TechArchive

Original article date: February 1998

There are more suppliers and more components to choose from every year. Alan Quinn and David Norris look at the current aluminium profile systems for machine building

Almost every year in our surveys of aluminium framework based machine building systems there have been another couple of suppliers to add to the list, and 1998 is no exception. In fact, the new names are two very familiar ones in engineering circles, Star Linear Products and Hepco Slide Systems, and their entry to the market underlines how much in demand the ‘kit component’ method of building machines, guards and other structures has become.

We decided this year to ask the suppliers about the extent of their component ranges, as more and more of them are arguing that what makes a true aluminium framework system is the number of compatible components which can be connected to the framework. Of course, what makes one part different to another is viewed differently by each supplier, and ‘size of range’ is a poor reason to opt for one supplier over another; that said, the exercise does give an idea of the extent of some of the systems available, which is truly impressive. More than one catalogue is over half an inch thick.

Most customers opt for the aluminium system of framework building because of the flexibility of being able to make and redesign assemblies quickly, so what’s probably more important than the number of components in a range is the number readily available in stock. For example, although Colin Ford of Parker Electromechanical says that his Parframe catalogue range is relatively small, around 250 parts, the company finds that these parts cater for most needs and it’s able to hold higher stock levels as a result of the small quantity.

So use the ‘number of parts in the catalogue’ with care. As Stuart Mitchell of Machine Building Systems says: “There are 761 different parts in addition to 170 different profiles in stock at our Ripley factory. I’m pretty sure this is the biggest range, but if you broke down the parts into sub-assemblies I could quote 10,000 parts easily. We count a ballscrew as a single part, but if a customer damaged the unit we would of course sell them the damaged constituent component only.” So there might be eight parts making up this overall ‘part’.

CAD support

Most suppliers of aluminium framework systems these days offer CAD support at least in the form of DXF files for extrusions and brackets. Both the systems commonly considered to be the big names in the business, Item (supplied by Machine Building Systems) and Quickbuild (supplied by Bosch) have useful CD-Roms containing details of the catalogue range as well as the CAD files and calculation programs for strength, stiffness and weight. The Bosch disc also has IGES data files for extrusions and accessories.

Parker Electromechanical also supplies DXF files of extrusions and many fixings and has a 3D modelling program called Structsure under beta-test which was developed in the US. This is compatible with Autocad 13 and 14.

Time & Precision has a 3.5in floppy disk offering DXF files for extrusions and brackets. A CD-Rom disk contains load calculations and will generate component lists, select prices and cutting lists to meet design requirements. It also offers 3D assemblies, including parametric features for door and frame assemblies. The CD-Rom disk is only compatible with Autocad 14.

Alusett offers a library disk to customers, showing all the parts in the catalogue (DXF or DWG) plus a strength/bend program. The web site (www.kanya.com) also shows the full catalogue. The Standex range from L Pickering is available on disk and on the internet. Paletti (supplied by Boldman) has the complete catalogue in various languages on CD-Rom, with Autocad 13/DXF libraries of the profiles. A full priced quotation can be calculated, and there are photographic images of parts should you require them. And Flexlink has all its components available on a DXF/DWG format CD-Rom, and has the catalogue available too. The company’s Anders Pihl points out that the CD-Rom catalogue “is not proving as popular as the printed version” but we’re sure that would be the case for all the suppliers!

Hints and Tips

According to Colin Ford of Parker, traditional steel structures consume too much time and effort in cutting, welding, deburring and painting. Structural aluminium components also score on appearance. Since the aluminium system are modular by design, almost all the components can be used repeatedly as machine requirements change.

Gary Livingstone of Minitec supplier Time & Precision says that when designing an aluminium framework, vertical elements should be formed using a single, unbroken extrusion. Horizontal elements can be fixed to these, making for easier assembly and improved mechanical rigidity. Its patented Powerlock fastening system is typical of the methods in which extrusions can be easily repositioned to meet any subsequent design changes. Only two allen keys are needed to assemble even the most complex framework; there’s no need for extensive drilling and processing. Subsequent adjustment or complete repositioning can then be quickly and easily carried out simply by loosening the connector and sliding the extrusion along an integral groove to its new position before re-tightening.

New customers converting from steel to Alusett’s Kanya range are advised to send in the steel drawing and the company will redesign and redraw free of charge. The company recommends one of its engineers visits the customer so that they can design it together. The new PVS Light clamp, known as the ‘Hole-in-One’ is a clamp which can be fitted without any machining work or special equipment.

In conjunction with the launch of a brand new 30x30mm range in March, called XF, Flexlink is introducing a ‘Basic Engineering Guide’ which aims to take users through all the questions ­ step by step ­ arising in frameworks, enclosures and linear motion. This new range, like the existing Flexlink components, will also be available through the RS Components catalogue.

Boldman’s Nigel Clarke says that most users of aluminium systems who build frameworks will tell you that used correctly, an aluminium framework will easily surpass a steel one for many reasons. Little or no drawing is required on how the frame is to be made, for example. With the availability of large profiles such as 80×80 or 80×200, large free standing frames can be designed to carry working mechanisms mounted to steel baseplates with supported loads of over 1500kg. Windows, doors and accessories can be positioned without machining and should a mistake be made it can usually be rectified without drastic recutting or rewelding.

As for Stuart Mitchell of Machine Building Systems, he says that: “The best design advice I could give anyone new to the system is: give the problem to the supplier. Send him a fag-packet sketch on the fax, tell him you want it first thing in the morning, and put your feet up. If he’s any good he can design it ten times faster than you, and should be able to give you a workable design which can the be easily fine-tuned. He also knows all the new products which save time and money, details of which you either filed in Box 13 or simply haven’t heard about yet. If he can’t, or won’t, respond, ditch him!”

Looks like this is one market that’s as lively as ever.

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Contact details for these suppliers can be found on theSuppliers Guide pageson this site.

February 1998