CMM retrofit reduces cycle time by 60%

After losing its 3-axis co-ordinate measuring machine (CMM) to a devastating flood, Precision Machine & Auto Components (PMAC) had to act fast to find an alternative solution. Renishaw's REVO^® 5-axis measurement system not only helped return a water-damaged CMM to operation, it also reduced cycle times by 60%.

Background
Founded in 1974, PMAC is regarded as one of India's most respected and trusted manufacturers of large, high quality mechanical components. It operates 35 CNC machines at two factory sites in Chennai, India and employs more than 350 people.

Serving seven major industrial sectors, PMAC works with market-leading OEMs in the USA, Europe, the Middle East and throughout India. Its diverse manufacturing output includes transmission cases, gearboxes, cylinder blocks, knuckle joints, valves and compressors.

Quality has always been a fundamental cornerstone of all PMAC operations. Its precision manufacturing processes and procedures comply with recognised national and international standards. Importantly, PMAC's product quality inspection facilities are all in-house and feature state-of-the-art equipment staffed by an expert quality management team.

Challenge
Located in Chennai, the capital of India's southern Tamil Nadu state, PMAC's manufacturing base is in an area that is no stranger to heavy rains and cyclonic storms. The north-east monsoon brings intense rain to the region during October and November.

Relentless rainfall caused widespread flooding in Chennai. Rivers burst their banks and PMAC, like many other businesses in the surrounding area, was unable to escape the devastating effects. One of its two factories, which houses its CMM facility, was severely flooded. The company's CMM, while rendered inoperable due to water damage, still had an operational frame and could be salvaged.

The strategic importance of the company's quality inspection facilities demanded swift action. Many of the components produced by PMAC, such as locomotive parts, were subject to 100% CMM inspection. A practical solution was needed fast.

PMAC's Executive Director, Mr Karthik requested the immediate replacement of the damaged CMM with a brand new upgraded version of the existing 3-axis machine. At the same time, Mr Karthik saw an opportunity to double the company's CMM capacity by repairing the damaged CMM. However, a system retrofit by the original supplier for the salvaged CMM frame was too costly, at almost 70% of the cost of a new machine.

Solution
At a meeting with Renishaw during the IMTEX exhibition, Mr Karthik was introduced to the REVO 5-axis measurement system and the idea of using it to retrofit the water damaged CMM machine. After deciding to purchase a complete REVO 5-axis measurement system from Renishaw, PMAC's CMM was retrofitted within just six weeks from order placement. The 5-axis measurement technology embedded in Renishaw's UCC S5 CMM controller lies at the heart of the retrofit for PMAC, synchronising the 3-axes of the CMM with the two additional rotary axes of the REVO-2 probe head.

By programming the REVO-2 head to perform the fastest acceleration and deceleration motion during the inspection process whilst leaving the CMM to move in a slower linear fashion, the REVO 5-axis system minimises dynamic deflections and inertia loads on PMAC's machine frame.

Unlike alternative systems based around indexing heads or fixed probes, the 5-axis motion enables the stylus to follow a continuous path around even the largest and most complex features, without having to leave the surface to change stylus or re-index the head. Using the RSP2 probe for scanning and touch-trigger measurement, fitted with RSH350 and RSH500 extended-reach stylus holders, the refurbished CMM system was able to meet all PMAC's inspection requirements.

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