3-D Shaper for Surfboards with 3-Axis CNC Control
Shapers Australia has teamed up with 3EMMEGI S.A.S to promote their new specialised 3-Axis, 3-D Surfboard Shaping Machine with CNC Control. 3EMMEGI S.A.S. are Specialist Engineers in Robotics, Automation and Special Machines and they have utilised these expertise to engineer and deliver a first class 3-Axis, 3-D Surfboard Shaping Machine with CNC Control.
The advanced system works by means of brushless motors controlled in closed-loop by a main control unit. The control is completely automatic according to common 2-D and 3-D software design. The machinery has been specifically designed to shape Surfboards, Kite boards and Sailboards and allows the 3-D shaping of any kind of material with soft structural resistance, including foams, plastics, Fiberglass, wood and many others. The durable and highly effective Profile Cutters are a product supplied by Shapers Australia who specialise in cutters for Surfboard Manufacturers. Please click on the following link for more information regarding our Profile Cutters and scroll down to the 4th product on the page: http://www.shapers.com.au/category1_1.htm
MACHINE SHAPES a 6’6 Surfboard in 7-8 minutes per side (at 80% speed)
The Mainframe is manufactured in carbon steel, with overall dimensions approximately; 3800(L) x 1100(W) x 2000(H) mm and is provided with adjustable anti-vibrating stands. Movements along the axis are realised by means of 3 couples of slides with ball bearings cars with maximum length equal to 700, 3100, 300 mm. Power trains are achieved by means of 3 groups constituted by motor, reducer, main gear and rack. The system is provided with vacuum and filtering device for suction of powders produced during working.
Support plane for pieces to be shaped is realised by means of adjustable aluminium profiles, each of them is equipped with n.2 suckers made in silicon with 75 mm diameter so to hold the piece by means of vacuum. Vacuum pump is dry type and performs a suction of 35 mc/h. It is complete with pressure limit control and manometer for the regulation of the vacuum pressure in function of different type of materials to be shaped.
3-axis logic control is commanded by means of software and hardware predisposed to read typical ISO languages (G code) for CNC control. The system allows also the possibility to accurately replicate the acquisition of the shape of existing surfboard designs by means of a laser photo-electric cell with maximum dept of 400 mm
TYPICAL SYSTEM CHARACTERISTICS
|
Linear positioning precision: |
0.1 |
mm/1000mm |
|
Linear direction precision: |
0.1 |
mm/1000mm |
|
Repeatable position precision: |
+/- 0.1 |
mm |
|
X axis working length: |
700 |
mm |
|
Y axis working length: |
3100 |
mm |
|
Z axis working length: |
300 |
mm |
|
Combined total linear precision: |
0.25 +/- 0.1 |
mm |
|
Working speed: |
0 – 50 |
cm/s |
|
Power supply: |
As requested |
|
Frequently Asked Questions:
What kind of design software is used on the machine?
The machine uses the latest SHAPE-3D CNC version, however it is possible to run the machine with any kind of 3D design software that provides an output in G-CODE language.
How does the scanning system works?
The machine has a laser photoelectric cell that measures the vertical distance (along Z axis) of the top installed surface of the board from an adjustable Zero point. Moving the cell along X and Y-axis it is possible to read all the typical points of the board so to recreate the existing shape.
Which brand are electrical equipments?
All electrical equipment’s including motors are produced by internationally certified and recognized companies; CE (Europe), UL (USA), CSA (Canada). These parts are our preferred choice however the whole machine may be realised with any brand with same characteristics and certifications that you request (NOT INCLUDING MOTORS, DRIVERS and CNC control).
It is possible to manufacture the machine with different working dimensions?
Yes it is - the machine can be customized to the dimensions you need.
What is the time taken to shape one side of a 6’6” board on a normal setting?
The time to shape one side of the board is 7 – 8 minutes. Obviously the time vary in function of number of shaping lines you chose. This time corresponds to a speed of approximately 80% of the machines maximum speed (recommend speed).
Is the operating platform Windows based?
The CNC software we use works under DOS and we utilize Windows 98 for the PC that actuates the command and control. However if you prefer there is no problem to choose CNC software that works with any version of Windows or other platforms.
What is the 1-year maintenance cost and what would they consist of for the year?
Maintenance is very low:
· The Profile Cutter provided is supplied by the industry specialists - Shapers Australia. All Cutters are coated in the same highly effective Tungsten Carbide Gritting as their famous Shapers Barrel® (http://www.shapers.com.au/category1_1.htm). The Cutters are highly durable, cost-effective and do not chop the foam or chip the stringers, hence leaving an ultra clean and smooth finish.
· Motors are all maintenance free for several years;
· The only bearings that you will need to replace are the one of the spindle motor just for precaution every 5.000 hours working;
· Vacuum pump is dry type, reducers are with everlasting grease and all other components only need to be greased every 300 hours (close to one month).
NOTE: Maintenance costs in terms of spare parts are ZERO because the supply of the machine includes spare parts for the first year including bearings and grease.
What is the total floor space of the machine and operating station?
The overall floor dimensions of the machine are 4000 mm x 1500 mm. Main electrical board is inside the machine. Outside this you need close to 0.5 squared meter for the vacuum and filtering device. The PC station has a 5-meter long cable to be connected to the main board of the machine.
How is the blank secured to the machine?
The blank is held by means of ‘adjustable suckers’ and is centered by means of pneumatic auto-centering pliers so to hold the board aligned with the Y axis of the machine.
The procedure of setting up is simply:
- Insert the board between the two (front and tail) pliers;
- Put the suckers close to the board untied in their adjustable supports;
- Turn on the vacuum pump and let the (free of moving) suckers stick to the board;
- Lock the adjustable suckers simply by means of handles.
How long does it takes to install the machine?
The machine is one-piece and takes a couple of hours to install it. Main electrical board is already part of the machine itself and the only things needed are compressed air and 3-phase power supply.
Does the machine come with a control cabinet computer or would I need a control room?Included in supply is a PC with Monitor and 5 meter long cable that you may position to personal preference. If you need a cabinet there is no problem to locate the PC into it.
What kind of materials can I fit on the machine?
You can fit almost anything on the machine, from any kind of foam to wood and plastics. The machinery has been specifically designed to shape Surfboards, Kite boards and Sailboards and allows the 3-D shaping of any kind of material with soft structural resistance, including foams, plastics, Fiberglass, wood and many others.
To view a video clip of the 3-Axis, 3-D Surfboard Shaping Machine in action please click on the following link (link may take a while to load)
http://www.3emmegi.com/Immagini/3d-shaper-video-176x144.wmv
