Boring machinery breaks the bottleneck.

Production backups caused by boring operations have woodworkers looking toward machinery manufacturers to help speed production.

Boring and drilling have long been associated with production bottlenecks in woodworking shops. In many instances, how efficient a company's boring operation is can have ripple effects on other areas of production and even dictate the speed of the company's entire production line.

Two major causes of bottlenecks have been the downtime required for boring machine operators to change drill bits or to readjust boring measurements and set-ups required for different parts.

"In today's panel processing operations, flexibility is more important and larger production runs are becoming less common," said Rusty Denson, panel processing product manager with SCMI Corp. "The large through-feed boring machines and even the early CNC drills are more suited for these larger runs. With the advent of faster point-to-point drills and more user-friendly software, the time needed to change from one job to another is shorter than it's ever been."

Some current trends targeted at reducing today's boring operation bottlenecks are machines that work smarter by utilizing software programs and electronic controls specifically designed for boring applications. These developments have led to wider acceptance of point-to-point boring systems and faster product handling.

Soft(ware) spoken

Rather than experimenting with radical new boring machine designs, many equipment manufacturers are adding software programs to computer-controlled boring machinery to streamline production bottlenecks. Benefits from the addition of software include reduced time for changeovers and consistent accuracy in set-ups.

"Software program manufacturers first offered programs for panel saw systems to help optimize panels and cut waste," said Kevin Walsh, sales manager with Richard T. Byrnes Co. Inc. "But now these software manufacturers have started offering programs for boring machinery. The result is computer programs that eliminate the time-consuming need for an operator to individually program a boring operation. Programming used to take as long or longer to perform as it did to manually change spindles and bits. With these new programs, all you have to do is punch up the desired pattern and the machine will adjust itself and start boring."

The software can also be custom tailored to a manufacturer's specifications. A part can be designed and the program can be stored or modified for later use.

"When part size or some other detail changes slightly, like a 23 1/2-in. base cabinet end panel is required rather than 24-in. one, the software is capable of making a global change and the program is ready to run," said Denson.

If a company has produced many of its product designs on AutoCAD, there are even computer programs for boring machines which can convert the AutoCAD program to a computer manufacturing language to perform the necessary boring functions on the machine. CAD/CAM software is having a tremendous impact on speeding up boring operations.

"The software can read the CAD plan and then translate the specifications into a numerical language that the machine interprets as the correct point and depth to bore," said Rob Howell, sales engineer with Tekna Machinery Inc. "There is no need to manually load a new program in, if the program can read the CAD plan."

A logical solution

Boring machines using pneumatic logic controls to control machine functions are being replaced with programmable logic control (PLC), a solid state electronic function control system.

"If you look at pneumatic logic systems. there are a lot of valves which can be subject to failure because they can be contaminated by dirty air or humidity," said Gary Wells, president of Tritec Assoc. Inc. "Troubleshooting a pneumatic system is hard because it's difficult to locate the exact problem. With programmable logic control, they are more resistant to environmental changes because they are electronic and resistant to contaminants in the air. They also can tell the operator where the problem originates."

PLC units can be utilized in small, medium and large boring machines and the controllers can be used to meter a wide variety of functions such as pre-programmed glue amounts or mirror-image dowel inserting sequences without cumbersome mechanical setups.

"If you want to change the amount of glue used in a dowel inserter with a PLC unit, all you have to do is dial in the new amount and run it," said Wells. "The PLC units are good for minimizing downtime because they are easy to adjust and diagnose."

A case in point-to-point

Point-to-point boring machines are gaining in popularity in today's woodworking operations because of their increased capabilities and more attractive prices. Unlike manual multiple spindle machines, which can be useful for long runs with little or no changeovers, point-to-point machines can quickly adjust to different part settings through the aid of computer programming.

"The strongest uses for point-to-point machines are in flat panel processing," said Howell. "They have a lot of capability when it comes to producing cabinetry, store fixtures and stereo speakers."

In addition to their rapid ability of changeover, prices of point-to-point machines are becoming more attractive.

"For the cost of two good standard machines (line boring and dowel drilling), customers are now finding the cost very close to that of a basic point-to-point machine," said Steve Jones, sales manager with Altendorf America. "The advantages include no fence setting requirements and you only have to handle the workpiece once with a point-to-point system."

Hands-off handling

The axiom "too many cooks will spoil the soup," also holds true for product handling. The more handling of a part, the greater the opportunity for it to suffer dings, dents and delays when moving from machine to machine. The ideal boring operation will be able to quickly and accurately drill all necessary holes into a panel with minimal or no handling after the workpiece is affixed to the worktable.

"Putting a piece onto the worktable and letting the boring machine perform all the boring, maybe even some light routing or sawing, cuts down on this handling and that will save time and reduce defects," said Walsh.

Arguably one of the fastest ways to setup a boring machine for machining parts is through the use of universal bar coding systems. The bar coding scanning operation for machining in a woodworking operation is similar in principle to those used in grocery stores across the country.

In a woodworking operation, a scanner is waved over a bar code tag on a part and the bar code reader translates information such as what type of part it is and what machining operation needs to be performed. The boring machine will react by changing over to the next setting that corresponds with the scanned part.

"Bar coding is the quickest, most reliable method to load new programs," said Greg Hammersley, Weeke product manager with Stiles Machinery Inc. "Programs are automatically loaded as each part comes to the machine. Minimizing the time required to load the program, reducing changeover times and reducing errors in incorrect programs being loaded by other means are benefits to any size manufacturer."

The price of this technology is also more affordable than many may think, according to Hammersley. "A bar code reader adds a minimal amount to a machinery purchase," he said. "But if you're spending $100,000 or more on a boring machine, the money spent on the bar code reader will seem like a small investment when you're talking about saving time and reducing rejects."

Conclusion

Regardless of its size, many woodworking operations suffer from boring operations which experience product backups. However, there are efficient solutions to reducing these bottlenecks.

"Even in the custom shop, where you may run 20 or 30 different jobs, adopting some of these techniques can minimize set-up and programming time while allowing the shop to become more profitable," said Denson.

If companies take the time to research current software programs and control systems designed for boring operations, find the correct boring system and utilize an effective program which reduces handling and changeover, the chances of speeding production in a notoriously slow area can be increased.

Available equipment

The following is a review of some boring equipment available to the woodworking industry. For more information, circle the corresponding numbers on the Reader's Service Card. For a more comprehensive overview of the boring equipment market, consult the 1994 Red Book Annual Buyer's Specification Guide.

The Rover 346 point-to-point boring machine from Biesse America features vertical and horizontal drilling on four sides of the panel, heavy-duty routing with 9-hp router motors, automatic tool changing, edge sanding. grooving and hardware inserting capabilities and more.

The Scheer/Byrnes Model DB22 in-line multiple spindle drilling machines from Richard T. Byrnes Co. Inc. are designed so that two rows of holes can be drilled in one working cycle. The unit comes standard with an extraction hood which can be connected to a central dust system to keep the workpiece free of chips and dust. The machine is also equipped with an electric switching cabinet and a pneumatic maintenance unit. A special system of stops for left and right hand panels avoid offset errors.

The Weeke BP-15 Optimat CNC point-to-point boring machine from Stiles Machinery Inc. offers vertical boring with 22 individually selectable spindles, horizontal boring with five individually selectable spindles. X/Y programmable grooving saw, Homatic 2000 CNC control with intuitive programming software, offline programming software and many safety features.

The Model BL-G universal boring machine from Koch Machinery & Systems has been designed for boring applications in rail and panel manufacturing and for back-post boring in the chair and upholstery industry. The machine can perform vertical boring from the top and bottom and end/edge boring horizontally. All boring units can be equipped with swivel capacity. Digital and/or LED readouts reduce set-up time. Optional features include a trim saw, hopper feeder and computer set-up.

The Vitap line of semi-automatic and automatic drills from Atlantic Machinery Corp. are available in many standard configurations or can be customized for your specific applications. The Sigma 2TO and 2TA are reported to be compact, fast and accurate to 0.00394 in., according to the company.

The Morbidelli U 550 point-to-point boring machine from Tekna Machinery Inc. is a flexible CNC machining center that allows JIT processing of panels. The machine is reported to offer 29 independently-controlled spindles as well as a full compliment of optional equipment, including routers with automatic tool changing capability, disc saw attachments and horizontal boring. The machine can be programmed off-line in the office with newly developed customized American CAD/CAM software.

The Tech 100 CNC machining center from SCMI uses 14 independent spindles for horizontal boring on the X axis and two independent spindles for horizontal boring on the Y axis. The machine uses brushless AC Serve motors and linear prismatic bearings for fast, accurate positioning of the groups and is available with one or two 9-hp motors.

The Jonsdorf Unidrill point-to-point machining center from Altendorf America, div. of Stiles Machinery Inc. can perform dowel drilling, line boring and grooving by means of a five-aggregate revolving turret-style machine unit. Multiple hole diameters are possible without changing the drill bit. Drill pattern software is included at no additional cost, according to the company.

The Pade Uni 5 CNC numerically-controlled work center from Macoser Inc. is based on a five-axis head with universal bits for boring and mortising, as well as shaping tools for contouring jobs. Features include fast set-ups, teach-in programming, flexibility and precision, table divided into two stations for piece loading and double piece clamping system by vacuum table and pneumatic cylinders.

The Ayen DBE from Force Machinery Co. is a single-sided dowel boring, gluing and inserting machine designed for heavy-duty use and offers a new glue system. The list of options for the machine is extensive according to the company. Features include a cast iron machine table, six glue and dowel insertion units, and heavy casting precision fences.

The J-690 automatic boring machine from Doucet Machineries Inc. is specifically designed for angular drilling on chair cross bars and legs. It can be equipped with one or two self feed hydraulic spindles that are mounted on a dovetail beam, one vertical and the second one adjustable from 0 to 90 degrees from vertical. Loading and unloading is performed in front of the machine and the company says the machine is capable of producing six to eight pieces per minute.

The Tritec/Gannomat Model 280 series of fully automatic drilling, gluing and dowel inserting machine from Tritec Associates Inc. features a high-pressure closed glue system, 23-spindle drill head on standard 32mm centers (other centers on special request), six standard (16 optional) movable gluing and inserting units, self-diagnostic electronic programmer for control of all machine functions including glue amount and programmable mirror-image dowel selection.

The Octo-Control machining center from Holz-Her U.S. Inc. reportedly can do the work of six or more machines including horizontal or vertical boring, line boring, back panel grooving, hinge inserting and optional door hinge hole boring. Other features include a color-coded revolving turret, eight way programmable fence, centralized dust extraction and air floatation table.

The Cartesian Eagle point-to-point boring machines from Thermwood Corp. are now available in 30 in. x 90 in. tables in addition to the original 30 in. x 60 in. tables. The tables are equipped with a vacuum that is reported to eliminate the set-up needed with vacuum pod hold-down.

The Bridgewood BW-808 boring machine from Wilke Machinery Co. comes equipped with 12-drill spindles that may be positioned anywhere above the 2-ft x 4-ft worktable. The machine may be operated automatically with adjustable time delay or semi-automatically using the foot pedal to cycle the table up and down. Two 2-hp motors power the 12-drill spindles via large fiat drive belts.

Brema through-feed machining centers from Servatek Inc. fully machine both sides of a panel simultaneously. The eight-station turret accepts boring, mortising, sawing and high-speed router heads with up to 15 hp. All axis movement is accomplished on THK multi-faceted guideways utilizing precision hardened and ground ball screws and AC motor drives. All machining functions are controlled utilizing an IBM 486 computer featuring advanced graphics programming.

The Speedy 207 CNC point-to-point boring machine from Holz-Her=U.S. Inc. features a compact, fabricated steel body, heavy-duty, high precision gantry construction, five vertical and one double horizontal independent spindles, one grooving saw (X axis), vacuum clamping and four support tables.

The SAB vertical angular boring machine from J.S. Richardson Co. Inc. has a 14-in. x 36-in. table, 11-in. throat clearance and a 6-in. stroke. The 2-hp 3,600 rpm motor will accept the company's geared boring heads. The angular adjustment is 30 [degrees] left or right and 30 [degrees] backward. The feeding unit is air with hydraulic control and the cycle can either be one stroke at a time or automatic with variable time delay between strokes.

The Masterwood/Riebling Ligna MP3 modular multi-boring machine from Eric Riebling Co. Inc. offers horizontal and vertical independent boring units with optical readouts and pneumatic locking. Pneumatic stops with micrometer perform centering of left and right panels. The machine is available with 0-90 degree rotating heads and split heads.

The Tyler Drill Unit from Tyler Machinery Co. Inc. can be used for drilling two holes with variable center distance. The drill unit is comprised of a Tyler Model 2111 drill head and a TEFC spindle drive motor. Available with two spindles having an adjustable spindle distance of 1 in. through 6.6 in., eliminating the need for collets and assuring proper drill positioning, according to the company. Maximum drill spindle speed is 4,500 rpm with a maximum 2-hp drive motor.

The Inverted Boring Machine (IVB) from Cemco is a custom built unit, specified around a customer's applications. The unit acts first as a stable work station, providing a platform of jigs to assemble various components such as chair/couch end pieces. As two end frames are assembled, drill bits then rise from the interior of the table and bore both assembled frames to insure a match.

The horizontal boring machine from Delta Int'l Machinery has been designed for cabinet and furniture shops and can perform repetitive boring operations quickly, according to the company. A foot pedal pneumatically controls the machine. Features include a cast iron table, adjustable hold-down and boring head, standard-equipped stock shop plus a steel cabinet. The company says the machine can bore holes up to 1/2 in. in workpieces up to 8 1/2 in. thick. The distance between spindle centers may also be adjusted from 3/4 in. to 3 in.

Friulmac offers the Model FN Kombi boring machine. The company says the machines are fully adapted to the customers specific requirements using standard units and a modular system. All the machines are equipped with a hopper feeder and a workpiece return system to the operator. The company adds that the machine is capable of being linked with other machines, such as moulders.

The Unipress from Grass America Inc. can be used for 32mm line boring. Features include precision boring depth and the automatic removal of wood chips with air pressure. The company says the drill is built to drill through the hardest materials.

Ritter Mfg.'s R-1800 CNC horizontal boring center is designed to fill a need for heavy-duty applications requiring horizontal boring with holes up to 3/4 in. diameter and countersinks up to 1 1/2 in. diameter. Interior and exterior doors, furniture component parts, cabinet face frames and window frames are a few of the applications the machine can handle.

The Maggi System 2232 is available from Woodworking Machinery Distributors USA Inc. It features 22 spindles, measuring positioners for panel and spindle head unit, a device for 45 [degrees] boring and a graduated scale showing head angle.

The Blum Minipress from Julius Blum Inc. can be used for hinge drilling and insertion. The machine can perform 32mm line boring and features seven spindles for end panel drilling.