CRITICAL SUCCESS FACTORS

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1 Features Critical Success Factors Position Sensing Swing Clamps New Item: Hydraulic Intensifier 4:1 Power to Hold, Prices in Check 1334 East 6th Avenue Emporia, KS R Made in the USA Fall 2005 CRITICAL SUCCESS FACTORS As Americans often do, Engineered Machined Products has found a better way to work smarter not harder. The pressure from low-labor-cost competitors is being beaten back through the direct application of machine tool technology, sophisticated manufacturing processes and productivity devices that include VektorFlo hydraulic workholding. The result is a world-class manufacturing operation in Escanaba, Michigan that can output millions of parts for the automotive and diesel engine industry with unparalleled accuracy and precision while enjoying a unit cost competitive advantage. EMP focused on their customers success, studied their needs, considered the best parts making procedures across all processes and went to work to fulfill customer requirements with quality, timeliness and pricing that exceeds expectations. Collaborating closely with its partners and suppliers, EMP develops processes that enable extremely high volume manufacturing on medium to complex machining processes (beyond the scope of the low-labor-cost competitors) and capitalizes on all volume efficiencies. According to James Hill, President of Vektek, many of the processes that Engineered Machined Products has perfected are direct contributions to the success of American Manufacturing. American Company Besting Cheap Labor Pictured here are high pressure fuel rails being prepared for milling. The path of this streamlined approach has robots loading the parts which are secured in position by VektorFlo workholding devices. Once these parts are milled, they proceed to additional process areas for thorough de-burring, cleaning and stress relieving by the latest technology for high volume parts manufacturing. These fuel rails, like all EMP Products, have been custom designed to meet each manufacturer s specifications. Engineered Machined Products not only reaches high volume parts manufacturing but the quality of their product, like their operation, is world-class. This quality, has earned them the status of key supplier to diesel engine and automotive vehicle OEMs. This status has advanced EMP s operations into other areas of new technology for the power train. Thermal management and oil management patented technologies are becoming integral to the EMP product array and have become a critical success factor to fuel economy for automotive and truck power-train manufacturers. These products are helping to grow EMP even further and; even more importantly, helping engine manufacturers meet fuel economy requirements and emissions control regulations.

2 Technical Perspective: POSITION SENSING CLAMPS General Information This section provides basic information for incorporating position sensing on fixtures using hydraulic clamping. The concepts provided here suggest possible sensing methods using Vektorflo devices. These illustrations show both clamp and unclamp sensing. In many cases when sensing is required for either the clamp or unclamp (not both) simply remove the second sensor mechanism. However, these concepts are not the only methods that can be used. High-speed bottom flange swing clamps are used for illustration purposes but the Vektorflo line also offers position sensing configurations in the top flange and threaded body styles of the high-speed swing clamps. All of the methods illustrated use Vektorflo devices and are designed to keep the sensing function as isolated as possible from the clamp/machine operation area. AIR LOGIC OR BACK PRESSURE SENSING This type of position sensing uses pneumatic back pressure against a sensor module to determine the position of the clamp. The air back-pressure signal trips a relay in the module, which converts the signal to electrical output. These sensors are device specific and a module must be used on each clamp. There are several manufactures of this type of module and each of the products has its own requirement for air pressure orifice size and distance to contact surface. Customers are urged to design sensor interface components for full system compatibility. AIR PRESSURE SENSING This type of sensing uses a common air inlet line to allow air into the sensing area of the clamp. A piston attached to the position rod then directs the airflow to either the clamp port or the unclamp port depending on the clamp position. The output signal is then transmitted to a customer provided device that provides the required control input. Swing Clamp with Position sensing rod Unclamp air passage diameter set by customer Swing Clamp with Position sensing rod Unclamp air passage orifice diameter based on sensor Air sensor piston (by customer) threaded to sensor rod. Lock Optional vent location half way between clamp and unclamp ports Suggested Clearance is.0005" to.0008". Testing may be required to determine clearance needed to give accurate position reading in reach application Air sensor piston (by customer) threaded to sensor rod. Lock Air inlet passage location half way between clamp and unclamp port Based on full stroke Catalog dimension+.2 inches (drill point permissable) Required Clearance based on air sensor Diameter to be determined by customer Clamp air passage orifice diameter based on sensor Vent Based on full stroke Catalog dimension+.2 inches (drill point permissable) Sensor piston must have enough air contact surface so that it can indicate a clamp condition for variations in part thickness tolerances. Concentricity must be within.005 between the centerline of fixture bore and the centerline of the position rod on the clamp. Clamp air passage diameter set by customer Diameter to be determined by customer Sensor piston must have enough air contact surface so that it can indicate a clamp condition for variations in part thickness tolerances. Concentricity must be with in.001 between the centerline of fixture bore and the centerline of the position rod on the clamp. A good fit between the sensor piston and the bore prevents false signals being received by the blocked port. The piston may utilize seals to prevent this possibility and allow more piston to bore clearance. If this is the method used, take care that leak paths do not occur because of seals being cut as they pass over the ports.

3 PROXIMITY SWITCH SENSING This sensing uses commercial proximity switches or reedtype switches to signal clamp position directly to the control input. These type of switches do not require contact with the cam or position rod, but the customer must maintain the correct clearance as recommended by the switch manufacturer. Mounting bracket by customer. Swing clamp with position sensing rod. Unclamp switch or air limit valve (by customer). Clamp switch or air limit valve (by customer). Swing clamp with position sensing rod Unclamp position proximity switch or reed type switch by customer. Distance determined by switch type. Cam (by customer) thread to sensor rod. Lock. Switch mounting bracket by customer Clamp position proximity switch or reed type switch by customer. Distance determined by switch type. Customer provided mount must provide enough rigidity so that the switches maintain position and contact with cam. Cam or magnet for reed type switch (by customer) thread to sensor rod. Lock Sensor cam must have enough surface area to indicate a clamp condition for variations in part thickness tolerances. the Care must be taken to prevent contamination from machine chips and fines interfering with sensing. Switch contact force must not cause deflection of the position rod. MAGNETIC PROXIMITY SWITCH SENSING Vektorflo clamps fitted with this option eliminates need for the customer to provide any sensor mounting or special machining to incorporate clamp position sensing. The position sensing signal is sent directly to the control input by magnetic position switch available from Vektorflo. Swing clamp furnished for use with magnetic proximity position sensing switch. MECHANICAL SWITCH SENSING This type of sensing uses either a commercial mechanical electric or pneumatic limit switch to determine clamp position. Direct contact with the cam or rod is required to trigger output. The electric limit switch signals clamp position directly to the control input. The pneumatic limit switch s output signal is then transmitted to a customer provided device that supplies the required control input. Sensor cam must have enough surface area to indicate a clamp condition for variations in part thickness tolerances. Care must be taken to prevent contamination from machine chips and fines interfering with the switch closing function. Set Screw Cable One magnetic position switch is required for each clamp position. Clamp adjustment must be made to each clamp at PNP or NPN signal available Groove for magnetic proximity position switch typical (2) o 180 Magnetic proximity switch see Vektek catalog for type and part number. One switch required for clamp and one required for unclamp position sensing. "LED" Indicator

4 Value Services Cost Savings Passed to Customers Your costs are going up. From transportation, to raw materials, to labor costs and a myriad of expenses that you must confront yet stay competitive in your market. Vektek s commitment to you, our customers, is that we will hold the line on pricing. Team Vektek, for more than 20 years, has conducted its business, product development and manufacturing activities with a deliberate and dedicated customer focus from the heart of the Midwest. This has resulted in products that customers want, performing functions that customers need with a durability that sets the standard of quality in the industry, all delivered on time at a fair price. Successful organizations can be evaluated by a planning effort that constantly improves the products offered and moves the company into the future with stability. W. Edwards Deming, in his book Out of the Crisis, proposed 14 Points for Management. The first point Deming makes is that companies must Create a constancy of purpose toward improvement of product and service, with an aim to become competitive, to stay in business and provide jobs. 1 This constancy of purpose drives Vektek toward improvements in technology, methods, efficiency and cost containment practices in all departments. As a partner to North American Manufacturing, VEKTEK continues to pass these savings on to its customers. When a particular machine technology improves efficiency, we buy it. When a new process yields time savings that improve customer value, we practice it. When a product is not performing as expected, we evaluate the design and fix it. Throughout these processes Vektek customers are the beneficiaries in the form of focused, topflight customer service and long-term product price stability. Commitment to this philosophy is not an option for Team Vektek. The company s objectives are translated to every member within the organization and single-mindedness about customer service, in all its aspects, is our way of doing business. You can rely on Vektek to continuously develop and improve products and services that increase quality and productivity. Consequently, Vektek customers enjoy solid quality, stable performance and high value. 1 W. Edwards Deming, Out of the Crisis (Published by M.I.T. Center for Advanced Engineering Study, Cambridge, MA 1982, 1986) Ch. 2, Condensation of the 14 Points for Management

5 1334 East 6th Avenue Emporia, KS R