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<font size="-2">Machine Tools The FAS Lathe heralds an entirely new generation of production
lathes. It combines the user-friendliness of a CNC lathe with the fast cycle
times of a Cam-automatic lathe, all at an affordable price. The FAS Lathe
has the potential to bring about a global shift in production turning
economics. FAS Machine Tools (Pty) Ltd. Unit 11 Riverdale Dawnhill road
Maxmead Pinetown South Africa 3604 PO Box 15371 Westmead 3608 Contact :
Peter Frow Peter Korck Tel: (027) 702 7318
Fax: (027) 701 3157 E-Mail: info@faslathe.com Machine Tools The Lathe
allows extremely fast change over times due to it's unique design features.
achieves rapid cycle times because several tools can work simultaneously on
the workpiece. makes lower demands on setting and operating personnel due to
it's user-friendly design. is robust, reliable and elegant in construction
yet manufactured to close tolerances to allow precision production of turned
components. Typical Components that can be made on a FAS Lathe Drive Unit
Threading Attachment Actuator Area WorkArea Machine Tools New S.A. Lathe
cuts setup from half day to half hour Lani Holtzhausen Engineering News
Staff Writer A new lathe design that combines the user-friendliness of a
CNC lathe with the fast cycle times of a Cam-Automatic lathe has been
developed by the Pinetown, KwaZulu Natal, firm FAS Machine Tools. Believed
to be the first of its kind in the international manufacturing industry, the
FAS lathe features unusual patented features, dramatically reducing setup
times, typically from a half day to half an hour, reveals CEO Peter Frow.
"This means that the machine can be cost-effective down to small batch
sizes" he tells Engineering News. The machine is cost-effective across a
range of batch sizes from 50 to 500 000 and upwards," he adds. Among its
features are universal cams which are fitted for the life of the machine,
eliminating the need for additional cams to be designed, made or fitted.
The machine also features constant feed rates which, once set are maintained
irrespective of spindle speed. An infinitely variable spindle speed allows
for the optimum speed to be set quickly and accurately, while the fingertip
setting includes virtually all settings, such as changing of collets, which
can be undertaken without the use of hand tools. In addition, tool
parameters are stored with form tools, enabling the first component of a new
batch to be within, or close to, specification.
Components can be threaded by setting of pitch and length variables on the
synchronised threading attachment. Thread production is unaffected by
changes in spindle speed, and the entire threading sequence, including
indexing, is pre-timed and synchronised to produce a variety of different
threads. Conceptual design work began in 1990. Having rebuilt and operated
most available makes of cam-automatics, the company could evaluate existing
designs, and extract the best features from each. In addition, each step of
the setup procedure was analysed to see whether, by innovative design, it
could be either eliminated entirely or minimized. By 1995 a practical design
was on the drawing board, which embodied a number of features which have
subsequently been patented and, by 1998, the prototype was sufficiently
advanced to attract the interest of an outside investor who injected funding
to unable the completion of the machine in February 1999. In addition,
funding was awarded from the Department of Trade and Industry's Support
Program for industrial Innovation. Since its completion the prototype has
been in continuous production and has proved to be highly cost-effective.
With experience gained on this machine, numerous detail improvements have
been incorporated in the final design. Existing Cam automatic lathe users,
users of CNC lathes and users of turned components who have formerly
subcontracted their requirements, but who will now find in-house manufacture
accessible, are some of the potential markets. Potential clients have
already expressed a keen interest in the machine, reports Frow. At the
launch of the lathe late last year, the machine was demonstrated being
changed over from a brass nozzle with external thread to a round tapered
steel nut with knurl and internal thread The entire changeover took just 15
minutes, resulting in very positive responses form prospective clients, 'he
says. This year the company hopes to exploit the machine's export potential.
We believe that the machine has the potential to bring about a global shift
in production turning economics and that, in time, many existing machines
will be replaced by this lathe,'concludes Frow. NEWSFLASH At a recent
launch of the FAS Lathe, a changeover from a round tapered steel nut with
knurl and internal thread, to a hexagonal brass nozzle with external thread
was achieved in 15 minutes. This included changing collet, spindle speed,
cycle time, cutting tools and the setting of all size parameters . The FAS
lathe has been specifically designed to meet the need for a production lathe
with fast cycle times and rapid changeover times. The fast cycle times are
achieved by means of multislide operation where as many as 5 tools can work
simultaneously. The quick changeover capability is made possible by a number
of unique features. Answer to "Engineering News " Questionnaire Question1)
Please provide some background information on your company, i.e. when
established, where based, main activity, number of employees etc. The FAS
Lathe is manufactured and marketed by FAS Machine Tools (Pty) Ltd, which is
based in Pinetown (near Durban). This company was set up specifically for
this purpose by Renfield Machine Tools which handled the initial design and
development work on the FAS Lathe. Renfield Machine Tool has since 1991
supplied the production turning sector in South Africa with reconditioned
automatic lathes, in most cases tooled up to produce specific components. An
associate company Ninth Symphony Engineering operates single and
Multispindle automatic lathes in a production environment. Mr. Peter Frow,
C.E.O. of both companies and a graduate mechanical engineer, identified a
need for a machine that would combine the user friendliness of a C.N.C.lathe
with the fast cycle times of cam-operated automatic lathes, at an affordable
price. This was the impetus that eventually led to the birth of the FAS
Lathe. Question 2)
When was the new lathe developed? Conceptual design work began in 1990.
Initially a C.N.C. multislide concept was explored and discarded as not
being able to meet the affordability criterion. Next, the older
cam-automatic technology was studied to see if the "rocket scientist" factor
could be reduced. Cam-automatics achieve fast cycle times by having several
tools working simultaneously, whereas most C.N.C. lathes are sequential
machines applying one tool at a time to the workpiece. However for the
cam-automatic to achieve optimum production rates, job-specific cams must be
designed, made, fitted and timed. This leads to long set-up times which
tends to confine the cam-automatic to longer runs. Having re-built and
operated most available makes of cam-automatics, the company was uniquely
placed to evaluate existing designs, and extract the best features from
each.
In addition, each step of the setup procedure was analyzed to see whether by
innovative design it could be either eliminated entirely or minimized. By
1995 a practical design was on the drawing board. This lathe which became
known as the FAS lathe, embodied a number of unique features which have
subsequently been patented. Detailed design work began slowly, as this was
clearly a big project with no prospect of quick returns. It had to be done
in spare time, so to speak. Gradually a prototype began to take shape with
wooden mock-ups of the main castings. By 1998 the prototype was sufficiently
advanced to attract the interest of an outside investor who injected funding
to enable the completion of the machine in February 1999. In addition,
funding was awarded from the Department of Trade and Industry's Support
Program for Industrial Innovation.(S.P.I.I.)
Since its completion the prototype has been in continuous production and has
proved to be a highly cost-effective machine.
With experience gained on this machine, numerous detailed improvements have
been incorporated in the final design. These production versions are now
available for sale. Question3) What are the features, specifications etc of
the FAS Lathe?
Features and Specifications can be extracted from the attached brochure.
Question 3 A) Innovative Features: Although the FAS Lathe belongs to the
large family of cam-operated lathes, it is in fact a new generic type with
many unique, patented features. The most striking result of this combination
is that setup times are dramatically reduced, typically from half a day to
half an hour. This means that the machine can be cost-effective down to
small batch sizes (see Graphs) Of the features listed, the most important
in achieving these results are: Universal Cams: Fitted for life of machine:
no other cams need be designed, made or fitted. Constant Feed Rate: Feed
rates once set, are maintained irrespective of spindle speed. Infinitely
Variable Spindle Speed: Allows optimum spindle speed to be set quickly and
accurately. Micro Setting: Micrometer adjust and hand clamp on 10 setting
variables. Fingertip Setting: Virtually all settings, including changing of
collets, can be done without the use of hand tools. Memory Setting: Tool
parameters are stored with form tools enabling the first component of a new
batch to be within, or close to specification. Synchronized Threading:
Components can be threaded by setting of pitch and length variables on the
Synchronized Threading Attachment. Thread production is unaffected by
changes in spindle speed. The entire threading sequence including indexing,
is pre-timed and synchronized to produce a wide variety of different
threads. Question 4)
What kinds of volumes can the machine produce? As the graph indicates, the
machine is cost effective across a very wide range of batch sizes: Anything
from 50 to 500 000 and upwards. Question 5) Are you planning to market the
machine abroad as well as locally? The FAS Lathe has considerable export
potential which the company will begin to exploit later this year (2000)
Question 6) Have you received any initial reaction from potential clients
for the cam lathe? At the launch of the FAS Lathe in November 1999, the
machine was demonstrated being changed over from a brass nozzle with
external thread made from hexagonal material to a round tapered steel nut
with knurl and internal thread. The entire changeover took just 15 minutes.
The following comments were noted: "That would have taken at least 4 hours
on my existing machines even if I already had the cams" "This takes all the
hard work out of setting." "We have visited international machine tool
trade fairs and there is nothing like this available." "We think the price
is very reasonable." "This is the right machine for Africa." "You've got a
winner here."
"Why don't you market this more strongly." Question 7) How do you view the
marketability of the Fas Lathe, Do you expect it to be hugely successful?
We believe that the machine has the potential to bring about a global shift
in production turning economics, and that in time many existing machines
will be replaced by the FAS Lathe. Question 8) Which Industries is the Fas
Lathe aimed at? The FAS Lathe is expected to penetrate the following
markets: Existing Cam-Automatic users who will recognize the
cost-effectiveness of the machine in terms of its rapid changeover time and
reduced dependence on tool setting and cam design expertise. Existing
C.N.C. Lathe users who have been unable to access those markets serviced by
Cam-automatic users because of the technical demands associated with running
such machines. Users of turned components who have formerly subcontracted
their requirements, but who will now find in-house manufacture accessible.
Question 9 Anything else to add?
The FAS Lathe should preferably not be referred to as a "Cam Lathe" as this
will tend to associate it in people's minds with existing designs, whereas
it is in fact a new generic type.
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