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The manual rotary indexing machine is a work table that distributes products in circular parts. It gets powered by a motor or manually turned with a crank. These tables are used in assembly lines to help position workpieces for repetitive procedures like drilling or milling. They can be combined with other machines to make more complex systems and jig fixtures for products to be positioned at the right angle and orientation when being worked on. Some common types of rotary indexing tables are as follows.
Manual Crank Rotary Indexing Machines
The manual crank rotary indexing machines are turned by hand cranks. The stationary work table has a rotating disk mounted horizontally above it, dividing into equal billets or stops. Usually, a divider is placed on the perimeter of the disk to mark each section. This machine requires the operator to turn the hand crank in a circular motion to turn the workpiece for the desired operation to be performed.
Manual Rotary Indexing Plates
Manual indexing plates allow mechanical operation with an operator's manual assistance. It consists of a heavy-duty round plate with bolt holes to fasten it to a stationary base. It can be positioned vertically or horizontally. The machine works by moving the workpiece in specified degrees or stops by unclamping the handle, moving the workpiece to the desired location, and clamping it again. Manual indexing plates are commonly used in drill presses or saws.
Cam-driven Rotary Indexing Machines
In a cam-driven machine, an external drive motor powers the mechanism through a cam. The cam is a special-shaped rotating disk that imparts the stopping motion to the workpiece. The machine has a triangular housing enclosing the drive train with precise machining for durability. Like other indexing devices, the workpiece must be clamped to it. This clamp and stop work well in CNC milling machines and automates the workpiece feeding. CNC Routers use them to work more efficiently.
Pin and Hole Rotary Indexers
Pin and hole rotary indexers work like the claw or cam indexers because the pins engage the holes on the rotating disk. To ensure proper positioning and smooth operation, the pinion gear must align and engage with the driven gear. These machines are commonly used in welding or assembly lines.
The specifications of a manual rotary indexing machine will meet various machining needs. The indexing table is the key feature of an indexing machine. Its diameter measures from about 150 mm to 600 mm. With a larger table, operators can secure workpieces of greater sizes.On the table, there are T-slots. Their total number is usually around four to five with a depth of about 13 mm, which allows operators to use fixtures to secure workpieces with different shapes.The degree of rotation per index is either 15 degrees or 30 degrees. The former means that there are a total of 24 stops for each complete rotation, while the latter means that there are 12 stops. Moreover, it has a central shaft with a lock pin that engages and disengages different indexing positions altogether. The spindle's diameter is approximately 45 mm, and the lock pin's diameter is about 12 mm.The machine's body or frame has a casting material with a net weight of about 20 kg. It is a floor-standing model. The total height reaches around 870 mm, with a length and width of 600 mm and 300 mm, respectively.
Even though manual indexing machines are simple and easy to operate, they still need regular maintenance to improve their performance and prolong their lifespans. Before starting with the maintenance, operators need to check if the machine is turned off. Then, they should periodically lubricate the parts, such as spindles and gears, in accordance with the index model's manual instructions. Additionally, they need to clean the machine and remove debris or contaminants and inspect it after use for damage. If any part is loose, they need to tighten them. To protect the machine from environmental elements, they should store it in a dry and clean place.
The manual rotary indexing machine is popular industrial equipment in metalworking, woodworking, and assembly workshops. Here are some usage scenarios where these machines are commonly used.
Jig
In tooling operations, a manual indexing fixture or jig can be a workbench for different machining processes. In this case, the rotary indexing fixture is clamped on the worktable of the machine, and workpieces are mounted on the fixture. This sets workpieces at certain angles and positions for operations like welding, assembly, drilling, and painting. Using rotary indexing jigs helps increase work accuracy and efficiency.
Creating Holes and Cutouts
With the indexing as a guide, workers can easily drill workpieces, including cylinders, frames, and plates, in desired positions. The tool usually comes with a hole or a T-slot for easy clamping. Moreover, some models might have a pre-drilled hole pattern for customer access.
Generating Gears
As Gears Cutting Tool Blanks Fixtures, rotary indexing machines divide or space equal tooth gaps totalling high accuracy and uniformity. In this case, operators clamp the gear cutter fixture on the indexing table, which is then rotated incrementally to cut the required number of teeth. This method is effective for composite and circular gears with a large number of teeth.
Routing and Milling
With rotary indexing, operators can mill cavities, cutouts, features, and grooves in workpieces of various shapes. The machine's positional accuracy helps workpieces achieve consistent and good-quality results. Also, the indexing motion allows easy access to different workpiece sides.
Engraving and Etching
When performing engraving or etching actions on workpieces of various shapes and sizes, a rotary indexing machine can be very helpful. Its indexing accuracy allows operators to easily position workpieces for the engraving of designs, patterns, text, or graphics. The machine may include a rotary table for mounting the indexed workpieces, for example, cylinders and plates.
Fixture in Assembly Processes
In assembly operations, rotary indexing machines are used to locate and hold parts at certain positions and angles for proper alignment during assembly. This ensures efficient assembly line operations with accurate assemblies. Also, operators can easily access different workpiece sides.
When buying a rotary manual indexing machine, it is essential to choose one that will meet the production requirements while still being safe and easy to use. Factors like the workpiece's size, weight, and shape must be considered, as well as the indexing speed and accuracy needed for the specific application. If the machine is going to be used for multiple applications, it's a good idea to invest in one that comes with interchangeable fixtures so that it can be adapted to different workpieces. Similarly, adjustable indexing angles and speeds would make the machine more versatile.
Operators will need to load and unload parts from the indexing fixture, so consider the ergonomics of the setup to ensure it is user-friendly, and choose a machine that won't make the operator's job physically uncomfortable. Safety is important too, so look for machines that have quality guards and supports, as well as non-slip feed tables. Any manual machine will require regular maintenance to keep it performing well, so make sure it's easy to access and clean the indexing components, especially the belts and bearings. Rotary machines tend to differ a lot in terms of construction, so it's a good idea to check that the indexing system is made of durable materials that won't wear out quickly, which would reduce their indexing precision.
Finally, the manual machine chosen should have provisions for being anchored or mounted down securely. Unstable machines that move when parts are being indexed can result in inaccurate machining and dangerous situations.
Q1: How do users operate a manual rotary indexing machine?
A1: Operators use their hands to turn the rotating disc or table. They rotate it until the properly indexed workpiece station is in their designated position for the required operation.
Q2: What are the trends in manual indexing machines?
A2: The shift towards sustainability is causing indexing machines to adopt more sustainable practices. Many manual indexing machines are now designed to use less energy and made with more recyclable features. Furthermore, technology is helping to create smarter manual indexing machines, including connectivity options that permit remote monitoring and control.
Q3: What safety precautions should indexing machine operators follow?
A3: Operators should follow safety precautions. They include ensuring the workpiece is secure before starting the indexing cycle. Moreover, the operator should avoid reaching into the machine while it is rotating. They should also keep their hands away from moving parts.
Q4: What are the limitations of a manual rotary indexing machine?
A4: The manual indexing machine cannot offer the speed and efficiency of automated systems. They also provide limited production capacity. Furthermore, the machines require skilled operators to achieve optimal performance and accuracy.
