01 February 2012
'Take That' robot, Om, made on Amada technology by Warren Services
Amada technology at Warren Services played a pivotal role in the production of parts for Om, the giant robot taking centre-stage on 'Take That's' record-breaking Progress Tour, in 2011
The internal skeleton and drive tug for the 60 ft robotic Om featured a multitude of mild steel plate parts ranging in thickness from 5 to 20 mm. With a lead-time of just eight weeks between receipt of drawing and first rehearsals, the speed and flexibility of Warren Services' automated laser and folding cell was fundamental to the success of the project.
Image: Om as a work in progress
"We couldn't have done it without Amada," says the company's managing director, Will Bridgman. "The laser and software technology are absolutely amazing and, yet again, they have proved their value to Warren Services."
The company's operations director, Clive Poyner, takes up the story: "Virtually every part was different, albeit in left or right-hand form," he says. "Due to the complexity of the design, we were really up against it with the amount of programming and laser cutting that had to be done. The task was made harder because we didn't see the full plans to start with – they came through in sections, as we were building it. However, it was exciting to see Om develop and grow in front of our eyes."
The centrepiece of the automated fabrication cell at Warren Services is an Amada LC3015 F1 4kW CNC laser profiling centre. There is also a space-saving Amada ASLUL automation tower that stores pallets of raw material and automatically loads and off-loads sheets. This enables the F1 to operate without manual set-up or intervention, allowing lights-out production if required. The final element of the cell is an Amada HFP 220-4 (220 tonne, 4m) CNC seven-axis press brake.
Image: Amada machines helped make Om's rapid build possible
Accompanying the automated cell (installed in December 2009) at Warren Services is Amada's SheetWorks 3D solid modelling and un-fold CAD system, as well as Amada's Dr ABE Blank and Dr ABE Bend automatic CAM software.
"The ease of off-line unfolding and programming using Amada software helped get these parts on the laser in super-quick time," says Mr Poyner emphasises. "I dread to think how long the project would have taken without it."
The company also makes use of Amada's vFactory scheduling and production monitoring software, which allows management to check a machine's operating history, observe patterns between shifts, determine the exact production time required per part, and remotely monitor the machines.
It all helped make sure Om was delivered on time, ultimately providing enjoyment to more than 1.75 million fans.
Taller than the Angel of the North, Om is able to move forward and stand upright with outstretched arms, holding band members in his giant hands. The largest individual components profiled by Warren Services were some of the shoulder elements, which measured approximately 1.0 by 0.5 m.
"The project demonstrates the capabilities of Warren Services, from both a reactionary project management perspective and also the extent of our in-house manufacturing processes. It was a real team effort," concludes Mr Poyner.
Author
Andrew Allcock
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Related Companies
Amada United Kingdom Ltd
Warren Services Ltd