WEINIG Rondamat 960: Do-it-yourself precision tool-grinding
Become independent! The fastest moulders and most efficient setup systems can only be optimally used if the required tool can be ready to use at anytime at short notice. You only have a grasp of all factors if you produce your tools yourself: time, quality and tool costs. Weinig offers the ideal combination all round: moulders, tools and the Rondamat series for tool grinding. This is because WEINIG is not only concerned about moulders, but also has an eye on the entire environment so that your work stages upstream of production are also perfectly customized.
The Rondamat 960 presents the best equipment for your grinding room guaranteeing true running accuracy of less than 0.005 mm! When it is supplemented with additional equipment packages, it becomes a customized tool grinder for profile cutter heads that you can no longer live without.
The WEINIG Rondamat 960 offers you
- High precision grinding
- High level of repetition precision
- Can be adjusted flexibly to the parameters of the tool
- Coordination of the machine technology to the customer requirements
- Highly user-friendly
The high level of precision of the Rondamat 960 when grinding lays the foundations for producing precise profiles on the moulder. The efficiency of the machine setup, however, requires the tools to be measured. Only then, using the measurements, can the moulder be set up so that the spindles are in the exact position and the very first moulding comes out of the machine with a highly accurate profile. The WEINIG OptiControl is the ideal measuring stand because the data can be sent directly from here to the machine controls. This saves protracted work setting up the machine and it guarantees a highly accurate profile.
Making the templates
The Rondamat 960 is a copying grinder, which means that the profile contour of a template is transferred to the knife. For this purpose, WEINIG provides a template maker, which represents the ideal supplement to your Rondamat 960. Using the device, the profile templates can be made in a very short time and the tools can be grinded. The template maker has a CAD/CAM system, which can be used either to import or to draw the knife contour. The templates are then shaped using CNC control, which ensures a high level of accuracy.
Profiling jointing stones
Jointing is a complex process that requires bringing all the knives of a tool into the same cutting circle and in that way to increase the cuttermarks by the number of knives. For profile jointers the jointing stone must also be profiled. The Rondamat 960 guarantees that the jointing stone is grinded with the same level of precision as the knives, which is the basic requirement for the system to function.
Options for extension
Bringing processes together – working more efficiently
The WEINIG System Plus connects all processes through to setup of the machine. Following a positive start in Europe, the technology is now taking the USA by storm.
Sitting comfortably at the office PC, managing the entire automated process from the profile idea to the finished product is a philosophy currently taking hold in more and more countries. In the USA, the Legere Group recently became the first genuine sector heavyweight to invest in WEINIG System Plus. In this instance, it was the difficulty in finding well-trained, skilled personnel that prompted the decision in favor of the simple, networked solution. Like all other users of WEINIG System Plus, Legere’s production is characterized by profile diversity. The same is true of Anderson & McQuaid Co., Ltd. in Massachusetts. The company’s product range includes more than 240 different profiles. This spectrum ranges from rough-sawn to fine-planed, from cherry wood to mahogany. Everything is produced in the company workshop and is either held in stock or may be picked up as early as the same day.
Besides quality, flexibility is the primary USP of Anderson & McQuaid in the market. The company's high standards demanded a contemporary solution for work preparation. They found it in WEINIG System Plus. The centerpiece is the Moulder Master software. This is complemented by hardware components comprising the OptiControl Digital measuring stand, Rondamat 1000 CNC tool grinder and Powermat 700 profiling machine. Like Legere, Anderson & McQuaid also opted for the big CNC solution for grinding and sharpening. The Rondamat 1000 CNC delivers consistent quality and maximum processing precision – regardless of the complexity of the contours or the number of cuts.
Sales manager Patrick McQuaid is delighted with his new investment. “WEINIG System Plus can do everything we can as good craftsmen but faster and more precisely,” he says. Since the technology was introduced, his business has increased its throughput significantly.
Doing the job properly
Vietnam is among the “Tiger countries” of South-East Asia. San Lim Furniture is one example of the impressive growth in the region. The company's factory halls contain more WEINIG technology than the Expo Center in Tauberbischofsheim.
With GDP growth of more than six percent in 2016, Vietnam was among the fastest-growing nations in the world. The furniture industry is a significant contributor to the boom. San Lim Furniture is one of the companies in the sector that has particularly succeeded in exporting high-quality products to North America. During their rapid expansion in recent years, they have also invested in production technology. In doing so, they have set out a clear path: Only the best and only a complete solution from a single source. Their search for a partner who could fulfill these requirements led San Lim almost inevitably to the WEINIG Group. Owner Tony Sulimro underlines: “The brand name and the pioneering technology were instrumental in our decision.” Outstanding service was another key factor according to the customer. In our Singapore subsidiary, WEINIG has a point of contact in the region with an excellent track record. In 2015, San Lim purchased 14 machines and systems covering almost the entire value chain in wood processing. The spectrum ranges from an automatic moulder and tool grinding machine to an optimizing cross-cut saw and CNC center as well as automation and scanner technology. “With this production line, San Lim is a technological trailblazer in the region,” says Anthony Teo of Michael Weinig Asia. The company’s experiences with the highly-efficient technology have been positive from the outset. So much so that San Lim ordered another 16 machines in 2016. “Such confirmation of customer satisfaction may be almost unique worldwide,” beams Anthony Teo.
Like a hyphen across the sea
Some 3.5 million tourists cross it every year. The 1,600-metre-long bridge made from oak and steel provides the only access to French UNESCO World Heritage Site Le-Mont-Saint-Michel. All of the woodwork was completed by Les Ateliers Aubert-Labansat – one of the finest restorers in the country.
Even from a long distance, Le-Mont-Saint-Michel towers out of the shallows off the northern French coast. The medieval tourist attraction's imposing height is due to its fortified abbey with the pointed spire dating back to the 19th century. Today, the strong defensive walls surround a number of hotels and restaurants. There is also a post office, a police station and a town hall.
The castle in the sea is home to just 41 people, many of whom are the monks and nuns of the abbey. Restorers are part of the landscape in the narrow alleyways of the mini-community. Among them is Les Ateliers Aubert-Labansat. With its "Qualibat Monuments Historiques", the small operation holds one of the few licenses providing authorization to undertake public contracts for historical structures. The specialist's handiwork shapes the appearance of Le-Mont-Saint-Michel – from the church spire to the access to the island across the sea.
Since 2014, this access has been provided via a bridge laid with oak planks, which replaced a causeway more than 100 years old. The load-bearing structure is intended to prevent the increasing silting exacerbated by the lack of water drainage. The semi-circular bride was intended to connect the mainland to the island like a hyphen drawn with a pencil, according to architect Dietmar Feichtinger. The plan succeeded. The bridge spans the shallows inconspicuously without disrupting the views of the impressive natural spectacle. Some 2,000 m3 of oak was ordered for the project. However, only 550 m3 of this ultimately satisfied the high quality requirements. The structure costing 35 million euros required two years of construction. No cars are permitted. Instead, a shuttle bus takes passengers from the remote car park to the mid-point of the bridge. The remainder of the journey must be completed on foot. Hotel guests are advised to "travel lightly".
For Gilbert Pierre, Managing Director of creator Aubert-Labansat, the bridge to Le-Mont-Saint-Michel is a landmark project. He has also been involved with the restoration of numerous other cultural monuments, such as the Palace of Versailles. He works exclusively with oak, the traditional variety of wood in France. Most of the extremely challenging work carried out by his company is performed by hand. "As much machine technology as possible – whenever possible," however, is the maxim of the Managing
Director with a keen eye for profitability and quality. "WEINIG is synonymous with outstanding German engineering and is exactly the right partner for us," says Gilbert Pierre. The operation uses a Gold series Profimat Fortec for planing and profiling. Ripping is performed by a FlexiRip longitudinal circular saw. However, the centerpiece is a Rondamat series tool grinding machine. The machine perfectly delivers more than 600 different profiles that must be produced based upon historical designs. The profiles are taken from the old sample using a metal comb and then produced quickly and precisely on the Rondamat based upon the template. "Often, we only need a profile just once. However, production on the Rondamat is still profitable," stresses Gilbert Pierre.
All 49 employees of Atelier Aubert-Labansat use their expertise to accompany a project from beginning to end. "This creates a close affinity with their work," says Gilbert Pierre. The old restoration business has a surprising progressive participation model. Employees can become partners in the company and, thus, in the major challenge of preserving French cultural heritage. Majority owner Gilbert Pierre is retiring this year. He actually wanted to be a car mechanic. However, his father pushed him into joinery. "That was just how things worked back then," says the entrepreneur with a smile.
No regrets about using outsiders - the Dauerholz story
Peter Weller says: "If I want an entire concept, there is no alternative to Weinig."
The idea started in Hamburg. The production was outsourced to MeckPom. Using outsiders has really given the company a boost. But the Dauerholz decking boards are an obvious hot topic.
A few years ago, a Hamburg carpenter made a sensational discovery: Unlike similar preservatives, hot wax seeps into the core of the wood ensuring genuine deep protection. The researcher found bold investors who believed in the idea, primarily because the outdoor area, with decking and construction timber, provides vast scope for ecological wax-impregnated wood with its high resistance to weathering, moisture and pest infestations. A production plant was built in the perfect spot in Dabel near Schwerin.
The customized Dauerholz production line was designed and installed in close cooperation with the project specialists at Weinig Concept. As well as a planing and profiling machine, a high-speed optimizing cross-cut saw, a curve cross-cut saw, a scanner and a finger-jointing line, the site also includes a tool grinder machine from the Weinig portfolio. “We wanted to keep the entire process in-house as well as being completely autonomous in terms of tool preparation,” says Peter Weller, explaining the decision.
Dauerholz placed greatest emphasis on optimization of wood recovery and finishing. We performed a recovery analysis and established that we had more than halved cutting losses, reports Peter Weller. This success is also partly attributable to the new moulder. The moulder is equipped with “floating” vertical spindles whose flexible bearings allow it to follow the natural curvature of the wood over long lengths. This prevents “snipes” and “dips” on either end of the work piece and eliminates finish planing with further chip removal.