Laser-based gaging makes smart system smarter

Laser-based gaging makes smart system smarter

Bar Technologies developed and uses a smart system, called Synchronous Manufacturing, for its high-volume production of critically dimensioned items such as hydraulic piston rods. The system provides ultra-precise centerless grinding and polishing of cold

By incorporating laser-based gaging from Zumbach, Bar Technologies holds tighter tolerances with its system for grinding and polishing steel bars and tubing.


Bar Technologies developed and uses a smart system, called Synchronous Manufacturing, for its high-volume production of critically dimensioned items such as hydraulic piston rods. The system provides ultra-precise centerless grinding and polishing of cold-finished steel bars and tubing. It also changes a multistep discontinuous, multilocation, and costly process into a closed-cell continuous system. At the heart of this system is laser-based gaging.

A Zumbach ODAC laserbased diameter gaging system reports to the system's centerless turning machine operator the actual size of each bar from end to end. This ensures that bar diameters are held to preconfigured dimensions. The bars then feed through a finishing/straightening/burnishing process where the operation is controlled by an additional Zumbach ODAC laser-based gage. Because of this gaging, Bar Technologies holds bar straightness to 0.003 in. or less per foot for a centerless grinding operation.

Grinding takes place in specially designed Cincinnati Milacron Twin-Grip centerless grinders upgraded for precision tolerances, roundness, and finishes. Included in the grinder modifications are Zumbach ODAC 300 laser-based gages connected to an Allen Bradley PLC, which actuates a micro-stepper motor to control stock-removal rates and automatically compensate for grinding-wheel wear.

The incorporation of computer process control with laser-based gaging lets Bar Technologies' system achieve real-time feedback. All the system's processes are connected to a host computer and network that displays and sends process status to Bar Technologies' plant offices as well as to the homes of corporate officers and maintenance personnel.

Zumbach Electronics Corp.
Mount Kisco, N.Y.
www.zumbach.com

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