Page 89 - Modular design for machine tools

Basic Knowledge: What Is the Modular Design? 55

Science and Technology). Importantly, Ikegai Iron Works already applied
it to the large-size machine tool in the beginning of the 1960s, although
there were multiple obstacles derived from the optimization of the struc-
tural configuration. In fact, the optimization is in larger dependence
upon the differing magnitude and direction of external loads, difficulties
to provide rationally the subform generating function to each module, and
also the functionality to be provided to each module. Taking into account
the difficulties in the unit construction within the same kind, the obsta-
cles mentioned above are easily imaginable and acceptable.
In fact, Ikegai Iron Works tried to manufacture the planomiller,
bedway grinder, planer, vertical turning machine, and vertical boring
machine, from a group of the units in 1962, as shown in Fig. 1-37.
Regarding this trial, it was reported that the manufacturer was able to
reduce the design time and throughput time to a great extent.
Consequently, several vertical turning machines and planomillers were
actually installed in the factories of Toyota Motor Car and Nissan Motor
Car. Even in the late 1990s, a planomiller is used on work at the die manu -
facturing factory within Nissan Motor Car, after making the retrofit
compatible with the modern NC.
The same idea was later employed by the VEB of Karl-Marx-Stadt.
In this case, the planer, planomiller, boring machine, and guideway
grinder were produced from a group of modules, which were classified
into those for structural configuration, form-generating movement, and
additives. The machines can be characterized by the driving mecha-
nism consisting of the crossed helical pinion-rack mechanism of built-
in unit type, which was available for all the kinds possible. In contrast,
the driving source was varied depending on the kind; in addition, the
electric equipment was of modular type. As can readily be seen, the
user and manufacturer could expect high machine effectiveness and
high productivity, respectively. In fact, the manufacturer saved the
developing cost up to 10 percent in standard type and up to 20 percent
in special type by the employment of the modular design. Furthermore,
it is worth stating that the planomiller was used as a machining entity
within a system PRISMA II, which is the well-known FMS produced by
East Germany [27].
Following that of VEB, a machine with modular design of different-kind
generating type was conceptualized, as shown in Fig. 1-38, by the University
of Strathclyde in accordance with the ASP Plan [28], although the
responsible committee concluded that the machine was not to be a real-
ity. The machine aimed to be a kernel of the manufacturing system for
small batch size. In retrospect, it is very interesting that Mauser-schaerer
tried to produce an FMS called Produktionssystem 2000 using the MC
of column traveling type and vertical turning machine. These machines
were produced with the modular design of different-kind generating