March 2007 Edition

TOOLHOLDING

Quick-Change Artists

An ER-to-ER quick tool change adaptor maintains productivity

Lengthy setup times were consuming productivity at American Torch Tip, Bradenton, FL. The setups not only caused delays, the company also had to hire skilled machinists to perform them during the night shift. There had to be a way to reduce the downtime, and Dan Walters, a 17-year veteran of the firm set out to find it. The fix was his invention of the Q-Switch system, a quick-change ER-to-ER adaptor. It worked so well, he patented the product, struck out on his own, and founded American QC System Co., Bradenton, FL.

Drill changes take place in about 30 seconds without lengthy setups

Lengthy setup times were consuming productivity at American Torch Tip, Bradenton, FL. The setups not only caused delays, the company also had to hire skilled machinists to perform them during the night shift. There had to be a way to reduce the downtime, and Dan Walters, a 17-year veteran of the firm set out to find it. The fix was his invention of the Q-Switch system, a quick-change ER-to-ER adaptor. It worked so well, he patented the product, struck out on his own, and founded American QC System Co., Bradenton, FL.

While CNC manager at American Torch Tip, Walters saw how long setups dropped productivity and required the craft of skilled machinists.

Too Much Offline Time

“There were simply not enough skilled operators to keep all of the machines running,” Walters said.

Typically the process requires a skilled machinist to change a tool, jog the machine up to the workpiece, touch off the tool, enter its position into the control, and then jog it back without making a mistake in any step. Many of these steps occurred while the machine was offline. Even more time is required while centering small boring tools.

Setup and cycle times are important to a machine shop. Walters reasoned that tool changes should be more efficient. When a tool breaks or dulls, it seemed to Walters that the shop went into slow motion: some employees went to the tool crib, some to the grinding wheel, and others to the manager to get the tool changed. During all of this, the machine sat idle and unproductive.

The New Switcheroo

He created the Q-Switch system in which a drill change takes 30 seconds from the time the door is opened until the start button is pushed. During his last five years at American Torch Tip, Walters made and used these ER-style quick-change holders on all of 35 CNC machines under his supervision. When producing 50,000 parts per day, downtime had to be avoided. Using the Q-Switch adaptor cut downtime for tool changing.

The key feature of the quick-change system is the ER-to-ER adaptor. It has a male back end shaped exactly like an ER collet. The front has a female end for holding ER collets that are one or two sizes smaller than the back. When a tool is preset, it doesn’t move during tool changes.

Tools can be preset off the machine during first shift operations, and available when changes are needed during other shifts without the need for a fully-skilled machinist.

While time saved is one of the benefits, the system is also relatively inexpensive.

In the past, $400 toolholders required special tool blocks to receive them. The Q-Switch system is less expensive: $59 for an ER-16 to ER-11 adaptor assembly that fits any ER-16 holder. The device lets companies have several spare tools preset and ready.

Mistake Elimination

“By eliminating jogging the machine around, touching it off, and entering the tool’s position into the computer, there is almost no risk of mistakes,” Walters said. “It’s a matter of unscrewing a nut, taking the Q-Switch toolholder out, and replacing it with one that has been preset. Now there is less downtime because anyone can change a tool and do it right the first time.”

Q-Switch adaptors are set up in advance for multiple tools

After the first setup, the X and Z numbers for each tool are written on the tool layout sheet, keeping the tools preset. The setup times have been cut in half.

“We eliminated touching off, including for the setup,” Walters said.

A skilled setup person is no longer needed for repeat setups. The setup now involves installing the tools, typing in the X and Z numbers, and pushing the start button. All of the tools are in center and set the same as the last time the job was run.

American QC Systems has also developed a boring toolholder that fits in an ER-style holder. It centers boring or threading tools using a notch and a locating pin on the ER taper.

With this technology, a drill can be used for a job and a boring bar for the next without changing toolholders. A range of ER straight shank holders are available in any shank and ER size. American QC Systems

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