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Pump manufacturer Aquasub Engineering is using the wireless QC20-W ballbar system from Renishaw to reduce maintenance costs, increase capacity and reduce scrappage. Using the preventative maintenance tool, the Indian company has extended the life of its machine tools and reduced downtime by 10 per cent.

To reduce the necessity of purchasing new machines, Aquasub wanted to maintain its 200 existing machines, many of which are 25 years old. K Senthil Kumar, general manager, said: ‘We would obviously prefer to maintain our old machines and return them to their original condition rather than buying new machines. This a more cost-effective option than investing in new machines.’

During a demonstration of the QC20-W’s capabilities, Aquasub was impressed by the scope and precision of data given on various machine errors. With up to 18 separate geometric, plug and dynamic errors diagnosed, this offered more reliable diagnosis than the manufacturer’s existing practices.

Test data from each machine is stored in the Ballbar 20 software history function, allowing Aquasub to schedule machine maintenance and take remedial action before part quality becomes an issue.

Key benefits of product application

  • Aquasub has seen a 10 per cent reduction in machine downtime.
  • In order to extend the life of its machines, the manufacturer carries out regular tests with the QC20-W ballbar. It can now carry out three-plane testing with a single setup, which has reduced its maintenance inspection time by 20 per cent.
  • By incorporating the QC20-W into its total preventative maintenance programme, Aquasub has significantly reduced scrap and faulty product.
  • The QC20-W is also used to test new machines after they are first installed as damage during shipment from the machine OEM to the Aquasub factory could result in faulty components.
  • Aquasub described the QC20-W ballbar system from Renishaw as ‘the backbone’ of its quality system.

Renishaw

A world leader in engineering technologies, Renishaw’s core skills in measurement and precision machining serve sectors as diverse as dimensional metrology, spectroscopy, machine calibration, motion control, dentistry and surgical robotics.

A world leader in engineering technologies, Renishaw’s core skills in measurement and precision machining serve sectors as diverse as dimensional metrology, spectroscopy, machine calibration, motion control, dentistry and surgical robotics.

Sensors for co-ordinate measuring machines (CMMs) are an industry standard, from basic touch-trigger probes through to automated stylus and probe changers, motorised indexing probe heads, and revolutionary five-axis measurement systems.

Machine probes for CNC machine tools allow automated tool setting, workpiece set-up, in-cycle gauging and part inspection. Products include laser tool setters, contact tool setters, tool breakage detectors, touch probes and high accuracy inspection probes.

For motion control, Renishaw supplies laser encoders, optical linear encoders, optical angle encoders, optical rotary encoders, magnetic rotary encoders, magnetic chip encoders and magnetic linear encoders.

To analyse the static and dynamic performance of position-critical motion systems, Renishaw’s laser interferometer and environmental compensation system offers a linear measurement accuracy of 0.5 ppm, readings of up to 50 kHz and a linear measurement speed of up to 4 m/s, with a linear resolution of 1nm.

Renishaw’s Raman spectroscopy products exploit the Raman effect to identify and characterise the chemistry and structure of materials. A diverse range of analytical applications include pharmaceutical, forensic science, nanotechnology, biomedical and semiconductors.

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