Hayward Mills Associates, a firm of church bell hangers, has retrofitted a Newall B60 digital readout (DRO) and Spherosyn scales to a Colchester Triumph lathe to replace an older DRO that was difficult to use and becoming unreliable.
The addition of a Newall B60 digital readout (DRO) and Spherosyn scales to a 22-year-old Colchester Triumph lathe has helped cut cycle times by an impressive 50 per cent at the Nottingham facility of church bell hangers, Hayward Mills Associates.
The lathe in question was previously fitted with a DRO from another manufacturer, which, according to Hayward Mills, was both tedious to use and showing signs of increased reliability issues as it was getting older. The company therefore decided to source a replacement DRO, using the internet as a search tool.
Workshop Manager, Michael Semken, says: "We came across Newall's website and arranged to have a sales representative call in. He talked a lot of sense and recommended the B60 model, together with the Spherosyn scales, which is housed in a rugged die cast chassis and is well suited to the general machining applications we undertake."
The DRO was delivered in December 2006 and fitted and commissioned by Mr Semken in little more than half a day. He says: "The instructions were very clear and it proved to be a straightforward job. Since the B60 has been fitted, the benefits have been enormous, particularly in terms of ease-of-use."
But that is not all; the Newall DRO has allowed Hayward Mills to slash approximately 50 per cent from cycle times for 'end of shaft' bearing housings, which are integral components in the bell fittings it manufactures for churches across the UK and Ireland.
Mr Semken adds: "It is possible to buy standard housings that are 80mm wide but, due to the space restrictions in many church towers, we manufacture our own, which are 64mm wide to get the bells closer together end-on-end."
Manufactured from grey cast iron, the bearing houses are produced in batch sizes of around 15 pairs typically.
"Before we fitted the Newall B60 DRO we could turn these parts in around 10 passes. But now we can do the job in just five passes due to the increased reliability, confidence and accuracy this technology offers."
The Newall B60 DRO is available in two- or three-axis configuration and offers a host of high-specification features offset against an extremely competitive market price. These include: absolute/incremental operation; inch/metric conversion; zero reset/data preset; data recall; data hold; radius/diameter readings; centre find; home reference; linear error compensation; memory back-up; 99 tool offsets; switchable resolution by axis; and sleep mode.
Thanks to an innovative interface, the B60 DRO is compatible with Newall's Spherosyn and Microsyn linear encoders, both of which are designed to provide consistent accuracy and reliability even in the harshest of machine shop environments. Based on the principle of electromagnetics, Newall's analogue encoders, which are completely wear-free, embody a design whereby all of the electronic and measuring components are sealed and protected. The maintenance-free encoders carry an IP67 (NEMA 6) environmental rating and continue to provide accurate and reliable readings even when submerged in water, oil or coolant.
Mr Semken concludes: "The increased accuracy provided by the B60 means we have no problem holding our tolerances, which can sometimes be quite tight in order to allow the housings to slide lengthways in a controlled and smooth motion. On top of reduced cycle times and set-up times, we are now assured a good finished product time-after-time."
Hayward Mills has been established for 14 years and offers a complete bell hanging service that includes the manufacture and supply of parts such as bells, bell frames, stays and sliders, wheels, pulleys, headstocks, clappers, bell ropes and bosses. As well as end shaft bearing housings, the company also uses its Newall DRO-equipped Colchester lathe to turn components such as bell clappers, bespoke bolts and cast iron ceiling bosses.