez also supply a wide range of aerospace bearings from a number of leading manufacturers including Thin Section bearings, spherical joint bearings and airframe control bearings.

SPECIAL TURNTABLE BEARINGS

The news that the KAYDON® Corporation has recently acquired the Avon Bearings Corporation brings important advantages to the customers of R. A. Rodriguez.  This Letchworth-based supplier of precision engineering components is the longstanding sole distributor for KAYDON® bearings in the UK and this corporate development certainly extends its product scope.

With its headquarters in Ohio, Avon is a leading designer and manufacturer of custom, large diameter turntable bearings.  Indeed it is one of the most respected manufacturers in this field with customers in a diverse set of markets. Avon also re-manufactures bearings and is known globally for its focus on engineering support.

This acquisition complements manufacturing capabilities at KAYDON® and, in combination with ongoing capital investment programmes, has set the company on course to be the largest manufacturer of slewing ring bearings in North America.

“From our perspective in the UK this news gives our customers instant access to Avon’s flexible manufacturing capabilities for low volume, large diameter slewing ring bearings up to 240 inches (6m) in diameter,” concluded David Hey, Sales Manager at R. A. Rodriguez. “The arrangement also allows us to provide a re-work service for large diameter slewing ring bearings.”

DRIVE SYSTEMS' CATALOGUE

By turning to pages two and three of the new product range catalogue from Framo Morat readers will be left in no doubt that the company has a rich heritage in manufacture of quality drive systems components.  These products are now available from R. A. Rodriguez in the UK and many offer distinct performance benefits.

The Framo range includes compact slip-on geared motors, linear actuators and push-pull linear chains.  All are based on modular design principles and are customised to suit each application.  Full technical data on all of these products are provided in the catalogue together with extensive application notes.  The publication also includes information on Framo’s ability to design and manufacture custom drives.

The 80-page catalogue is entitled ‘Framo Morat Your Idea – Our Drive’ and is available from the R. A. Rodriguez sales office on 01462 670044 or via email to info@raruk.com

FIRST NEW APPOINTMENT IN MANAGEMENT RE-STRUCTURE

Continued investment in quality people and quality products is certainly paying dividends for precision engineering component specialist, R. A. Rodriguez.  As it records another year of increased sales the company is re-structuring its management team in anticipation of further growth in 2008.

The first confirmed appointment is David Hey to the post of Sales and Marketing Manager.  This is the first time in the company’s forty year history that the need has arisen for a manager to oversee all product divisions.  Until now product managers have reported directly to the MD but with increased sales across the board the need to change the infrastructure has become evident.

For seven years David has been one of those product managers, responsible for bearings.  Before joining R. A. Rodriguez he had spent seventeen years in direct engineering sales and latterly was European Sales Manager for Holroyd Gears.  

“R. A. Rodriguez is based on solid engineering integrity, giving customers’ confidence both in our products and professional support,” David asserts. “Technically superior products and customer service to the highest possible standard – it’s a good combination and one that I am determined to uphold.”

COMPACT GEARED MOTOR ROTARY ACTUATORS

The Framo Morat ‘Compacta’ slip-on geared motor is well named as it is ideal for applications where space is at a premium and they are designed for repeatable positioning and reversing tasks.  Models in the range are up to 10 kg lighter than nearest competitors with the same output torque and speed.  The ‘Compacta’ also provides 22 output speed options by comparison with the maximum of three available on alternatives and its motor choices offer a wide range of power and duty cycles.

The design’s integral and easily adjustable mechanical limit switch contributes to the product’s exceptional flexibility with a speed range 0.9 to 193 rpm and output torques from 6 to 600 Nm.  The range can also be equipped with ESA electronic limit switches with up to 10 set points and 2 end positions. These are easy to programme, provide an absolute encoder signal and therefore ensure precise positioning and repeatability.

The modular design of ‘Compacta’ allows easy customisation from standard parts. Its additional integrated features include choices such as brake, slip clutch, potentiometer, hand crank, encoder etc. This design flexibility differentiates the ‘Compacta’ from other models and greatly extends its scope of application from heavy duty material handling to semi-conductor production equipment in clean room conditions. As each ‘Compacta’ can be optimised for its specific task it is easy to install and there is generally no need for additional drive components.

The smaller dimensions and the low weight of ‘Compacta’ are achieved by the use of a spur and worm gear transmission combined with performance-optimised motors; the transmission is also exceptionally quiet.   Framo is a market leader in the production of worm gears and its products and systems are the preferred choice of many OEMs in the printing and textile machinery sector. 

Four standard models complete the ‘Compacta’ range offering torques up to 600 Nm. Higher torques, IP65 rating and explosion-proof ATEX 95 are also available.  The ‘Compacta’ series is designed for reliable operation under extreme heat, dust and moisture and models in the range are already in use in wider Europe in applications such as sheet metal forming, materials handling, food processing and electronics production. This highly flexible product is now available in the UK via sole UK representative R. A. Rodriguez.

EASY-FIT COMPACT LINEAR GUIDEWAY

The new and compact TMT Power-Line linear guideway T100 from R. A. Rodriguez couldn’t be simpler to assemble.  Just fit a motor and the product can then be used to move light loads with high acceleration and speed.  The self-supporting structure of the rail and its factory applied M6 mounting holes enable quick, easy and economic installation.

This belt-driven, four lubricated wheel design can accommodate direct loads of up to 400N and side loads of 1080N.  Maximum stroke from the single piece construction is up to 7000mm.  It is suitable for speeds up to 4.5m/sec and typical positioning accuracy is ±0.1mm.  The concentric bearing arrangement of the design allows easy adjustment of pre-load. 

Virtually silent in operation this new addition to the R. A. Rodriguez linear motion range is also maintenance-free.  The motor/geared motor can be mounted directly to the guideway or via a coupling. 

The Power-Line linear guideway T100 is the product of TMT, a company that specialises in the design and manufacture of robust rail profiles for automotive lift-and-carry transfer lines.  Its Speedy Rail® system is widely used by the world’s leading car manufacturers.

MACHINE BUILDING 2008, 13th and 14th February, NEC, Stand no. 2201

Machine Building is an important event for R. A. Rodriguez as it provides the opportunity for the company to showcase its new range of drives to UK industry and also to emphasise its competence in linear motion technology. In addition to the modular Werner systems the company will also be demonstrating examples from its own linear range.

R. A. Rodriguez has recently been appointed the exclusive UK representative for drive manufacturer Framo Morat. Its range of systems includes the Compacta slip-on geared motor with built-in limit switches. This is an ideal actuator for reverse motion and is available in four sizes with torques up to 600Nm.

In a similar vein the MINI is a range of extremely compact linear actuators with acme screws that are sealed to IP65. Minimum space requirement is also the main selling point of LinearChain that is capable of long strokes despite its small size.

COMPACT WHEEL DRIVE

For in-hub applications the new Framo Morat DiscPower electric motor driven gearbox provides a space-saving and economical solution.  The assembly comprises a dynamic, brushless and maintenance-free synchron pancake motor with integrated, low backlash planetary gearbox.

DiscPower models are available from 0.42W up to 1kW with up to 110Nm torque.  The compact planetary gearbox with lifetime lubrication is available in transmission ratios from 5:1 up to 50:1.  It is smaller and lighter than other gear configurations, has a higher efficiency and is exceptionally quiet running.

This latest addition to the R. A. Rodriguez Framo Morat range can be combined with a range of motor feedback systems such as hall effect sensors, encoders or resolvers to suit the application.  DiscPower is the ideal choice for automatic guided vehicles, fork lifts, wheel chairs and indeed any industrial application where minimal space and low noise are important design criteria.

Taking full advantage of Framo’s comprehensive manufacturing capabilities R. A. Rodriguez is also able to meet most custom drive requirements. In addition to special worm gear drives Framo has developed, for example, a 2-motor stairlift drive and intelligent actuators for tractors.

The Werner linear motion range of systems, modules and controllers is now one of the most comprehensive available. The products are designed to be freely combined enabling the user to create dedicated, multi-axes handling systems. They offer high load capacity, high rigidity, quiet operation and are complemented by a choice of motors, plug-in positioning systems and controllers.

Examples from the company’s own range of linear components will also be shown at Machine Building 2008. These include linear guideways, ball bushings, bearings housings, shaft supports and shaft blocks. R. A. Rodriguez is far more than just a supplier of linear motion components however. It has many years experience in designing and building bespoke handling systems for a broad spectrum of industries from food processing to automotive part manufacture. Full details will be available on the stand.

HIGH PRECISION SPIRAL BEVEL GEARS

For high speed and high torque applications the new KHK high precision, ground spiral bevel gears from R. A. Rodriguez are an excellent choice.  These strong gears have high load ratings and run at speed with minimal noise and vibration.

KHK have been making a wide range of standard stock gears for over sixty years and are one of the largest and most respected manufacturers in this field.  The company sells more than three million gears annually and invests heavily in new technology to ensure the KHK brand retains its high quality status.  Its entire product range comprising over 3500 gear types in 36 categories is available from sole UK distributor, R. A. Rodriguez (UK) Ltd.

These new spiral bevel gears are available in module sizes 1.5 – 6.  Options include fully hardened keyways and pilot bores that allow additional customer modification.

PUSH-PULL ACTUATION

The design of the precision chain links in the new Framo Morat LinearChain Actuation Device enables the chain to push as well as pull heavy loads.  Their special profile with interlocking fingers at one end enables the chain to roll up for efficient storage in one direction and form a rigid thrust device in the other. 

In the magazine the chain is stored spirally within a narrow chamber making LinearChain ideal for applications calling for long strokes where space is at a premium. The device provides high positioning accuracy, constant stroke speed and shock-free motion with no elastic hysteresis under load.  It has been designed for a long operational life and minimal maintenance.

LinearChain is available in three basic sizes allowing stroke lengths of up to 5m and a maximum push force of up to 35,000N.   Compact drive units for the chain and storage magazines are readily available for all chain sizes from

Framo Morat’s UK distributor,   R. A. Rodriguez. 

COMPACT AND MODULAR LINEAR ACTUATOR

The new Framo Morat MINI linear actuator from R. A. Rodriguez is aptly named as it uses a powerful coaxial motor to achieve the required stroke in minimum space.  The units are manufactured in stainless steel, IP65 rated, ATEX 95 explosion-proof certified and available with a wide range of options to allow them to be tailored to any application from food and pharmaceutical manufacturing to building envelope design.

The MINI range of electric motor driven actuators comprises five basic sizes with body diameters range from 60 to 128mm.  A choice of 3-phase, single phase AC or 24V DC drive motors are available.  Stroke lengths range from 100mm – 800mm, stroke speeds between 0.5 and 181 mm/s and stroke force of up 26,000N. 

A number of features ensure the MINI’s reliable operation even in extreme conditions such as heat, dust and moisture.  These include a thermally protected motor, life time lubrication and integral safety switches. This reliability is complemented by economical operation, low maintenance and a long service life.

The modular concept of the MINI offers great design freedom.  It can be specified with a choice of mounting and connecting arrangements and is easily interfaced with an existing controller.  Special stroke lengths and other custom features are available on request.

QUALITY TURBINE BEARINGS FOR WIND ENERGY

With renewable energy very much a hot topic, R. A. Rodriguez couldn’t be better placed to meet demand for critical drive components.  It is the UK factory representative for KAYDON®, an American bearings specialist whose largest ever order was recently received from an OEM in this application sector.

KAYDON® has been involved in wind energy for more than 20 years and has developed a range of bearing types that best meet critical pitch, yaw and gearbox applications in land-based or offshore systems from 200kW to 5MW and beyond. 

The typical requirement is for a large slewing ring – a large diameter bearing with a large bore – in diameters ranging from 2m – 5m. To combine the function of a bearing and gear, teeth can be cut into the inner or outer race to rotate with the assembly or remain stationary in respect to the ground during operation.

The use of a single larger diameter bearing allows wiring and other services to pass through the bore with ease.  This simplifies the overall system design, improves outward appearance and protects components.

Selecting the right bearing design depends on load, stiffness, speed, size and the smoothness of rotation required. One that has proven to be particularly popular for wind turbines however is the four-point contact ball bearing. 

This bearing accepts combinations of radial, thrust and moment loads.  It uses races shaped like gothic arches on both the inner and outer race ball paths that generate four points of contact on each ball.

To satisfy requirements for maximum load capacity within a given envelope, especially in larger sized bearings, KAYDON® has also developed an eight-point contact bearing that is also widely used in wind turbines.  This is an annular bearing with two rows of balls whose unique feature is its use of the gothic arch internal geometry in both rows.  Tests have confirmed that this additional row increases load capacity by an additional 80%.
 
Naturally corrosion resistance is an important consideration for outdoor use and the KAYDON® wind turbine bearings are therefore available with a range of surface treatments to meet the conditions of the application.  Selection of the most appropriate materials is also critical for operating temperatures that may be as low as -40°C; unique sealing arrangements are available for severe conditions.

While other manufacturers may specialise in one or two specific bearing types KAYDON® has the experience and manufacturing flexibility to match the product to the exact requirement. This includes accommodating special needs without sacrificing system performance or increasing cost. 

Further information on the KAYDON® wind turbine bearings and custom options is available from R. A. Rodriguez at www.rarodriguez.co.uk

NEW PRODUCT MANAGER FOR BEARINGS

KAYDON® is a bearing brand that has global recognition. In particular its Reali-Slim range is the preferred choice of designers seeking space and weight savings without compromising performance. For many years the sales and marketing of the entire KAYDON® range in the UK has been the responsibility of precision component supplier, R. A. Rodriguez.

Recent management changes at R. A. Rodriguez have created a vacancy for a product manager to represent the flagship KAYDON® range and the company is now pleased to confirm that Andrew Tilley has now taken on this role.

Andrew Tilley’s first steps into the world of engineering came with his appointment as prototype toolmaker at Cosworth Engineering. After three years Andrew moved into sales at Benzler (UK), the industrial drive and gearbox specialists. In 1991 came his first external sales job selling capital plant to British Rail and its second tier suppliers for Geismar UK. This was followed by a move to Marconi Data Systems to the post of major account executive for its ink jet and laser coding equipment.

Andrew joins R. A. Rodriguez from Bostik where he was south-east area sales manager for the development and management of key distributors and direct major accounts within the company’s Industrial Sealants Division.

NEW MINIATURE LINEAR GUIDEWAY

Linear motion is a field in which R. A. Rodriguez is able to offer a range of solutions and with the introduction of its own BM linear guideway the company has extended its miniature options. Four sizes complete this series with overall heights of 8mm – 16mm and carriage widths from 17mm – 32mm; basic dynamic loading capacities range from 850 to 6450N.

Compact for discrete installation, this ball-cage based design has high precision, gothic arch raceway profiles for long life, low noise and the accommodation of high loads. The high moment load ratings of the series make them ideal for single rail applications. Minimum vibration is assured by the quality of the raceway surface finish. This also contributes to the guideways long and trouble free working life as does the sealed carriage with lubrication nipple.

Available in five precision grades with a choice of five pre-load specifications, the BM linear guideway series is also available in stainless steel. These products have been proven in Europe in a range of applications including driven and manual positioning and X-Y combinations.

NEW BEARINGS FOR BALLSCREW DRIVES

For several years R. A. Rodriguez has marketed the UNITEC brand of ballscrew support bearings designed for high performance machine tool applications. Now in addition to the high load and exceptional performance capabilities of this needle roller bearing range, the company has introduced a new range of ball bearings to meet more general high precision needs of ballscrews.

Sourced from the R. A. Rodriguez German facility, the DRF/DRN double row ball bearings for screw drives are high precision components with a contact angle of 60°. They can absorb radial as well as axial forces from both directions and guarantee highest running accuracy due to their axial stiffness.  The range is therefore ideal for lighter-load applications that call for precise positioning and good repeatability.

The integrated, low-friction seal prevents the ingress of dirt, enhancing reliability and operating life. The bearings are supplied ready-to-fit and lubricated. They may be specified with or without fixing holes and their design ensures swift and easy installation.

Standard precision for the DRF/DRN range is the high accuracy p5/p6 precision class. For lower precision applications a commercial series of the DRF/DRN bearings is also available; this range carries the suffix NP.

Eight types of bearing support units are also introduced in block or flange design.

Full details of the newly extended range of bearings for ballscrew drives from R.A. Rodriguez is contained in a newly published brochure that is available from www.rarodriguez.co.uk.

FRAMO MORAT APPOINT R.A. RODRIGUEZ AS THEIR EXCLUSIVE REPRESENTATIVE IN UK

The parallels between the German drive specialist Framo Morat and precision engineering component supplier R. A. Rodriguez are striking. In addition to having a similar sales support structure and serving similar markets, both companies have common business values and provide a range of engineering services to complement their respective product lines.

This commonality has led a working relationship whereby R. A. Rodriguez is now responsible for Framo product sales in the UK and Ireland. The agreement, signed at the recent Hanover Fair, allows R. A. Rodriguez to market the full Framo range and call upon the company’s extensive manufacturing and assembly capabilities for custom drives.

The Framo range of drive systems includes compact slip-on geared motors; linear actuators and push-pull Linear Chains, all based on modular design principles and customised to suit each application.

The Compacta slip-on geared motor comes with built-in limit switches and is an ideal actuator for reverse motion. The Compacta is available in four sizes with torques up to 600Nm and for speeds from 0.9 to 193 rpm.

In a similar vein the Mini is a range of extremely compact linear actuators with acme screws that are sealed to IP65 and available in stainless steel. Minimum space requirement is also the main selling point of LinearChain that is capable of long strokes despite its small size.

The core competence of Framo is the production of gears and in particular worm gears for which the company is ranked amongst the leading suppliers in Europe. A full range is available including external and internal, spur, helical and spherical in modules from 0.5 to 6 and pitch diameter 15-250mm.

Another of the company’s key products that featured at Hanover is Discpower, a dynamic, brushless and maintenance-free synchronous disc motor with integrated and quiet-running, low backlash planetary gears.

Taking full advantage of Framo’s comprehensive manufacturing capabilities the company is also able to meet most custom drive requirements. In addition to special worm gear drives it has developed, for example, a 2-motor stairlift drive and intelligent actuators for tractors.

Framo Morat products are available from R. A. Rodriguez with immediate effect.

THE BEST BEARING CHOICE FOR ROBOTS

It is difficult to exaggerate the importance of bearing selection in robot performance, particularly in positioning accuracy.  The correct choice is crucial.  A partial list of robot performance elements directly affected by bearing selection includes total robot weight, compactness, cost, payload, reach, power requirements, positioning repeatability and responsiveness.

The inherent design and performance benefits of the KAYDON® REALI-SLIM® thin section bearings makes them a popular choice for robot applications.  Aside from their space and weight saving potential, high bearing stiffness and a large internal diameter to accommodate electrical, hydraulic and pneumatic services are the features that distinguish them.

A single four point contact bearing is ideal for shoulder, elbow and wrist joints.  Also available with integral gears and mounting holes reducing the number of the components and tolerance build-up.  This results in maximum accuracy and a simplified design. 

The 4-point contact bearing can accept combinations of radial, thrust and moment loads.  This is possible due to ‘gothic arch’ geometry of the raceways.  The ball raceway in each race has two radii that are larger than the ball radius and their centres are offset from the centre of the ball radius.  This generates the ‘gothic arch’ configuration in each of the raceways grooves making it possible for the two raceways to contact the ball at four points.

KAYDON® REALI-SLIM® thin section bearings have a radial cross section that remains constant with bore diameter.  They are considerably lighter in weight as bore diameter is increased than bearings with conventional cross sections.

As a rule of thumb every kilo saved by bearing weight is usually accompanied by almost ten kilos less on structural weight.  Such weight reductions in mechanical assemblies provide material and drive power economies that can significantly reduce the cost of a robot.

The bearings are available with bore diameters from 20mm to 1m.  By comparison, conventional bearings are generally limited to bores less than 200mm in standard sizes.  Also, for a given precision class, they are more accurate in large diameter sizes than standard-section bearings because tolerances do not increase as much with diameter.

The KAYDON® REALI-SLIM® range is widely used for light to medium loads at all robot joints, including the waist.  When robot payloads exceed 113 kg a KAYDON® turntable bearing is a good choice as it can handle combined loads at the waist without the need for pairs of standard-section bearings. Turntable bearings are ideal for supporting the intermittent rotating loads occurring at the waist of most robots.

A useful option is the KAYDON® REALI-SLIM® TT Series of miniature thin-section turntable bearings.  They are significantly smaller than conventional alternatives and offer performance advantages. 

DSEI 11th – 14th September 2007, EXCEL London, Stand no. 306

At this year’s DSEI the main focus for KAYDON® and its UK factory representatives R.A. Rodriguez, will be the REALI-SLIM® range of thin-section bearings that are readily available as fit-and-forget military spares and custom aerospace components. The range also benefits from a new and more accurate method of projecting bearing life. This has confirmed that the dynamic capacity rating of many of these bearings exceed previously published figures, by as much as five time in some cases.

The dynamic capacity improvements for REALI-SLIM® vary with type and size. For example for Type X, the four point contact bearing, the improvements range from 31% to 77%. As part of the validation process several competitors’ thin-section bearings were also tested. The actual dynamic capacity of those was found to be up to 72% lower than their published ratings.

Minimum space, very light weight and low torque are the key design credentials synonymous with KAYDON® REALI-SLIM®. This ever-popular range is now available in an expanded range of metric sizes with bores ranging from 20mm to 369mm in diameter in three different cross-sectional sizes of 8mm, 13mm and 20mm square.

Each bore size and cross-section is available in radial contact, angular contact and four-point contact ball construction. In total, R. A. Rodriguez now stocks more than 200 metric types and sizes as well as a comprehensive range of inch sizes.

In addition to the supply and support of aerospace products, R. A. Rodriguez provides a range of engineering services. As well as application engineering, the company is regularly consulted on special bearing design & development. It also undertakes bearing sub-assembly work and self-lube re-lining for military parts. Warehousing and stock supply management, kit-marshalling, labelling and JIT supply are services in which the company is well practised.

CATALOGUE INTRODUCES HIGHER CAPACITY BEARINGS

The higher dynamic ratings capacity of the KAYDON® REALI-SLIM® thin section bearings are detailed in the company’s newly published all-product catalogue. Developed specifically to save space and weight in a broad range of applications the entire REALI-SLIM® range and the new catalogue are available from UK factory representatives, R. A. Rodriguez.

The publication details the seven open and five sealed bearings that comprise the series including type ‘C’ for pure radial loads, ‘A’ for radial and thrust loading and ‘X’ that accommodates radial, thrust and moment loading in a single bearing. The catalogue also introduces seven new sizes and for the first time includes REALI-SLIM® TT™ compact turntable bearings and REALI-SLIM® MM™ metric series bearings.

Sizing charts guide engineers through the preliminary selection of standard, metric or stainless steel REALI-SLIM® bearings. An application worksheet is also included that designers can complete and fax to R. A. Rodriguez for a customised application engineering review and bearing recommendation.

A hard copy of the new catalogue is available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail to info@raruk.com. Alternatively a .pdf version can be downloaded from the company’s website at www.rarodriguez.co.uk. Also downloadable and available on CD is the comprehensive REALI-DESIGN™® software that provides engineers with bearing selection guidance and complete specifications.

THIN BEARING MEETS SPECIAL SEMICONDUCTOR DEMANDS

Without sacrificing bearing accuracy, the KAYDON® Corporation REALI-SLIM® bearings can be optimised to minimise friction, outgassing, contamination and even wear.  Indeed the company specialises in meeting the specific demands of semiconductor manufacturing by offering a range of options to create the optimum characteristics.

These custom REALI-SLIM® bearings were therefore the ideal choice for Applied Materials UK in Horsham for a gripper arm assembly on its Quantum X ion implant machine for the processing of silicon wafers. This is a single wafer, high current implanter using fixed beam technology.

Ion implantation is a process where electrically charged atoms are fired into the silicon wafer material to change the electrical properties of the material and can be applied at various points of the wafer process.  The gripper assembly is responsible for loading the wafer into the implant chamber and the role of the KAYDON® bearings is to support the rotation of the gripper.

UK factory representative for KAYDON® Corporation is bearing specialist R. A. Rodriguez with whom Applied Materials UK worked on this project.  The bearing selected was a customised Type X 4-point contact bearing that accepts radial, thrust and moment loading.  It was supplied with a flanged outer race for fixing to the gripper arm plate.

AISI 440C stainless steel races and balls were a must as the application called for contaminant-free, no-lube operation.  This material choice ensures minimum surface degradation and particulate formation that is common in harsh environment applications.  To accommodate the low torque operation under vacuum the bearing was also specified with PTFE cage.

“The gripper arm assembly and therefore the bearings needed to operate in a high vacuum environment of 10-7 Torr.  They also had to be electrically conductive,” explained Applied Materials Senior Design Engineer, Bert Webber. “Another important characteristic for this application was compact design”

Perhaps the best known of the REALI-SLIM® characteristics is the design’s minimum space requirement.  The single 4-point contact REALI-SLIM® effectively replaced the need for Applied Materials to specify two bearings, making the design more compact and simplifying the mounting.  In addition to the obvious cost savings this arrangement also created space for easy installation and maintenance and also saved weight.

The ability of this Type ‘X’ bearing to carry three types of loading simultaneously is thanks to the gothic arch geometry of the inner and outer races. It was also supplied with internal diametral pre-load to ensure zero free-play.  This is accomplished by using balls that are larger than the space provided in the raceways.  The balls and raceways therefore have some elastic deformation in the absence of an external load.

Such is the popularity of these thin section bearings for semiconductor applications that KAYDON® has now produced a dedicated brochure.  This publication and indeed the entire REALI-SLIM® range are available in the UK from R. A. Rodriguez in Letchworth.

KAYDON® BEARINGS SELECTED FOR LOW WEIGHT & HIGH SPEED

In medical diagnostics CAT scanners (computerised axial tomography) produce detailed images of internal body organs by rotating x-ray generators and detectors around the patient. The need for high positioning accuracy is of course paramount in these systems and scanner manufacturers therefore need to be assured of the quality of components such as bearings.

Development is firmly towards the production of faster systems to improve scanning time and reduce the patients’ exposure to radiation. For this reason weight and space are key factors in improving the speed and performance of the moving elements. For this reason KAYDON REALI-SLIM® thin-section bearings have become the choice of all major manufacturers of CAT scan equipment. They are primarily used in the mechanism that carries the x-ray head.

The REALI-SLIM® bearings specified by the leading names in the industry are generally custom made to provide diameters of 1.27m (50 inches). Inherent to the design is its suitability for high-speed rotation, with minimum vibration and ability to run quietly, an important consideration especially for the patient.

These qualities are ensured by KAYDON®'s high quality manufacturing processes. The KAYDON® Corporation has been a leading producer of large diameter custom bearings since its foundation in 1941. It manufactures combination load bearings up to nearly 4.6m and is unique in the breadth of product capabilities offered.

Bearing life is another critical factor as demand for CAT scanners in most hospitals far outweighs availability. Reliability is therefore a critical factor. Already considered to have an exceptional life rating REALI-SLIM® bearings have recently been reassessed using a brand new methodology that integrates theoretical life projections with actual test data. The result is that many KAYDON REALI-SLIM® bearings exceed previously published figures by as much as five times.

HIGHER DYNAMIC CAPACITY RATINGS FOR THIN SECTION BEARINGS

A new, more accurate method of projecting bearing life has confirmed that the ratings of many KAYDON REALI-SLIM® bearings exceed previously published figures, by five times in some cases. KAYDON® Corporation bearings are supplied in the UK by R. A. Rodriguez.

The dynamic capacity improvements for REALI-SLIM® bearings vary with type and size with increases for Type X, the four point contact bearing, ranging from 31% to 77%. As part of the validation process KAYDON® Corporation also tested several competitors’ thin-section bearings. The actual dynamic capacity of those bearings was found to be up to 72% lower than their published ratings.

The revised KAYDON® Corporation ratings are derived from a new method of calculation developed specifically for thin section bearings. It integrates theoretical projections with actual test data instead of simply estimating bearing life as is the practice of other manufacturers. The KAYDON® Corporation Bearings Division is believed to be the first thin-section bearing manufacturer to adopt this methodology.

These ratings have been published by KAYDON® Corporation in a new edition of its product catalogue and are naturally included in the new REALI-DESIGN™ software that is available for download at www.kaydonbearings.com

KAYDON EXTENDS PRODUCTION OF THIN SECTION BEARINGS

Investment in excess of $18.5m has expanded the Kaydon® bearing manufacturing site in Sumter County, USA, prompting the creation of 50 new jobs. Demands for Kaydon® bearing products worldwide has never been greater and this move will ensure the company can easily absorb this growth.

Kaydon® is the acknowledged leader in thin-section bearing technology and its sales and marketing interests are represented in the UK, Ireland and Scandinavia by precision components supplier, R. A. Rodriguez (UK) Ltd. The Kaydon® REALI-SLIM® and ULTRA-SLIM® brands are ideal for applications that call for low weight and compact size but also high performance.

Since opening in 1991, the Sumter County facility has performed at a very high level and Kaydon® has attracted a workforce whose skills are crucial to the continued success of Kaydon® bearing products. "The expansion of this site is good news for our customers," concludes David Hey of R. A. Rodriguez (UK) Ltd. "It ensures our lead times remain good in the face of growing demand and provides greater opportunity for product customisation."

LINEAR MOTION LITERATURE

The Ballscrew and Acmescrew range of components from R.A. Rodriguez is expanding to encompass a wider range of applications in a variety of industries. From slow lift mechanisms to high precision dynamic systems these products are proving to be a highly popular addition to the company’s range of linear motion components.

A new 24-page catalogue provides all the technical information. The publication details the leadscrew options available including the choice of ball transfer system, low backlash nuts and pre-loaded nuts for greater precision. And for less demanding applications it also provides a comprehensive guide to the Acmescrew choices. Both products are available ex-stock and in metric and inch sizes.

Entitled R. A. Rodriguez Ballscrews and Acmescrews, the A4 publication is available from the company’s Letchworth sales office on 01462 670044 or via e-mail to info@raruk.com

NEW STOCK GEAR CATALOGUE INTRODUCES NEW PRODUCTS

As its latest all-product catalogue confirms Japan’s leading manufacturer of gear products, KHK, continues to expand its range. This new publication introduces several new products and reinforces KHK’s status as a comprehensive single source supplier. The full KHK product programme is supplied in the UK by sole distributor R. A. Rodriguez from whom the new KHK 3009 product guide and technical data book is also now available.

The 382-page book has been designed for easy reference and to complement the company’s web-based catalogue. The range now comprises 133 standard gear products and more than 4000 individual items. Several new additions appear in this issue including an expanded range of racks, three types of bevel gearboxes and a new K-clamp for spur gears.

Copies of the 3009 KHK Stock Gear and Order Gear Guide are available from the R. A. Rodriguez sales office on 01462 670044 or by e-mailing info@raruk.com. A good comprehensive introduction to the range can also be found by visiting the company’s website at www.rarodriguez.co.uk

QUALITY, EX-STOCK BEVEL GEARBOXES… includes plastic-housed miniature version

New from KHK, Japan’s leading manufacturer of gear products, are two new ranges of spiral bevel gearboxes that have just been introduced to the UK by precision component supplier, R. A. Rodriguez. These products are ideal for specifiers who need a good quality gearbox available from stock.

Thanks to their plastic resin housing the new PBX miniature bevel gearboxes are lightweight and compact. They have superior chemical and thermal resistance, are maintenance free and have a speed ratio of 1:1. The units have through-holes and counter-bores allowing mounting in any orientation.

For applications involving high duty cycles and high speed the new CBX range of bevel gearboxes is a good, value-for-money choice. The units have a high grade case iron housing and use tapered roller bearings. The spiral bevel gears themselves are made from case-hardened alloy steel and the quality of their manufacture ensures both low noise and highly efficient motion control.

Gear ratios for the CBX range are 1:1 or 1:2 which meet the requirements of most applications. In common with the PBX range, the CBX is available with two or three output shafts and it also offers exceptional design flexibility; 24 permutations of shaft orientation and rotation are standard with the CBX bevel gearboxes.

PLASTIC HOUSED BEARING LITERATURE

Greenlign plastic housed bearings have proven to be a highly popular range of products for R. A. Rodriguez. The choice of types now amount to eight and it is to provide an overview of this extended range that the company has published a dedicated product folder.

Made from tough, precision-moulded thermoplastic that is chemical-resistant, the housed bearings broadly accommodate shaft sizes from 12 – 40mm; pillow block and four bolt flange types suit shafts up to 50mm. All sizes are available from stock and fitted with stainless steel bearings as standard.

The folder provides all the technical data needed for easy specification and holds individual, more-detailed data sheets on each of the product types. The new Greenlign literature is available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail to info@raruk.com

NEW, MACHINE TOOL BEARING ... with superior angle measuring system

A high precision combined radial, thrust bearing designed for machine tool rotary tables and spindle heads has been developed with an integrated angle measuring system by bearing manufacturer UNITEC. Available in the UK from factory representative, R. A. Rodriguez, the new UNITEC RTB AMS bearings use an inductive detecting principle. As a result no magnetic field, nor the presence of lubricating fluid or grease, interferes or influences measurement accuracy and the system is therefore understood to be more accurate than others currently available.

The system includes a graduated stainless steel scale that fits precisely onto the bearing’s washer ring and two sensor heads on the outer ring, sited at 180 ° to the centreline. During rotation, the sensors detect the slots on the scale and generate a 1 V pp output signal to the machine’s CNC enabling the angle to be continuously monitored. The scale slots – set at intervals of 1mm – are protected from dirt ingress by a metal cover.

This new bearing is available in seven sizes with bores from 150mm to 460mm. One reference point is provided as standard but on request several distance-coded reference marks can be specified at any angle from 40 ° to 15 ° depending on bearing size. The absolute position may be determined by detecting during rotation, the single reference point or alternatively two distance-coded marks.

HIGH PERFORMANCE BEARINGS FOR RACE CAR APPLICATIONS

In designing a high performance race car with a competitive edge, the choice of the bearing is critical. Weight and space are key factors in improving speed and fuel economy but this cannot be achieved at the expense of quality performance. For this reason Kaydon thin-section bearings have become the constructor’s choice across the motor racing sector whether it be for Formula 1, Formula 3000 or rally cars. In the UK, the entire Kaydon range is available from factory representative, R. A. Rodriguez.

In Reali-Slim bearings, each series is based on a single cross section that remains constant as the bore diameter is increased. This is in sharp contrast to standard bearings where the cross section increases as the bore diameter increases. Because the radial cross section and race width of Reali-Slim bearings are smaller than comparable diameter bearings from other manufacturers they take up less space. This allows designers to use thinner shafts, housings and other components resulting in not only a more compact design but cost reductions too.

The use of Kaydon Reali-Slim bearings on performance car wheel assemblies provides a good illustration of their technical merits. This is a particularly arduous application due the bearing speeds and the applied loads that are involved. Radial, thrust and moment loads that correspond to the pitch, roll and yaw of the vehicles are simultaneously applied to the wheel bearings.

Controlling pre-load for this type of application is vital. Too much pre-load would increase the loading on the bearings, reducing their life. Too little could lead to lower stiffness and deflections. Many constructors therefore take advantage of the specialist support from Kaydon and R. A. Rodriguez application engineers. Their advice on bearing preload adjustments and mounting arrangements has proved invaluable in achieving optimal bearing performance on the race track.

The Reali-Slim product programme comprises a wide range of choices to accommodate the combined loading that is typical of automotive applications. The range comprises seven open and five sealed series ranging in bore diameters from 20mm to 360mm; R. A. Rodriguez also supplies an Imperial size range.

If required, these bearings can be quickly modified to have special clearances, preloads, lubricants, separators and other features to meet the most demanding application requirements. In addition, the Reali-Slim bearings can be quickly modified to obtain corrosion resistance by applying Endurakote® thin-dense chrome plating. When assembled with 440C stainless steel balls, this modification forms the basis for Endura-Slim series of bearings that provide corrosion protection equal to or better than a full 440C stainless steel.

LINEAR SLIDE MEETS TURBOCHARGER ‘SPEC’

Fundamentally a turbocharger comprises a turbine and a compressor connected by a common shaft supported on a bearing system. It converts waste energy from the exhaust manifold into compressed air that is pushed into the engine. This allows the engine to produce more power and torque improving the overall efficiency of the combustion process.

Proving and measuring the air flow through a turbocharger is a critical process and to assist in this process R.A. Rodriguez has recently supplied the linear motion element for one of Europe’s leading turbocharger manufacturers. The special purpose test rig called for the incorporation of a short stroke, manually operated slide whose accuracy needed to be repeatable in all planes. This was required to ensure the concentricity of positioning two components.

The unit recommended by R. A. Rodriguez is from its IEF Werner range of hand-operated slides. Made from GG25 cast iron to provide greater stability, the slide section is 150mm wide with a 50mm stroke. The unit has 20mm diameter spindle with 1mm pitch and accuracy is ±0.02mm over a 300mm stroke. It was supplied with special fixing holes and a bronze, adjustable pressure plate for establishing a light pre-load in the slide to ensure precision positioning. To identify position, the linear system works in conjunction with a linear digital reader and it is required to carry a load of approximately 20 kg.

This manually operated slide is one of many IEF Werner options available from R. A. Rodriguez. The range can be equipped with dovetail, cross roller or Teflon guides. The latest addition to its slide range is DOMILINE, a variable-combination adjustable system. This visually and technically sound modular system can be specified in a large number of different variants and widths. There are also combinations with and without mechanical locking devices, with a spindle or if desired, a pneumatic or motor drive

NEW MINIATURE PLASTIC-HOUSED BEARINGS... bring even greater choice

Whilst there is nothing ground breaking about the new series of miniature plastic housed bearings from R. A. Rodriguez they perfectly complement the company’s established Greenlign and Redlign ranges. These products are in considerable demand in the hygiene-sensitive food, pharmaceutical and chemical industries where non-corrodible housings and stainless steel bearings are essential.

With the introduction of new Greenlign designs last year R.A. Rodriguez could already boast the widest the choice of plastic housed bearings. The new miniature additions give R. A. Rodriguez even greater scope to provide the right product for the job.

The new range introduces two basic types, the 2N 2-hole flanged bearing and the 4N, its 4-hole counterpart. Each housing type is available in a range of sizes to accommodate a self-aligning stainless steel insert bearing with bore diameters from 3mm to 12mm.

The housings are precision moulded from high-tensile plastic whose strength characteristics can be compared with those of die cast metal alloy. However, unlike cast iron housings, their smooth surface is easily cleaned and will not corrode, chip or scratch.

SMOOTH AND CONSISTENT LINEAR MOTION… for superior inkjet printing

The R. A. Rodriguez linear axis system chosen to carry an inkjet print head across a conveyor-width of food products has brought a range of operational benefits for a major food processing company. It has resulted in consistently high quality printing of ‘best before’ and ‘sell by’ dates, a factor that is all-important for any food processor dealing in the mass market.

Linear motion is now one of five main product sectors for Hertfordshire-based R.A. Rodriguez who represents the sales interests of German handling and automation specialists IEF Werner in the UK. However the company’s role was far more than just a supplier of components. Using elements from the Werner Easyline range of modules, R. A. Rodriguez designed and installed a complete package of equipment complete with programmed controller.

The Easyline axis is integrated into a dessert-packaging machine and used to transport the inkjet print head across a conveyor carrying rows of pots. Each row holds three pots and the conveyor indexes to the next row every three seconds. Smooth operation and consistent speed are vital components in the efficiency of the inkjet printing process and thanks to its controlled acceleration and deceleration the stepper motor controlled Easyline system ensures no disturbance to ink flow.

The IEF Werner linear motion product programme is now a popular programme especially for systems integrators. It has been designed to provide elements that are freely combined to create bespoke, multi-axes handling systems. They offer high loading capacity, high rigidity, quiet operation and are complemented by a wide choice of motors and controllers.

IP65 rating qualifies the system for the wash down environment required by this dairy application and its controller enables a range of different products and print positions to be accommodated. The freely programmable controller has integrated input/output processing enabling it to control all x-y movements; it has the ability to run a maximum of 32 programmes in parallel.

KAYDON CORPORATE BROCHURE

Although predominantly known in the UK for its rotary bearings and in particular its Reali-Slim thin-section range, the Kaydon Corporation is a manufacturer with diverse business interests. For the first time, details of all of the Kaydon Group companies - several of which are represented in the UK by R.A. Rodriguez – have been brought together in one publication.

Kaydon’s portfolio of products and services now span the metalworking, process and service industries incorporating brands such as Cooper®, Spirolox® ACE®, Purafil®, Tridan® and Canfield®. However leading this new corporate publication is Kaydon’s flagship, the Bearing Division.

In addition to concepts that are synonymous with weight, cost and space savings, the Division is also responsible for the design, manufacture and development of both heavy-duty and lightweight turntable bearings as well as custom miniature bearings for high-speed applications in aerospace, instrumentation and semiconductor manufacture.

LINEAR BEARINGS FOR HARSH ENVIRONMENTS

The fundamental design of the new Schatz Double V linear bearings from R. A. Rodriguez make them ideal for use in harsh environments. Unlike other systems that allow the ingress of dirt, the rolling elements of these components are enclosed and therefore safeguarded from contamination. As a result they provide a longer service life.

The new Schatz HC™ Series builds on these benefits providing a range of guide wheels and tracks that offer superior performance in demanding aerospace, medical, semiconductor, processing and packaging applications. Careful choice of materials is largely responsible for their longevity.

Most of the corrosion resistant bearings on the market use 440C stainless steel as their preferred material of manufacture. Whilst this steel offers better corrosion resistance than non-stainless bearing materials it is prone to wear. The material composition of the HC™ bearings is unusual in that it ensures both corrosion-resistance and long fatigue life.

The inner and outer rings of the HC™ guide wheels are EMS138 stainless steel as is the linear track whose V section hardened to Rc53 min. Ceramic balls are a standard feature of this range. EMS138 has a fatigue life that is at least five times greater than 440C and shows far greater resistance to oxidation especially in salt spray tests lasting 160 hours.

Four wheel-sizes are available in the standard range. Guide wheels can be mounted vertically or horizontally to suit differing space and application requirements and used to support rotary motion. A range of bushings and ancillary products are available for numerous mounting arrangements.

SEMICONDUCTOR THIN SECTION BEARINGS

As well as their compact design, the ability of Kaydon Reali-Slim® bearings to withstand high temperatures, their vacuum and chemical compatibility and low particulate generation make them the ideal choice for semiconductor manufacturing. Such is the popularity of these thin section bearings in this sector that Kaydon has now produced a dedicated brochure. This publication and indeed the entire Reali-Slim range are available in the UK from factory representatives, R. A. Rodriguez.

The brochure covers the three basic configurations, 'C' type for pure radial loads, 'A' for radial and thrust loading and 'X' for any combination or radial, thrust and moment loading on a single bearing. All bearings can be customised to minimise torque, outgassing, contamination, corrosion and wear. The wide selection of ball, race and cage materials that help optimise bearing life and performance are also detailed.

An application worksheet is included in the publication for designers to complete for a free customised engineering review and bearing recommendation. Other free engineering aids are also listed in the catalogue and include the company’s popular Reali-Design™ CD software and the comprehensive Reali-Slim Catalogue 300. All are available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail, info@raruk.com

R. A. RODRIGUEZ IS NOW AS9120 ACCREDITED

Aerospace is a prime market for R. A. Rodriguez. Indeed its products are used on most military and civil aircraft in the Western world. In particular, the company’s Kaydon thin section bearings and Schatz aircraft control bearings are considered by many customers to be industry standards.

It is to ensure its quality management systems are in harmony with the specific needs of the industry that R. A. Rodriguez has sought certification to AS9120. This sector-specific, ISO 9001-based standard focuses on areas with the greatest impact on safety, reliability and regulatory compliance of aerospace products.

R. A. Rodriguez has now received its certificate of registration confirming its compliance with AS9120 Quality Management System Requirements for Stockist Distributors. Developed under the auspices of the International Aerospace Quality Group this standard provides the assurance that all R. A. Rodriguez aerospace products meet this industry’s stringent requirements.

ANOTHER SALES APPOINTMENT FOR R. A. RODRIGUEZ

The second phase of sales team re-structuring at R. A. Rodriguez has been completed with the appointment of Andrew Mason. Working in parallel with Dave Young in the North, Andrew is now responsible for the sale of all product lines in the South. Based in Reading he is supported by four dedicated product managers and the internal sales team.

Having served his engineering apprenticeship with a company specialising in fluid power, Andrew made his first transition into sales in the mid-nineties. He subsequently returned to the factory floor and indeed joins R. A. Rodriguez from Blatchford Products where as manufacturing engineer his role was to bring new artificial limb components from design development to production.

THIN SECTION BEARING WEBSITE

Visitors to the new www.reali-slim.com website can now quickly access a wide range of helpful engineering tools and information to simplify and speed up product design cycles. Kaydon has created this dedicated website for its thin-section bearings to ensure the efficient selection of standard or custom bearings that optimise bearing life and performance in the given application.

Products featured include the company’s space-, weight- and cost-saving Reali-Slim® thin section and turntable bearings and Ultra-Slim bearings. All are available in both imperial and metric sizes. Product descriptions, technical literature, 2D, 3D and CAD drawings can quickly be downloaded. Dimensional drawings are imported directly as native CAD files saving re-drawing time and eliminating compatibility problems.

To save time-consuming manual calculation, the site also includes the Reali-Design™ Engineering Aid. Available calculations include bearing life and load analysis, maximum safe operating speeds and axial play due to internal clearances.
Further information on the Kaydon range is available from factory representatives, R. A. Rodriguez on 01462 670044, www.rarodriguez.co.uk.

R. A. RODRIGUEZ BOOSTS ITS MACHINING CAPABILITY

Thanks to a substantial factory expansion at its sister plant in Germany, R. A. Rodriguez now has far greater capacity to supply UK customers with its own range of linear motion products machined to order. Investment in the facility also includes new CNC production machinery and equipment to enable far greater stock holding.

This next phase of the company’s development extends by a third its purpose-built premises in Eschweiler near Achen. It provides a dedicated machining and assembly shop for the R. A. Rodriguez range that in addition to shafts includes linear guideways, ball bushings, bearing housings, shaft supports, shaft blocks, ballscrews and acmescrews.

1M DIAMETER HYBRID BEARING GOES INTO PRODUCTION

Kaydon’s ability to engineer bearings to suit the individual requirements of a specific application is well exemplified by a unique product that has just gone into production. This special hybrid bearing, used in a three-bearing swivel module on a new fighter jet exhaust system, is the first of its kind to be commercially adopted.

Whilst other companies were initially involved in the project, the Kaydon design proved its outstanding ability to operate well in temperatures up to 600ºC. The bearing has a bore diameter of 1m and its manufacture has required the design of bespoke tooling and the use of special, difficult-to-machine materials.

As well as these bespoke hybrid bearings, R. A. Rodriguez also offers a standard range for general harsh environment applications. These bearings owe their ability to extend the mean time between performance failure to a combination of ceramic balls and hardened steel races. This combination offers several advantages over all-steel bearings and makes hybrid bearings the ideal choice for harsh environments.

Hybrid bearings provide longer life and lower wear than steel bearings because the ceramic rolling elements reduce surface flow induced fatigue. And the higher ball hardness minimises the effects of wear debris tracking. Due to their low friction characteristics, hybrid bearings therefore perform well with minimal lubrication and indeed greatly extend lubricant life.

MULTI AXIS PROGRAMMABLE HANDLING SYSTEM
ensures accuracy and speed in car part production

The economics of the automotive business requires supreme manufacturing efficiency to keep unit costs down. Therefore in designing a timing mark milling machine for a major German second-tier supplier Feasey, the West Midlands based special purpose machine builder, was sure to specify elements that would meet the high productivity needs of the sector.

The role of the machine is to cut notches in timing belts for car engines with extreme precision. A robust construction suited to operation in a demanding environment for up to 20 hours a day was a pre-requisite of the system. At its heart is a 4-axis IEF Werner Easyline programmable handling system with rotary indexing table from R. A. Rodriguez. It was supplied with integral controller responsible for running the entire machining process via parallel programmes.

Having collected a pulley from the in feed conveyor, the system orientates it to find a keyway in the bore. The pulley is then transferred onto the programmable rotary index table where is it carefully positioned to receive the timing mark notches. A rotary cutter creates 2, 3 or 4 notches according to requirements. On completion of the process the pulley is transported out of the system via out feed conveyor.

The system can accommodate a range of pulley types. To ensure easy use and minimum downtime changeover is accomplished via a selector switch. The typical cycle time is approximately 25 seconds dependent on the number of notches required.

EasyLine, whose quality of manufacture also allows it to be used safely in cleanrooms, is compact, light-weight and has the ability to deliver high positioning speeds of up to 2.5m/sec with repetition accuracy to ±0.04mm. It has integral limit switches and a range of drive options making it ideal for a broad spectrum of production needs. Rated for loads up to 30kg, EasyLine provides stroke lengths up to 5.5m.

DOUBLE QUALITY LINEAR BEARINGS

MORE ADDITIONS TO THE AEROSPACE BEARING RANGE

DSEi EXHIBITION, EXCEL – LONDON, 13th – 16th September 2005, Stand no: 721r

LARGEST RANGE OF PLASTIC HOUSED BEARINGS

LINEAR MOTION SYSTEM FOR HIGH PRECISION HEAT TREATMENT PROCESS

The application of a carburising inhibitor to shafts and gears at a second tier automotive supplier is an important one. Brushed-on in liquid form before heat treatment, CarboStop keeps the coated area soft and suitable for welding or secondary machining after hardening. Knowing where to put the coating is a skilled task. Its application has always been a manual job but not only was this proving time-consuming and messy, it was also relatively wasteful and therefore uneconomic. Could automation provide a solution?

The resultant IEF Werner 2-axis linear motion system, supplied and supported by R. A. Rodriguez has indeed been highly successful in cutting application time and costs whilst enhancing process quality and the working environment. Equipped with interchangeable tooling for processing a range of parts, this free-standing, bespoke machine is driven in both horizontal and vertical axes by stepper motors. Parts are manually loaded and unloaded but the remainder of the cycle is fully automatic - light guards ensure easy operator access to minimise cycle time.

The blue-coloured CarboStop is delivered precisely via a 2-position dosing nozzle from a secure 5-litre reservoir onto the part that rotates at a constant speed. The system can apply the liquid material around a radius or chamfer and is fully programmable to ensure optimum coating of a variety of gears and shafts. Time and cost savings have been sufficiently high to ensure an early payback on this machine.

AUTOMATIC WELDING SYSTEM FOR AUTOMOTIVE PRODUCTION

Having won the contract from Magna Kansei to produce a special purpose machine for use in the production of car fascia panels, ICS Robotics & Automation Ltd., sought the linear motion expertise of R. A. Rodriguez. The application called for a programmable X-Y positioning system to carry a Branson ultrasonic welding head and the IEF Werner system proposed by R. A. Rodriguez was judged to provide the required high level of performance. A key element was the system's linear speed of 1m/second to achieve an overall cycle time of 20 seconds.

The process for which the machine was specified is the ultrasonic welding of sound insulation fabric to instrumentation fascia mouldings. This requires the operator to load the black fascia panel into the machine in the upside down position. White insulation fabric is then laid into position automatically - a machine vision system is used to ensure the integrity of the process.

The 2m x 0.8m IEF Werner EasyLine gantry system then positions the ultrasonic welding head to 20 pre-programmed locations on the assembly. At each position it welds the fabric to the moulding, providing a secure weld. Stepper motors are used for high holding torque whilst welding is in process and for their ability to move the head in short, fast steps.

The system's two-axis IEF Werner PA Control Compact is freely programmable and has integrated input/output processing enabling it to control all x-y movements; it has the ability to run a maximum of 32 programmes in parallel.

The IEF Werner linear motion product programme is now a popular programme for systems integrators such as ICS Robotics & Automation. It has been designed to provide elements that are freely combined to create bespoke, multi-axes handling systems. They offer high loading capacity, high rigidity, quiet operation and are complemented by a wide choice of motors and controllers.

ICS Robotics & Automation report "Absolutely no problems with the installed system," and testimony to its success has been the order of two further identical special purpose ultrasonic welding machines by Magna Kansei.

NEW POST IN THE NORTH

With demand for its engineering products very much in the ascendancy, R. A. Rodriguez is re-structuring its sales team to provide the best possible support for its customers. The first step has been to appoint a Sales Engineer for the North, a newly created post that has been filled by Dave Young who joined the company on 1st January 2005. Dave will be responsible for the sale of all product lines in the territory with the support of four dedicated product managers and the internal sales team.

A qualified mechanical engineer, Dave has spent the last nine years of his working life in industrial technical sales and sales management. He joined R. A. Rodriguez from J. H. Fenner where his role was the domestic and export sale of the Fenner-Dunlop range of industrial conveyor belting.

WORLD'S FIRST THIN-SECTION TURNTABLE BEARINGS

Customer demand for a more compact turntable bearing has prompted Kaydon® to design its new Custom Reali-Slim® TT Series thin section bearings. They save weight, reduce product design envelope size and increase design flexibility without compromising bearing performance and life. This new series is now available in the UK from Kaydon's exclusive UK distributor, R. A. Rodriguez.

These miniature thin-section turntable bearings offer significant advantages over conventional alternatives. They are significantly smaller allowing greater design versatility. The smallest bore is 1.5 inches, the largest 6 inches and the height only .25 of an inch. Yet despite their small size they offer greater accuracy. The extended radial bearing cross-section increases rigidity and optional pre-load or clearances meet application torque or deflection requirements.

Designed for fast and convenient installation, these bearings feature stainless steel races and steel-reinforced seals to ensure their suitability for operation in harsh environments.

The Reali-Slim® TT Series bearings are a proven, single 4-point contact ball design, consisting of a single row of balls with a unique 'gothic arch' raceway and one-piece separators for low frictional torque. Capable of supporting radial, axial and moment-loads, they are dispatched pre-lubricated and ready for use. Installation is fast and easy; the bearing is positioned on the mounting face and tightened down by mounting screws.

Versions are available with optional internal or external spur gear, or in non-geared designs. The geared versions are 64 diameter pitch with 20° pressure angle, AGMA Class 10 and provide low-backlash operation. The bearings are cleaned and packed in a Class 10,000 clean room; up to Class 100 standards are also available. Custom configurations are also available.

CONSISTENT, HIGH SPEED CODING
... thanks to a programmable IEF Werner linear system

With its existing coding and marking system's frequent failures equating to a production loss of 18,000 milk pots per 15 minutes of downtime, a Scottish dairy knew it was time for an upgrade. Inconsistent positioning and speed resulted from the friction between the system's piston and cylinder. Inkflow was also disturbed by inefficient shock absorption at the end of each stroke. Downtime for printer maintenance was becoming excessive and costly.

The chosen successor, based on a standard IEF Werner linear axis from R. A. Rodriguez, is responsible for positioning two inkjet print heads. Both work in conjunction with a filling and sealing machine. The one-shot milkpots are delivered to the filling and coding station in rows of twelve by a conveyor that indexes 100 times/min., stopping for 0.3 second per row to allow for filling and coding. Throughput is therefore 1200 pots/min., 72,000/hour.

The stepper motor driven linear axis is controlled by an IEF Werner PA Control that positions the print heads over the 12-pot row; one print head passes over the first 6 pots, and second over the remaining 6. At each print position the controller sends a signal to the initiate printing.

"High constant speed and consistent print quality were our prime requirements from this system and we are now achieving this 100%," explained the customer. The free running linear axis with rolling element bearings combined with programmable acceleration and deceleration ensure uninterrupted ink flow in the print heads. These features are complemented by the system's robust 8 Amp stepper motor for high duty and long life.

In addition to ensuring optimum movement and positioning, the user-friendly IEF Werner control can easily be re-programmed to accommodate a new print position in the event of a change of product, pack-size or artwork on the lid. The linear axis is also designed for quick and easy disassembly for routine maintenance.

INVESTMENT CROWNS A GREAT SALES YEAR

R. A. Rodriguez is actively seeking to build on the success of its operation in 2004 by increasing product storage capacity at its UK sales headquarters in Letchworth, Hertfordshire. A mezzanine floor has been installed providing 100m2 of additional storage space for the company's ever-expanding range of engineering products. It also accommodates a brand new computer system that has been specified to meet the growing needs of this business whose sales both in the UK and abroad have increased significantly in the last year.

During 2004, R. A. Rodriguez increased its UK sales by over 20%. "Surprisingly this boost has been across our product range," explained MD John Williamson. "As soon as one of our product divisions edged ahead, the others followed suit!"

Another significant contributor to last year's growth was export sales. Although R. A. Rodriguez acts as sole UK distributor for several of its product ranges, the scope of its operation for others is far more international. "We are now selling Greenlign bearing housings to Australia, KHK stock gears to the wider Europe and Spirolox retaining rings to Japan," John Williamson concluded. In 2004, the company's export quota increased by an impressive 50%.

LINEAR MOTION OVERVIEW

Linear motion technology is now one of the five principal operating divisions at R. A. Rodriguez and within that product programme the IEF Werner range now dominates. Year on year the company has introduced new systems, modules and controllers making this range one of the most comprehensive available. Communicating the wide scope of these systems to design engineers is the purpose of a brochure, simply entitled IEF Werner - A Product Overview.

The 16-page brochure introduces the reader all the IEF Werner linear elements, slideways, compound tables and controllers with specific reference to precision positioning, handling and material flow. The final section is devoted to typical applications and shows examples of the turnkey systems now available from R. A. Rodriguez. The brochure is available from the company's sales office on 01462 670044 or via e-mail sales@raruk.co.uk.

KAYDON ENGINEERING AID ON CD

Manual bearing selection can involve hours of tedious computations and, due to the complexity of those calculations, a greater chance of error. The new Kaydon REALI-DESIGN™ software, available in the UK from R. A. Rodriguez, allows the selection process to be accomplished in just minutes. It undertakes essential life and load analyses, determines maximum safe operating speeds and calculates axial play due to internal clearances.

This innovative programme also allows the user to import CAD drawings from a .DXF library and access various tutorials including a guide to the wide-ranging uses of thin-section bearings and ideas for bearing mounting. Also contained on the CD is the complete Kaydon Catalogue 300 in PDF format. System requirements are Windows® 95 or later and the availability of 34mb of disc space.

SPECIALITY BALLS NOW AVAILABLE IN UK FROM R.A.RODRIGUEZ

Unlike other commercial ball suppliers, Industrial Tectonics Incorporated design and manufacture only dedicated precision balls and related spherical products from a wide choice of engineering materials, alloys and elements. Now a Kaydon company, ITI has just placed its UK sales interests in the capable hands of precision component suppliers, R. A. Rodriguez.

As a result of this arrangement, R. A. Rodriguez is now able to supply balls made from any workable material to meet specific requirements for weight, magnetic properties, self-lubrication and abrasion resistance. The specification can also include service at elevated or cryogenic temperatures or under noisy or radioactive conditions.

The list of special materials and their alloys from which balls can be made, literally runs into hundreds. The choice also includes plastics, ceramics, glass and piezoelectric quartz. The quality control programme for ITI's ball manufacture meets the stringent requirements of the aerospace, defence, medical and automotive industries. And since many products are used in the food and drug industries, their manufacture is compliant with Food and Drug Administration's 21 Code of Federal Regulations (CFR) Part II that requires electronically logged production records and audit trail.

ITI Inc., also maintains stock of the largest selection of standard ball materials in the industry. This allows R. A. Rodriguez to offer its customers short lead times on delivery. Orders are also welcomed for any application that requires design modifications, unusual ball sizes, materials or tolerances.

R.A. RODRIGUEZ EXTENDS GREENLIGN PLASTIC BEARING RANGE

The introduction of yet another plastic housed bearing type to the R.A. Rodriguez Greenlign range extends the choice to eight. Greenlign continues to be in great demand in the food, pharmaceutical and chemical industries, the sectors in which non-corrodible housings and stainless steel bearings are essential. The new addition incorporates a triangular mounting base, allowing the bearing to stand proud.

The new FBL bearing is suitable for shaft sizes from 12 - 35mm. In common with all models in the Greenlign range, FBL is interchangeable with most cast iron units to provide a component that is easily cleaned, will not corrode or promote the growth of micro-organisms. Furthermore, Greenlign has no coating to chip or scratch.

The tough precision-moulded thermoplastic used is characterised by its excellent resistance to a wide range of chemicals. Although the standard product is fitted with a stainless steel bearing an economy insert bearing can also be specified. End covers are provided as standard.

KHK EX-STOCK SPIRAL BEVEL GEARS

Their ability to transmit motion exceptionally smoothly makes the new range of KHK spiral bevel gears from R. A. Rodriguez the ideal choice for turning a drive through 90º.

Few companies in the UK are able to offer such a comprehensive range of bevel gears as R. A. Rodriguez. In addition to the 5 spiral bevel series', the product line includes bevel gears in 4 different materials, pinion shafts, high ratio hypoid gears and sintered metal bushings. All benefit from being available on very short lead times.

The stock spiral bevel gears are supplied in gear ratios from 0.67:1 to 1.5:1 and in a wide variety of modules, styles, number of teeth and materials. Two of the series are precision ground, providing high strength and abrasion resistance. The MMSG style is compact and ideal for high speed, high torque applications. These qualities are shared by the SMSG series that also allows secondary machining.

Comprehensive technical data on the entire range of KHK stock gears is provided in a new 380-page catalogue available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail to info@raruk.com

HANDLING SYSTEM NOW HAS ROTARY OPTION

The Werner domiLINE slide system from R. A. Rodriguez was designed to provide high flexibility for X-Y-Z configurations but until now the options have not included a rotary element. With the introduction of a new module however, this has been rectified, greatly extending the application potential of this versatile system.

The new addition is a low cost turntable. Manufactured from high-grade steel, the basic unit is designed for manual operation and easy adjustment but can also be specified with a digital display. A further option is the inclusion of a motor and an inductive sensor to provide a zero point for NC positioning.

Two sizes of this new Werner product are available with diameters of 55mm and 80mm. They can act as turntables, rotating mounting blocks or connecting elements between two linear modules.

NEW HIGH SPEED LONG STROKE TELESCOPE MODULE

The new Werner Linear 90/15 Telescope from R. A. Rodriguez is designed to be freely combined with other modules in the Werner range to enable dedicated multi-axes handling systems to be created simply and quickly.

Despite its compact size, the unit offers a maximum stroke of 1400mm and is rated for loads up to 5kg. Made from extruded aluminium section with high torsional strength and driven by toothed belts, the unit can achieve a maximum operating speed of 2.8 m/sec. Its integrated planetary gearbox is designed to accept a wide choice of motors to suit the application.

The Linear Telescope is ideal for any loading/unloading application of process machines and is expected to appeal particularly to those involved in the plastic moulding industry.

REALI-SLIM ON MARS

For the Mars Explorer Rover vehicle, its designers needed bearings whose performance was literally, out-of-this-world! They had to survive sub-zero temperatures on Mars and withstand the tremendous shock and vibration loads of the probe's launch phase.

Customised Reali-Slim® bearings have proven equal to the task. These compact bearings combine low weight and space savings with the reliable, precise performance needed to position the Rover's camera accurately during pan and tilt functions.

The Reali-Slim® standard product programme comprises 7 open and 5 sealed series of bearings ranging in Imperial bore sizes from 1" to 40" and in metric, 20mm to 360mm. Where required, R. A. Rodriguez can also provide preloaded bearings, lubricants, separators and other features to meet the most demanding application requirements.

TRW CHOOSES WERNER FOR HIGH PRECISION LASER WELDING

When leading automotive component manufacturer TRW required a bespoke laser welding system that had a positioning accuracy of ±5 microns, it instructed its system integrator, Chess Systems of Horsham, to contact Werner's representative in the UK, R. A. Rodriguez. The move was prompted by TRW's positive experience of Werner linear motion systems in Germany and the resultant UK installation has proved just as successful as its counterparts in mainland Europe.

The now-installed system is required to weld a small field-effect transistor, used in an automotive power steering control system. These units are welded at the rate of 2500 units per day. To do this, the operator manually loads the component onto a rotary table that turns 180° to position the FET in the laser field.

The accurate positioning of the FET under the Nd:YAG laser head is critical, as the laser is required to weld a copper post to a chassis. The post itself stands proud of the chassis by 10mm or