OneSteel has a significant presence in Australian steel as an integrated manufacturer of steel andfinished steel products. OneSteel is Australia’s premier manufacturer of steel long products and is a leading metals distribution company in Australia and New Zealand. The company manufactures and distributes a wide range of steel products including hot rolled structural sections, rail, rod, bar, wire and structural pipe. OneSteel Whyalla Steelworks includes structural rolling mills, rail products facilities, slabs and billets, steelmaking by-products and Roll and Tackle service shops.
The location, the very busy schedule of the roll lathes, the complexity of the parts and the very short installation for the CNC new systems were big challenges when retrofitting the large Waldrich, Froriep and Toshiba roll lathes. These important machines were updated with state-of-the-art current technology: the latest SINUMERIK controller and SINAMICS drives, with common Operate system software and ShopTurn interface.
Why CNC Design?
Mr. Oliver Rosalia, technical services leader of OneSteel Whyalla describes the cooperation with CNC Design in the process of upgrading their machines: “Complete customer package: When planning the upgrade of the Waldrich lathe in our Roll Shop, CNC Design took care of the electrical design, hardware components selection, project planning, software changes and drawing updates. On site work was carried out by CNC Design Electrical and Engineering personnel working closely with OneSteel’s Electricians and Technicians. Project plan was followed to ensure work was completed and commissioned in full and on time. CNCDesign’s thorough understanding of our process and equipment was a significant advantage in the successful upgrade of the lathes with no interruptions to production schedules.
“The Team approach: Success during recent upgrades all hinged on CNC Design working with OneSteel’s maintenance and operations personnel to achieve the desired outcomes. CNC Design ensured everyone was involved in the planning, installation, commissioning and training. After service support was all part of the deal as operators identified minor changes and enhancements in the following weeks after completion. OneSteel sees CNC Design as a vital partner in the support and upgrades of its CNC machines for now and the future. Implementing emerging technologies and equipment optimisation go hand in hand to ensure our lathes are at the fore front of operational capability. It is reassuring to know that CNC Design share our vision to have modern reliable equipment to ensure our stringent production targets are met. A partner we hope to have for years to come.”
Ueda Heavy Gear Works Ltd. is one of the Japan’s flagships of heavy industry. Established in 1893, Ueda Heavy Gear Works became the leading gear manufacturer in Japan, supplying large gears, pinions and other power transmission components to all major steel and machinery manufacturers in Japan. Located in Osaka, specialising in manufacturing large cylindrical girth gears, pinions and also bevel gears, Ueda Heavy Gear Works has a large number of MAAG gear cutting machines.
CNC Design’s task was to develop a CNC conversion solution which will retain the machine’s flexibility and accuracy and offer additional high level functions such as: gear measuring; simpler operation, integration with the factory network, easy work setup and increased machine productivity. For this type of machine, CNC conversion requires significant mechanical and electrical re-design including: new transmissions for all axes, new electrical control cabinet, new machine operating system and training for the operators. Very short installation time was also critical to maximise availability of the equipment. Working closely with machine users in developing this solution was essential for the successful completion of this project.
Why CNC Design?
CNC Design has developed a complex solution for CNC conversion of the MAAG shapers and tested it in several successful installations around the world (Australia, USA, Japan, South Africa) for all types of MAAG heavy duty gear cutting shapers (SH250, SH450, SH600, SH1200) Mr Masakatsu Ueda, President of Ueda Heavy Gear Works, explains his decision to work with CNC Design: “CNC Design has done conversions for many types of machine tools and we trusted they have the best solution for our MAAG. I am happy they solved all the requests for our MAAG shapers”.
Our first project in Osaka for a MAAG SH250/300 was completed in April 2011, in record time (two weeks full installation). With Ueda Heavy Gear Works Ltd having already placed an order to convert an even larger machine, their MAAG SH600/735, to CNC, the success of this project is undoubted. In Mr Ueda’s words: “After the conversion done by CNC Design, we have been using our MAAG shapers without any troubles. The removal of many mechanical settings and the user friendly operating panel are saving us so much time. Our MAAG shapers were revived completely by CNC Design”.
Nexans Olex Australia is a branch of one the largest global cable manufacturers. This particular site has been manufacturing cable for more than 70 years. This site has 2 Henrich Copper Wire Drawing Machines, each has 12 capstans which draws the copper wire from 8 mm down to various diameters ranging from 3.5 mm to 1.47 mm. These two machines are key assets in the cable making process, all of the cables manufactured on this site use the copper that’s been drawn in either of these two machines.
The task was to develop a new AC drive and control solution that would replace the existing troublesome DC drive, motor and gearbox setup. CNC Design selected the latest in direct drive technology installing individual SIMOTICS 1FW3 torque motors in combination with SINAMICS S120 AC drives. Our solution provides an elegant and complete low risk solution which improved the original machine capabilities, particular in line speed. We dramatically improved the reliability of the line reducing to zero the production stops due the wire breakage. Using SINAMICS technology we have been able to reduce the power usage and thus the running costs and factory power factor rating.
Why CNC Design?
CNC Design has the ability to develop complex solutions for existing manufacturing machines. We can test and pre-commission our software, drive systems and machine control in house well before we arrive on-site and the machine is taken out of production. Nexans required limited disruption to their production, they wanted their machine down for as short a time as possible, we achieved this by having a solution that worked and was well test.
Mr Sam D’Amico, Engineering Manager at Nexans explains his decision to work with CNC Design:
“CNC Design provided us with the most cost effective, low risk solution for our wire drawer. As a key asset in our plant, we needed to know they were capable, we also like the use of the new torque motors, which would put us ahead of our completion”
Our solution has resulted in a significant increase in production, due to the zero wire breaks per shift; our customer has reduced the machine downtime from faulty DC motors and gearbox problems to zero. This has significantly impacted on the amount of hours that were once required by the mechanical maintenance team for this machine. We have also reduced our customer’s power usage.
Mr Sam D’Amico again:
“We are very happy with the outcomes from the upgrade, we hadn’t expected such a positive impact on our production and the ease in which our operators now find the machine. Payback from our investment in this project will be within 48 months, we fully anticipate to covert our 2nd Henrich Wire Drawer with CNC Design’s solution within the next 2 years”.