machine

Mechanical Installations
machine

Mechanical Installations

Laser alignment - experience matters!
machine

Laser alignment – experience matters!

Laser alignment – experience matters! – Would you let someone perform laser surgery on your eyes without knowing how much experience he has on the equipment or whether the person using the laser is qualified?

The same applies to your machines. If you are expecting the best results possible, you need to know if the technician performing the alignments and accuracys on your equipment is factory trained and certified with the laser equipment they are using. Not only are our technicians fully trained and factory certified on the laser equipment, they all have a minimum of 8 years experience in the field.

Training and Experience – Team Qualifications

The laser technicians on staff at Maverick Systems Corporation have undergone extensive factory classroom training and certification through Hamar Laser, Inc. and Renishaw Laser. They are certified and experienced in all fields of machine geometry’s with the Hamar laser to ensure flatness, straightness, parallelism, perpendicularity of all axes, as well as extruder barrel alignment, injection molding platen alignment, spindle and bore alignment. With the Renishaw laser, they are trained and certified for linear positioning, repeatability, accuracy of movement, and are qualified to perform linear axis compensation in system controls to match the actual movement of the machines. They are fully trained on both the laser systems software and reporting systems so they can provide you with accurate and instant results on the machines alignment and accuracy.

Insist on more than just laser equipment knowledge

All of our laser technicians are also experienced millwrights in the machine tool and plastics industries, with up to 20 years of hands-on experience on a wide variety of machines. They know and understand the specifics of an extensive array of machines and can clearly communicate the factory requirements of your equipment and the steps necessary to correct misalignments.

Laser alignment - experience matters!

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They have an arsenal of laser equipment and software at their disposal to assist them in determining any problems or issues you may have with your machines. They work intimately with your technicians on each project to ensure that all misalignments or the issues causing the misalignments are corrected according to factory specifications or as close to tolerance as the machine’s condition will allow. They also work directly with our electronics and controls technician, if needed, to ensure that during the alignment process the machine is operated correctly and that the alignments are in strict adherence to the programming within the control. On new machine installations, the laser technician will also work directly with the control manufacturer representative on site.

Leadership and industry expertise

Maverick Systems Corporation’s Field Services division is led by one of the foremost laser and machine experts in the field with almost two decades of industry experience. Building on this leadership, with our commitment to training and innovation, we have assembled a professional, highly qualified team who has undergone extensive classroom training and certification in all facets of machine tool and manufacturing installation, maintenance and laser alignment.

Base-line injection mold machine
machine

Base-line injection mold machine

Several Factors Could Be the Issue

Base-line injection mold machine – Maverick Systems technicians are all factory trained and certified by Hamar Laser for Injection Molding Machines. All have hands on experience working with customers to provide them with alignment solutions on their injection molding machines. We have run into various obstacles along the way with foundation settling issues, level issues, platens not parallel to one another, molds not parallel to the platens, bent tie rods, injectors not aligning with molds and the list goes on.

Base-line your Injection Molding Machine

We recommend base lining your machine. While there may be only one issue with the machine there may also be several factors creating that problem. If you initially find the platens are not parallel to one another, stop there and try to find out why. Base lining the machine and doing a full inspection of level, flatness, squareness and parallelism of all the components may help you in your search.

When sufficient evidence is gathered, you should then correct all the issues to prevent similar mistakes in the future. On the bigger injection molding machines (1500 ton+), a series of data collecting needs to take place that requires more than one set up. Though it may require a full day to troubleshoot, afterward you will know the full geometries of the machine and where to start with corrections.

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Base-line injection mold machine

Reduce Downtime Changing Molds

Changing a mold is time consuming and realignment is a necessity. If a mold is slightly out of parallel to the platen, costly flashing and premature wear can occur. Inadequate alignment also results in excess wear on the injection-molding machine and can even lead to tie-bar breakage. With each tie bar costing at least $10,000, proper alignment is crucial. Maverick Systems can save you time and money with the mold changing process. Rather than using the traditional methods of alignment, we can “buck-in” to your platen plane and provide live alignment data. Misalignment errors can then be quickly adjusted using just one setup. Use of the Hamar laser L-723 speeds the alignment process significantly, and also reduces tooling and maintenance costs.

Reduce Stack Up Errors

One of the biggest complications with aligning machine tools using conventional methods is that many different alignment tools must be used, requiring a lot of time and increasing stack-up errors. Another concern is that an alignment is only as good as the tools used to perform it. The machinist master level is a good example: it has a resolution of .0005″ per foot, not very accurate for today’s ever-tightening tolerances.

The L-723 laser planes, by contrast, are flat to 1/2 an arc second (0.00003″/ft or 0.0025mm/M) in a 180° sweep and 1/4 arc second (0.000015″/ft or 0.001 mm/M) in 90° sweep. The laser planes are square to each other to within 1 arc second (0.00006″/ft or 0.005 mm/M). They further have the advantage of creating a single reference from which to measure machine geometry, significantly reducing stack-up errors.

Extruder barrel alignment
machine

Extruder barrel alignment

The facts about Extruder Barrel Alignment or Bore Scoping

Extruder barrel alignment – Most extruding machines are built with the thrust bearings, shaft assembly, and the output shaft of the gearbox as one unit. The thrust shaft (which is splined, or keyed) holds and turns the screw, which is the centerline of the axis of rotation. If any of the components are not aligned from the centerline of the thrust shaft there will be friction between the barrel and screw or feed chamber and screw. Sometimes, both situations happen, depending on the amount of error off centerline. If there is friction between the barrel and screw, the amount of wear will increase causing either the barrel or screw (or both) to wear faster increasing your replacement costs dramatically.

The feed chamber is the next component. If the feed chamber screw guides are offset too far from the thrust shaft centerline, (feed chamber offsets are discussed in more detail in the offset section) it will put strain on the gearbox thrust shaft bearings, causing them to wear faster.

Next is the barrel input. Again, it’s important to know if there is an offset from the thrust shaft centerline either horizontally or vertically; it could cause the screw to rub at the input end of the barrel. More importantly, the offsets of the feed chamber need to be the same as the offsets at the barrel input. Offsets that differ would definitely create friction between the screw and the input end of the barrel. If offsets sound confusing, you can read more about them in the offset article.

Last is the barrel output. Most errors will be found from the centerline of the thrust shaft, and will usually be in both vertical and horizontal. Excess misalignment here will cause friction between the screw and barrel somewhere in the length of the barrel. Sag can also be an alignment issue in longer barrels.

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Extruder barrel alignment

Taking all of this into consideration, the following paragraph should make it more clear as to why the extruder components should be aligned to the centerline of the axis of rotation and why the thrust shaft is the logical choice for establishing the centerline.

Tolerances between the barrel and screw will average .008 total clearance, which is only .004 on all sides. The extruder is designed to shear, melt, and mix the plastic materials to give a good, uniform flow. If the output end of the barrel is out of alignment, then the screw is rubbing against the barrel at some point. At that contact point, there is minimal shearing and minimal mixing because there is no clearance at the rubbing point. However, there is a hot spot generated from frictional heat due to the screw rubbing against the barrel, causing the plastic material to melt hotter and faster. Now you have an area of material that is of different consistency. On the opposite side of the screw, there is also an area of material that is of different consistency. Because you have a wide gap of .008 that the plastic material is rolling over, not shearing, or mixing properly, the plastic material here will be cooler and harder. Now that you have plastic materials flowing at an uneven temperature, pulsating and surging has to take place. While it may be a very small amount, it could be serious enough that you can’t hold size.

The thrust shaft is what holds and turns the screw. If you have the feed chamber and the barrel aligned to the centerline of the thrust shaft, it will alleviate the friction areas in the barrel and allow the proper amounts and consistency for a uniform flow.

Maverick Systems can bore scope your extruder barrel using the latest laser technologies available. Giving you the most accurate barrel alignment possible.

Injection molding service and repair
machine

Injection molding service and repair

Injection molding service and repair – Maverick Systems offers troubleshooting and repair of Injection Molding machines, including all equipment related to the molding process: Material handling, loaders, dryers, hot runner controls, robots and pickers, color mixing and material mixing equipment, cooling towers, pneumatic systems, hydraulic troubleshooting and repair, control issues, platen alignment, and tie bar inspection/replacement.

In addition we offer complete installation of injection molding equipment from arrival to production with a strong after installation commitment to the customer.

We strive to offer a complete maintenance and repair service no matter what brand of injection molding machine you own.

Maverick Systems technicians have over 30 years of experience in installation and maintenance of injection molding machines and we continue our training in the latest technologies to provide the highest quality of service to our customers. We work closely with manufacturers to ensure top quality repairs and stay within OEM specifications during an installation or retrofit. In addition to the newest machines on the market, we also service older models that are typically out of warranty and are no longer serviced by the OEM.

Are you experiencing any of these issues?

  • Slow recovery times
  • Having trouble with the hydraulics
  • Issues with the control
  • Process problems
  • Molds do not align properly
  • Platens aren’t parallel
  • PM program not satisfactory

Maverick Systems Corporation Services

  • Injection molding and extruder repair
  • Complete maintenance programs
  • Control repair and troubleshooting
  • PM programs
  • Repair to OEM specs
  • Material-handling systems
  • Retro fitting older machines
  • Peripheral equipment
  • Retrofit to customer specs
  • Hydraulic system troubleshooting
  • Extruder barrel laser alignment
  • Injection molding machine leveling
  • Motor coupling laser alignment
  • Platen parallelism alignment
  • Barrel wear inspection
  • Platen center alignment
  • Screw wear inspection
  • Tie bar inspection
  • Seized screw removal
  • Bent tie bar removal and installation

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Injection molding service and repair

Auxiliary equipment including

  • Hot runner systems
  • Pneumatic control and supply
  • Material handling
  • Bed conveyor and overhead conveyor
  • Color mixing and material mixing
  • Dryer systems
  • Water-cooling systems
  • Barrel heater bands
  • Film lines
  • Blow form lines
Other services provided include turnkey installations, foundations engineered for your specific needs, grouting of machine bases, and isolator pads designed for injection mold machines and extruders.

 

Maverick Systems Corporation provides a complete solution to the plastics processing field. Located in Hurst, Texas 5-miles from DFW Airport. We provide local service to the Metroplex and surrounding areas as well as nationwide including Mexico and Canada.

Machine tool laser alignment and calibration
machine

Machine tool laser alignment and calibration

Reduce scrap parts and protect your investment by having a quarterly or annual machine tool laser alignment. Machine tool alignment and calibration is required to maintain your ISO certification!

 

There is much more to maintenance than keeping the machine running!

Machine tool laser alignment and calibration – One of the most critical factors in any machine tool maintenance program is knowing your machine’s level of accuracy and tolerances. Your machine tool should be level, flat, and square in all axes, mechanically adjusted to acceptable tolerances, and any linear error should be corrected to OEM specifications – which includes documentation certifying the accuracy of the machine.

 

Significantly Reduce Part Setup Time

One benefit of having a properly aligned machine tool is that part setup time is significantly reduced. An article in the October 1998 issue of Quality in Manufacturing Magazine describes the incredible benefit of laser alignment to the John Deere Corporation. In the words of Jim Abitz, tool and die maker, “…[laser alignment] makes the operators a lot happier because they don’t have to struggle for two or three shifts to get a machine to work properly.”

Our Lasers Align 70% Faster Than Other Methods

Continuously sweeping lasers and live data output create a powerful combination to align machining centers up to 70% faster than traditional or interferometer methods. Downed machines will be up and running, producing quality parts in record time. Hamar’s continuously sweeping lasers are far superior to other point-and-shoot laser systems that require time-consuming manual laser rotation and target setup for each point measured. They also allow the use of multiple targets, which is especially helpful for large machine tools.


Simultaneously Measure 3 Axes with One Setup

Another great time saver is the laser’s ability to measure the three main axes of a machine at the same time. Not only can we measure the flatness and straightness of each axis, but we can also measure the squareness of the three axes. And if there are any additional axes, such as a rotary table or extending quill, we can easily check the parallelism to the main machine axes with the same setup!


How many of the statements below describe your machine? Do you know?

Machine

  • Circle interpolation perfect.
  • Part programs never edited.
  • Zero offsets in control.
  • Shims are never required.
  • Holds thickness tolerance.

Machine tool laser alignment and calibration

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Parts

  • Hole locations are exact.
  • Top and bottom parallel
  • All sides square.
  • Surface finish smooth
  • 180° center locations precise.
If three or more of the items above don’t describe your machine or the parts it produces then you probably have a misalignment or calibration issue. Machine tool alignment and calibration issues don’t go away, they get worse and create more problems and significant downtime. That’s why it’s critical to remove as many elements out of the equation as possible. Depending on the size and numbers of axes of the machine tool, the inspection and correction process for your geometrical errors and calibration of your linear axes may render your machine inoperable for a short time. However, once the initial corrections have been made, minor adjustments should be all that’s required if you have a scheduled inspection and correction performed annually.

 

Get an Annual Checkup

At Maverick Systems Corporation, we recommend performing a machine tool laser alignment and calibration check on an annual basis after the initial alignment has been performed. Afterwards, any problems that arise can be addressed immediately and corrected quickly.

The Machine Tool Alignment Process

During the course of a typical alignment and calibration session of a machine tool, it is not unusual to encounter some hidden problems. This is where our experience pays off. Having worked on a wide variety of machine tools, we can efficiently identify the problems and correct them as necessary.
Beginning with the machine base, we laser level and align it back to OEM specifications. Next, the ball screw is checked for endplay, and adjusted if needed. The gibs are then checked and adjusted back to specifications. Finally, we continue through all axes of the machine, ensuring the axes are square, parallel, and perpendicular to one another.
The geometry’s of the machine must be aligned before performing any linear calibrations as errors in geometry can effect the linear movement. After completion of alignment, we then proceed on with the linear error compensation of the axes in the control.

Return on Investment

Whether it’s one machine or an entire shop, Maverick Systems Corporation can set up your company with a scheduled laser alignment and calibration program that will fit your maintenance calendar. Your ROI will be immediate and your overall maintenance budget will go down.
It’s time to incorporate laser alignment and calibrations into your maintenance schedule.