Why Tolomatic? Metal Fabrication

Glazing contractors (glazing refers to installing glass in a building's fixed openings, such as windows and doors) must work quickly, accurately, and safely at a building site to install window frame facings, curtain walls and storefronts in multi-story commercial buildings. Problems arise if holes drilled in extruded metal are not correctly cut to size or are misplaced. Multiplied over numerous applications, these issues can slow a project and make it go over budget. All it takes is a mis-placed quarter-inch diameter hole.

The Challenge:

DeMichele Group (DMG) makes fabrication machines that pre-drill and cut lineal materials to high tolerance specification. Their newest 9-axis RhinoFab glazing machine is designed to deliver the required force and pressure to drill perfectly placed holes and route intricate patterns. "We started developing our new CNC machines with some readily available actuators on the market, " said Brian Hefner (DMG President). "But they weren't rigid enough to properly hold our tolerances, plus they allowed for particulate to ingress, causing problems. So we committed R&D to investigate solutions to these issues, and by working closely with Tolomatic, we developed an actuator that has the sealing and rigidity we needed."

In the building industry, framing materials such as curtain walls made of extruded aluminum. To speed installation, these materials are pre-drilled and cut to specific lengths. Combining DMG's software and automation, the extruded materials is moved into position and a multiple 3-axis linear actuator system drills and finishes the material. A high-speed tool set is used to create holes and shapes while a 90-degree upcut saw trims or cuts the product to the required size. If the actuator system does not provide precise control and stability, the material may be improperly drilled and cut.

Deflection is another challenge DMG experiences when finishing materials. As the material moves through the machine, the cutting axis may bite, bend or wobble. If the actuator does not properly hold the drill or withstand the force of the press, the drill will mis-place or incorrectly cut the holes. This slows the production because the material must be re-drilled and cut.

Solving The Problem:  Tolomatic 3-axis System

The challenge was to create a multi-axis system that can push, pull, and position the drill accurately. "The Twin profile Rail Stage (TRS) rodless screw-driving actuator solves two issues. " Said Andy Zaske, Vice President - Tolomatic, "Not just rigidity, but also cleanliness. The aluminum single-body actuator design prevents deflection and ensures a perfect cut every time."

The Tolomatic actuator's flat carriage design and sealed components are critical to prevent metal shavings from getting inside the unit.  The unique mounting solution of the TRS multi-axis (XY) system allow the design to carry loads up to 6.0kN (1349 lbf).  The actuator can be used in any application requiring two or three axis configurations, such as machining centers, laser positioning, collaborative robot movement, pick-and-place, and material handling.

Solution:  RhinoFab 9-Axis Machine

The DeMichele Group (DMG) RhinoFab 9-axis machine moves in nine different axes. Each axis (top, bottom, and front) accommodates up to three different tools sets allowing it to fabricate materials. The RhinoFab can drill from the top and bottom at the same time. Combined with DMG's Glazier Studio line of software, the RhinoFab system can design, estimate, and fabricate each project.

According to Brian Hefner, the new machine opens the bidding process to more players. "The faster throughput gives smaller companies and economical, automated process which allows them to optimize manual labor and also bid on larger opportunities."  The RhinoFab 9-axis machine has been so successful that DMG has expanded machine line to include 11 and 13-axis machines and introduced another line of more rigid and robust TRS actuators for even more challenging jobs.