Multi-function CNC lathe builder has developed an integrated loading and unloading system within the existing machine footprint and it integrates with user specified material handling systems.

The European Machine Tool exhibition EMO 2005 was the launch pad for Colchester Lathe's expansion of its 'Lights-out' productivity package introducing new levels of automation involving multi-axis machining technology. At the exhibition, the six-axis Tornado T8MSY driven tool lathe with a Y-axis cross feed to the turret and the fully integrated seven-axis T6MS turning cell with a programmable APL5000 automatic loading system were demonstrated to wide acclaim of the company's international distributors and customers at the show. Over the last 12 months Colchester Lathe has pushed ahead its design and development programme and simultaneously re-organised the production of Tornado lathes at Heckmondwike in West Yorkshire to enable assembly to build the new machines using a cell-based strategy.

This was a major change to the previous flow line principle for the more simple two-axis Tornado machines that took market leading shares for the value for money turning solutions they provided.

The whole machine shop has been re-organised with its two flexible manufacturing systems running around the clock alongside large mill/turn centres and slideway grinding equipment.

Sheetmetal assembly for guarding, previously produced at a Colchester Lathe facility in Halifax is now fully integrated onto the shopfloor at Heckmondwike working double shifts with support of Electrox CNC laser profiling, press brakes and a new automated powder coating and cleaning plant.

In addition, individual welding cells now fabricate the bases for the Tornado lathe with a special area dedicated to ensure the base fill of the lathe structure with an engineered polymer concrete is correctly administered.

This is an important part of the company's patented 'Duo-Stable' construction that improves machine stability by some 300%.

Now with the two-axis, three-axis with driven tools, six-axis with driven tools, sub-spindle and Y-axis and seven-axis machines with integrated loading in the portfolio, the whole concept of design and build has changed while the 'value-for-money' philosophy has been retained as a 'brand' marker to this very competitive sector.

The T6MS APL is a totally novel Colchester development that integrates a loading and unloading system within the confines of the existing machine footprint.

At a stroke, this new development provides users with a 'Lights-out' chucking lathe machine package capable of extended running in unmanned situations with the loading system having the flexibility to integrate with user specified material handling systems such as part stockers, carousel palletising or conveyor systems.

In addition, such has been the detail involved in designing the system that it can be switched-out and parked clear of the working area allowing the machine to operate in a normal manned fashion.

The automation is fully programmable via teach pendant and operates through the Fanuc 18i-TB control with Manual Guide i software on the machine as standard while being integrated with Colchester Lathe developed automation programs.

As a result, loading sequences are combined with first and second chucking operations having automatic part transfer between main and subspindle for parts up to 80mm diameter by 100mm long and weighing up to 5kg.

The machine concept involves a loading beam mounted above and onto the headstock and running parallel to the centre line or Z-axis to link component storage at the headstock side of the machine to the cutting zone.

Powered via ballscrew and servo drives, a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems.

The Tornado T6MS has a 440mm swing over bed and 220mm maximum turned diameter by 450mm long with a 54mm bar capacity and either 170mm or 210mm chuck size.

The 15kW, 6,000 rev/min main spindle and 5.5kW, 6,000 rev/min subspindle are serviced by a 12 station all-driven tool turret with 3.7kW, 5,000 rev/min drive.

Rapid traverse rates are 30m/min in Z and 25m/min in X.

Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that uses an encapsulated polymer concrete base fill mounted with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.