A new generation of woodworking technology.

Every 30 years or so, a major break-through in systems or factory processes occurs that changes the face and function of the world of manufacturing radically. Small incremental improvements, such as the Japanese using their "Kaizan" process are fine but no longer high-profit revolutions.

These breakthroughs are a combination of major technology factors already existing but now combined for the first time for optimum results.

Perhaps the single biggest trend witnessed at Ligna Hannover '99 is one in which computers, previously attached to a well established machine, are now built into the machine with new high technology functions. Integrated computer-driven machines take up less floor space and run at high speeds without rework and with no set-up time, making complete custom orders of one or 100 units/parts in any sequence. As a result, manufacturers stand to gain the following benefits:

* Zero set-up time; the machines are productive all day.

* The machines provide repeatable accuracy.

* Higher output rates.

* The ability to manufacture parts or products in any sequence, size and quantity.

Following are some examples of new breakthrough technologies exhibited at Ligna that represent the direction for the next millennium and your factory.

Modular Machines

Ever purchase an edgebander and then realize you wanted hotmelts and PVA glue pots, or perhaps a sanding attachment? In the past, once the machine was installed it was too late to do much about it except to go out and buy a new machine.

This is not a problem anymore. The new technology allows totally modular machines. You buy what you need for today and when you need more, you buy more machine modules and plug them in. This is a today solution to an old problem and will have a low-cost future with super high customer acceptance.

The modular machine concept works for:

* Tenoners,

* Edgebanders,

* CNC boring and routing equipment,

* CNC case presses, and

* Assembly lines.

Modularity is new in machine building and each unit stands alone. Most importantly it increases the machine's current and future flexibility.

Fiber Optic Wiring

Closely tied to modular machinery is the emerging trend toward fiber optic wiring.

Electric wiring on machines, buildings and factories has been around since Edison, only today it is more sophisticated. Relays and controls are used today. Up to now, 125 volts has been the control voltage with copper wiring for controls, while 480 volts has been used for power wiring with multiple copper wires used in a conduit.

New is the combination of the computer and fiber optic wiring with bus-type computer-driven controls. These relatively simple functioning controls are easily installed, are quite sophisticated and result in the following:

* Lower cost for wiring a total factory.

* Reduction of machine switchboards to half or less their size.

* Reduction of combined relay functions in smaller inter-linkable bus controls that drive the machine totally by computer.

* The ability to send information to specific points in the circuit using the same circuit for the relay-type messages, such as instructing a machine station to tilt 45 degrees.

* Uniformly using only one type of system for wiring a machine or a whole factory, thus standardizing all electric and electronic systems.

Super-Fast Machining

In addition to being built modularly, the new generation of edgebanders are capable of operating at speeds of 160 ft per minute. Gone are all the electro-mechanical or pneumatic controls that were relatively slow and cumbersome to maintain. All new electronic controls are now able to instantly change edgebanding color or thickness while the machine speeds at an incredible 160m per minute.

At this rate, three conventional machines can be replaced with one machine to save valuable floor space.

What's more, new in-line machines are available to completely size, profile and shape up to three curvilinear desktops in a one-minute cycle. They incorporate zero-point registration, which eliminates the need to turn tops and index them underneath. Load and unload equipment built to accommodate the speed, size and shape of the table or desktop requires only one operator.

The in-line configuration saves time for loading and unloading the heavy desktops and arms the new machining centers with the ability to out-perform big multi-head routers with single or multiple shuttle tables.

Super Finishes

The new technology in applying water-based UV materials by roller or spray gun reduces the VOC content to a minimum while reducing drying times to a matter of seconds.

A winning strategy is to apply these new super finishes to your product as a flat unassembled part, then machine and assemble to order. Further advantages are gained by recovering the materials automatically to reuse the stain, sealer or topcoat that is oversprayed. The new super finishes are extremely effective, especially when covering 1,600 square feet with one gallon of material using a roll coater or 1,200 square feet using automated spray coaters.

Gunter Geiger is president of Gunter Geiger Systems Ltd. of King of Prussia, PA, an international consulting firm to the woodworking industry. Geiger can be reached at [phone]; e-mail [e-mail].