ng frets and more omputer controlled high tech guitar tool ... · omputer controlled high tech guitar tool for dressi ng ... This is a major breakthrough since the P LEK P RO identifies

Designed for guitar production

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(15) Designed for guitar production 1 | 8

© A+D Gitarrentechnologie GmbH March 2011

ProductionProductionProductionProduction The PLEK PRO has been developed to be used in guitar production factories and/or service-repair shops as a tool that not only does precise fret dressing but also helps with quality control and R&D. This computer controlled device scans and dresses a guitar under actual playing conditions, strung and tuned to pitch. This is a major breakthrough since the PLEK PRO identifies precisely what needs to be done for perfect fretwork, executes this rapidly, and delivers perfect results on the instrument when restrung. PLEK PRO speeds up the production process and raises the quality of instruments to an extremely high and consistent level.

Multifunctional CapabilityMultifunctional CapabilityMultifunctional CapabilityMultifunctional Capability As a result of a new electronic and hardware concept, upgrades do not require special effort. The PLEK PRO represents uncompromising modular design that makes it easy to develop and add additional tool modules and process features.

Research and developmentResearch and developmentResearch and developmentResearch and development Its measuring and graphic display capabilities open up a wide range of R&D applications. For example, one important use would be studying the workings of the truss rod and how it affects the neck. Fingerboard issues can be evaluated in accurate 3-D, the effect of humidity and gluing procedures can be studied, and instruments can be observed over the long term for stability and setup issues.

Quality controlQuality controlQuality controlQuality control The impact of material defects, manufacturing problems, and customer returns can be studied and will decrease. PLEK PRO creates printable graphic feedback to improve employee performance. Consistency of innumerable manufacturing processes can be seen and stored for later comparisons. A permanent record of all instruments remains in the database for later reference as needed.

High frequency spindle (nut and saddle cutting, engraving)

Sensor finger

Fret cutter (w/ replaceable cutter head)




PPPPLEKLEKLEKLEK P P P PRORORORO standard tool modules standard tool modules standard tool modules standard tool modules

The PLEK PRO is delivered with a scanning modulescanning modulescanning modulescanning module and two cutting mocutting mocutting mocutting moddddulesulesulesules.

Scanning moduleScanning moduleScanning moduleScanning module

The scanning module basically consists of a sensor fingersensor fingersensor fingersensor finger combined with a high-resolution magnetic linear encoder. This sensor is able to measure all relevant parameters of a guitar's playability: action, fretboard relief, fretboard contour, fret height, fret spacing as well as nut and saddle details. For further processing PLEK PRO's software analyzes and displays all measurements numerically and as diagrams.

Cutting modCutting modCutting modCutting modulesulesulesules

For fret dressing the PLEK PRO makes use of a specially manufactured carbide cutting wheel contoured for cutting the fret height as well as rounding the fret crown simultaneously. Each fret cutterfret cutterfret cutterfret cutter comes with 2 or 3 customized shapes.

PLEK PRO's second cutting module is a HHHHigh F F F Frequency Motor SSSSpindle (HFSHFSHFSHFS) with 5.000 – 50.000 r.p.m., which is used for cutting nut string slots and saddle slots as well as for engraving. A selection of several precision rotary bits (ball-, shaft-, cone-type) can be automatically loaded from a toolholder panel.

The HFS can cut a perfect calperfect calperfect calperfect caliiiibrated nut slotbrated nut slotbrated nut slotbrated nut slot for even the smallest string gauge. For wider slots the HFS cuts the slot in multiple passes or can pick up a larger router bit as needed. All nut slot specs are fully adjustable in 3 dimensions precisely referenced to the fret plane. The slot spacingslot spacingslot spacingslot spacing and style can be selected from a menu which offers a choice of spacing formats, break anglesbreak anglesbreak anglesbreak angles and splay anglessplay anglessplay anglessplay angles as desired.

The HFS also cuts the precise bridge saddle height of acoustic guitars, automatically achieving the desired action.

Engraving any motif into nuts and/or fingerboards is another feature of the HFS. Typical examples are signing instruments or cutting the necessary cavities for inlay work. Image data can be imported as any common format and are transformed into black & white for the engraving process. Lines with a resolution as fine as 0.2 mm can be worked with.




PPPPLEKLEKLEKLEK P P P PRORORORO in small production (or QC, R&D, repair) in small production (or QC, R&D, repair) in small production (or QC, R&D, repair) in small production (or QC, R&D, repair)

Preparing the instrument The operator places the instrument - strung to pitch - in the cradle doorcradle doorcradle doorcradle door and aligns it with a simple positioning devicepositioning devicepositioning devicepositioning device. String gauge, fret width measurements and some basic info are entered in searchable fields. The cradle door is closed and the operator starts the program sequence.

Plek ScanPlek ScanPlek ScanPlek Scan

The instrument scan measures string spacing, distances to neck edge, action at the first and twelfth frets, board radius and relief and fret height throughout. This can be graphically displayed to compare the existing fret-plane, board adjustment, fret height and action to any target info inputted with that info file. This not only illustrates problem areas, but also aids with adjustment and serves as a source for all the procedures that follow. All data is filtered through the proven PLEK algorithms of fret plane relief for a given action and gauge.

The Virtual Fret Dress

The heart of the PLEK process is the "Virtual Fret Dress". In this interactive windowinteractive windowinteractive windowinteractive window, the frets can be "dressed" using an idealized surface, a software "dressing file" that can be manipulated until all low spots are touched either with minimum amount of fret material removed or until the "finished" frets are at target height. This is an extremely user-oriented program that allows any preferred dress to be done for any actionactionactionaction and with any compound rcompound rcompound rcompound raaaadiusdiusdiusdius and/or upper end "fallfallfallfall----offoffoffoff" implemented etc. The operator can work in his/her usual style except that many different fret "solutions" can be studied in a virtual mode. Then, when ready, the strings are loosened, held to the side and the frets are cut exactly as designed.

Processing With the strings out of the way, the fret dressing gets done, the nut slots and nut surface can be cut if selected, and a saddle, mounted in the saddle vise can be trimmed, all in one process. If the HFS cutter bits need to be changed, the PLEK program will produce an audio signal and screen command when necessary. A final scan after re-stringing is suggested for the history files. Again, this will result in an extremely precise fret plane, nut slots and a saddle height that yields the exact target action when re-strung.

Cleanup The frets, nut and saddle will only require a minimum of surface polishing, a matter of a few minutes, to complete the job. There is a simple suggested procedure for this.

Small production



PPPPLEKLEKLEKLEK P P P PRORORORO performance in small production (using templates) performance in small production (using templates) performance in small production (using templates) performance in small production (using templates)

Required preparatory work Required preparatory work Required preparatory work Required preparatory work For machine processing the instrument has to be strung up to pitch.

Machine processingMachine processingMachine processingMachine processing

Processing times (min:sec)

Loading a guitar 0:25

Load template 0:15

Pre-scan (Checking number of frets)

Automated measurement: neck width, spacings, action

3:30

Scan (instrument strung up)

TOTAL PREPARATION ANTOTAL PREPARATION ANTOTAL PREPARATION ANTOTAL PREPARATION AND SCANNINGD SCANNINGD SCANNINGD SCANNING 7:00 7:00 7:00 7:00 –––– 8:00 min. 8:00 min. 8:00 min. 8:00 min.

It takes less than 6 minutes to have a complete graphic and numerical evalution of the fretboard at your disposal: relief, scale length, fret positions, fret heights, nut, and saddle height.

Truss rod adjustment and rescan (optional)

2:00

Setting parameters (Virtual Fret Dress)

0:30

Loosening strings 1:30

Scan (without strings) 1:00

Fret cutting Processing times range from ~ 3:00 min. minimum to ~ 8:00 min. maximum.

4:30

TOTOTOTOTAL FRETBOARD WORKTAL FRETBOARD WORKTAL FRETBOARD WORKTAL FRETBOARD WORK 8:00 8:00 8:00 8:00 –––– 10:00 min. 10:00 min. 10:00 min. 10:00 min.

Optimal truss rod adjustment and fret dressing takes under 10 minutes.

Nut string slot cutting 1:30

Nut surface cutting 1:00

Cutting bridge saddle height 1:30

MAX. COMBINED NUT/SAMAX. COMBINED NUT/SAMAX. COMBINED NUT/SAMAX. COMBINED NUT/SADDLE WORKDDLE WORKDDLE WORKDDLE WORK 1:30 1:30 1:30 1:30 –––– 4:00 min. 4:00 min. 4:00 min. 4:00 min.

Restringing and tuning 1:30

Rescan 3:30

(1:20 w/out nut/saddle work)

Unloading guitar 0:15

RESCAN FOR QC (OPTIORESCAN FOR QC (OPTIORESCAN FOR QC (OPTIORESCAN FOR QC (OPTIONAL)NAL)NAL)NAL) 3:00 3:00 3:00 3:00 –––– 5:00 min. 5:00 min. 5:00 min. 5:00 min.

Cleanup

Strings are loosened for polishing the frets which takes 1 to 5 minutes if a PLEK recommended procedure is used.

Please note:Please note:Please note:Please note: the times given above are sample times for 6-string guitars. In general processing times depend on:

• number of strings / neck width • number and width of frets/ fret material (temper) • accuracy of fretting and neck work / required amount of fret removal • evenness of truss rod operation • size of nut and saddle blanks / required amount of removal • operator's skills

Accuracy mm inches

Sensor Finger Sensor Finger Sensor Finger Sensor Finger Magnetic transmission linear encoder Resolution: 0.001 mm (0.00004'')

+/- 0.005

+/- 0.0002

Fret cutter Fret cutter Fret cutter Fret cutter +/- 0.01 +/- 0.0004

HFS (nut/saddle cutting)HFS (nut/saddle cutting)HFS (nut/saddle cutting)HFS (nut/saddle cutting) +/- 0.05 +/- 0.002

Small production



Requirements Requirements Requirements Requirements for using a P P P PLEKLEKLEKLEK P P P PRO RO RO RO in a small production small production small production small production environment (without STS)

SpaceSpaceSpaceSpace for serviceserviceserviceservice machinemachinemachinemachine (width/depth inc. operator space/height):

158 cm x 180 cm x 230 cm 62.21" x 70.87" x 90.6"

Lifting deviceLifting deviceLifting deviceLifting device (fork lift, crane, etc.) for moving shipping crate (600 – 950 kg).

PowerPowerPowerPower AC 110-220 V, fuse 15 A

Compressed airCompressed airCompressed airCompressed air 0.6 – 0.8 MPa / 85 – 116 PSI tank capacity unimportant

If you wish to protect the PLEK Pro machine in the event of a power failure we recommendwe recommendwe recommendwe recommend to use a UPS (uninteuninteuninteuninterrrrruptable poweruptable poweruptable poweruptable power supplyr supplyr supplyr supply) with a power of approx. 1000 W.

Phone linePhone linePhone linePhone line and internet accessinternet accessinternet accessinternet access (DSL) is required for online support / maintenance via remote computer.

The ethernet connection (internet access) of the PLEK Station machine is not set up for wireless access points. For operational safety reasons and for a smooth online remote PLEK support wireless is not an option.

ManpowerManpowerManpowerManpower

Any person with a basic knowledge of MS Windows and guitars. An operator can be trained in 2-3 days.

Small production



PPPPLEK LEK LEK LEK PPPPRORORORO/STS/STS/STS/STS inininin massmassmassmass productiproductiproductiproductionononon

The PLEK PRO machine is supplemented in mass production with a STSSTSSTSSTS (= SSSString TTTTension SSSSimulation) that is capable of simulating the tension of guitar and bass strings, so that the guitar and bass necks can be processed without strings.

With the aid of headstock and body adapters the instrument is placed into the STS adapter cradle. With a computer controlled pneumatic procedure a defined string tension is produced for each individual neck. The truss rod respectively the guitar neck reacts as if they were strung up. An interesting advantage of using the STS is the possibility to process just the necks, that means the body of the instrument is not required.

STS internal typeSTS internal typeSTS internal typeSTS internal type The internal STS is controlled by the software of the PLEK PRO machine and is inserted into the machine in place of the service door. Depending on the chosen guitar / bass model all the relevant process parameters are loaded with a preassigned template, including the required STS air pressure.

STS external typeSTS external typeSTS external typeSTS external type The external STS is a stand-alone device with an independent numerical control unit. With it the desired neck relief can be obtained by adjusting the truss rod under simulated string tension prior to processing. When working simultaneously with the internal and external STS production-time is optimized.

A typical operation sequence with the PLEK PRO/STS

The operator fixes the adapters on the instrument, inserts it into the external STS and activates the string tension simulation via the touchpad. The truss rod is adjusted until the “dial indicator neck relief gauge” shows the desired result. This procedure takes about one minute.

The pre-adjusted guitar is taken out of the external STS and placed into the internal STS. If the saddle is to be cut as well, it should be fixed into a special vice located in the machine. The appropriate template is selected, the parameters in the "Virtual Fret Dress" menu are set and processing starts. Under simulated string tension the frets are cut including all other process functions (nut or saddle cutting, etc.) that have been selected in the template.

While the machine is processing, pre-adjustment and finishing work can be carried out, such as:

- Taking off the adapters of the processed guitar. - Polishing the frets of the processed guitar. - Fixing adapters to the next guitar to be processed and adjusting the neck relief with the truss rod using the external STS.

Mass production/STS



PPPPLEKLEKLEKLEK P P P PRORORORO/STS/STS/STS/STS performance in (mass) production performance in (mass) production performance in (mass) production performance in (mass) production

Required preparatory workRequired preparatory workRequired preparatory workRequired preparatory work

The STS adapters have to be fixed to the instrument (without strings) and the neck relief must have been pre-adjusted in the external STS. The time needed for this preparatory work has no impact on the overall processing time since another instrument is being processed by the PLEK PRO simultaneously.

Machine processingMachine processingMachine processingMachine processing

Processing times (min:sec)

Loading a guitar 0:05

Load template 0:05

Pre-scan (Checking number of frets)

Automated measurement: neck width 1:45

Scan (without strings)

Setting parameters (Virtual Fret Dress)

0:30

Fret cutting Processing times range from ~ 3:00 min. minimum to ~ 8:00 min. maximum.

4:30

PREPARATIONS, SCANNIPREPARATIONS, SCANNIPREPARATIONS, SCANNIPREPARATIONS, SCANNING, FRET CUTTINGNG, FRET CUTTINGNG, FRET CUTTINGNG, FRET CUTTING 7:00 7:00 7:00 7:00 –––– 10:00 min. 10:00 min. 10:00 min. 10:00 min.

A complete evaluation of the instrument and fret dressing can be done in less than 10 minutes.

Nut string slot cutting 1:30

Nut surface cutting 1:00

Cutting bridge saddle height 1:30

MAX. COMBINED NUT/SAMAX. COMBINED NUT/SAMAX. COMBINED NUT/SAMAX. COMBINED NUT/SADDLE WORKDDLE WORKDDLE WORKDDLE WORK 1:30 1:30 1:30 1:30 –––– 4:00 min. 4:00 min. 4:00 min. 4:00 min.

Rescan e.g. for every 10

th instrument

-> 6 seconds average per instrument

0:06

Unloading guitar 0:05

RESCAN FOR QC (OPTIORESCAN FOR QC (OPTIORESCAN FOR QC (OPTIORESCAN FOR QC (OPTIONAL)NAL)NAL)NAL) ~ 0:10~ 0:10~ 0:10~ 0:10 min. min. min. min.

CleanupCleanupCleanupCleanup

STS adapters are taken off and the frets are polished. This takes about 1 to 5 minutes if a PLEK recommended procedure is used. Finally the instrument is strung up to pitch. These activities are also carried out when another instrument is being processed at the same time. Hence the overall processing time per instrument is not prolonged.

Please note:Please note:Please note:Please note: the times given above are sample times for 6-string guitars. In general processing times depend on:

• number of strings / neck width • number and width of frets/ fret material (temper) • accuracy of fretting and neck work / required amount of fret removal • evenness of truss rod operation • size of nut and saddle blanks / required amount of removal • operator's skills

Furthermore we assume that an internal and external STS are used simultaneously thus making parallel working possible.

Accuracy mm inches

Sensor Finger Sensor Finger Sensor Finger Sensor Finger Magnetic transmission linear encoder Resolution: 0.001 mm (0.00004'')

+/- 0.005

+/- 0.0002

Fret cut Fret cut Fret cut Fret cutterterterter +/- 0.01 +/- 0.0004

HFS (nut/saddle cutting)HFS (nut/saddle cutting)HFS (nut/saddle cutting)HFS (nut/saddle cutting) +/- 0.05 +/- 0.002

Mass production/STS



Requirements Requirements Requirements Requirements for using a P P P PLEKLEKLEKLEK P P P PRORORORO/STS/STS/STS/STS in a (mass) production (mass) production (mass) production (mass) production environment

SpaceSpaceSpaceSpace for machinemachinemachinemachine (width/depth incl. operator space/height):

158 cm x 180 cm x 230 cm 62.21" x 70.87" x 90.6"

Extra space for external STSexternal STSexternal STSexternal STS (width/depth/height):

60 cm x 51 cm x 180 cm 23.6" x 20.1" x 70.9"

Lifting deviceLifting deviceLifting deviceLifting device (fork lift, crane, etc.) for moving shipping crate (600 – 950 kg).

PowerPowerPowerPower AC 110-220 V, fuse 15 A

Compressed airCompressed airCompressed airCompressed air 0.6 – 0.8 MPa / 85 – 116 PSI tank capacity unimportant

If you wish to protect the PLEK Pro machine in the event of a power failure we recommendwe recommendwe recommendwe recommend to use a UPS (uninteuninteuninteuninterrrrruptable power supplyruptable power supplyruptable power supplyruptable power supply) with a power of approx. 1000 W.

Phone linePhone linePhone linePhone line and internet accessinternet accessinternet accessinternet access (DSL) is required for online support / maintenance via remote computer.

The ethernet connection (internet access) of the PLEK Station machine is not set up for wireless access points. For operational safety reasons and for a smooth online remote PLEK support wireless is not an option.

ManpowerManpowerManpowerManpower

Any person with a basic knowledge of MS Windows and guitars. An operator can be trained in 2-3 days.

Mass production/STS

A+D Gitarrentechnologie GmbHD-10967 Berlin, Hasenheide 54 • Tel. +49 30 53 69 63 39 • [email protected] • www.plek.com

= Service= Manufacturing

Plek is a registered trademark | All rights reserved | © 2011 A+D Gitarrentechnologie GmbH

EuropeGUITAR SERVICE & REPAIR

GUITAR MANUFACTURING

GUITAR SERVICE & REPAIR


16 Charlie Chandler’s Guitar Experience, London/UK17 Chandler Guitars, London/UK18 Haar Guitars, Utrecht/Netherlands19 PlekHaus Berlin | A+D Gitarrentechnologie GmbH, Berlin/Germany20212223

12 Duesenberg, Hannover/Germany13 Warwick | Framus, Markneukirchen/Germany

24 Sleek Elite, Tokyo/Japan25 Sydney Guitar Setups, Sydney/Australia

14 Takamine, Gifu/Japan15 Stranough Voicemate, Surabaya/Indonesia

Asia / Australia

Paris/France (not public)CLOE, Roma/ItalyGulden Guitars, Oslo/NorwayGuitarlabs Scandinavia, Stockholm/Sweden

North AmericaGUITAR SERVICE & REPAIR


1 Mike Lull Custom Guitars, Seattle/WA2 Marz Guitars, Roseville/CA3 Brawer Stringed Instrument Repair, San Francisco/CA4 Westwood Music, Los Angeles/CA5 J. Mahoney, Minneapolis/MI6 Norman Music, Norman/OH7 Music Gallery, Chicago/IL8 Glaser Instruments | Plek USA, Nashville/TN9 Weber Custom Guitars, Granville/OH10 Dan Erlewine, Athens/OH11 Sam Ash, Huntington Station/NY12 Peekamoose, New York/NY13 Philtone, Baltimore/MD14 Crossroads Guitar Shop, Washington DC15 Wolfe Guitars, Jupiter/FL

1 G&L Guitars, Fullerton/CA2 Suhr Guitars, Lake Elsinore/CA3 McPherson Guitars, Sparta/WI4 Lakland, Chicago/IL5 Heritage Guitars, Kalamazoo/MI6 Wechter Guitars, Fort Wayne/IN7 Gibson Custom Shop, Memphis/TN8 Gibson Custom Shop, Nashville/TN9 Gibson USA, Nashville/TN10 Martin Guitars, Nazareth/PA11 Martin Guitars, Navojoa/Mexico

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the optimum in tone & playability

Documents

ng frets and more omputer controlled high tech guitar tool ... · omputer controlled high tech guitar tool for dressi ng ... This is a major breakthrough since the P LEK P RO identifies