Machining to Win

With all three drivers currently in the top ten slots of the NASCAR Nextel Race to the Chase, and recently securing 2nd, 3rd and 4th place finishes at Infineon Raceway in Sonoma, California, Richard Childress Racing is the driving force not only behind great drivers, but great engines that make a difference every weekend on the track. So don't forget to thank the boys back in the shop and your sponsors…in this case, Okuma America Corporation.

Although on race days it's all about the teams, sponsors and drivers, many forget that behind the scenes is where a lot of action takes place. Okuma Corporation, a sponsor of RCR since 2001, is the "Official Machine Tool" for RCR. Okuma, a leader in machine tools for over 108 years, is the partner and supplier of CNC lathes, machining centers and grinders that are manufacturing over 300 unique engine parts for the 500 engines RCR will produce this year.

"We supply a majority of the components to the engine shop," said RCR Manufacturing Manager Rick Grimes. "Every cylinder head that goes through this building, every water pump pulley, alternator/crank pulley, alternator bracket, the motor plate, and lifter - are all either manufactured or configured (in the case of a cylinder head) on Okuma machines at our facility."

You'll find the Okuma logo on the left back tail light of the RCR Cup cars, and on the C post of its Busch cars. You'll also find a multitude of Okuma Computer Numeric Control (CNC) machines at the on-site Okuma Technology Center that meet the growing needs and responsibilities of the RCR cars and partnerships - including engine building collaborations with Dale Earnhardt Incorporated (DEI).

"We couldn't be where we are today in this industry without Okuma equipment," continues Grimes. "It's a partnership that goes both ways: Okuma supplies the equipment, the application engineering support, and the technical support that we need, and we help them grow the Motorsports side of their business."

When this partnership began in 2001, RCR recognized the need to control their cam shaft destiny. Interestingly, it was RCR that introduced COMP Cams, the leading camshaft manufacturing for high performance racing components, to Okuma shortly after the partnership began. And it was COMP Cams that was instrumental in helping to develop the next generation CAM Grinder (GC-34NH) and continues to use Okuma lathes and grinders on their shop floor every day. When RCR spoke with Comp Cams, the choice for product was simple…use the best! RCR became the first NASCAR team to own a dedicated cam grinder. Not only can they turn out a camshaft from cam core to finished product and test within four hours, but finished cams off the grinder are put directly into the Cup, Busch and Truck Series engines that have produced more than 60 victories since 2001.

With the release of The Intelligent Numerical Control (THINC), Okuma has taken technology to the next level and beyond with plug and play capabilities and an infinite number of possible programming solutions. Add more than 30 partners from Partners in THINC, from Renishaw and Marposs to Sandvik and Zeiss, and you have a one-stop facility for securing multiple solutions - all from one physical location in Charlotte, North Carolina.

With the THINC-OSP control at the center of all solutions, RCR is considering a variety of options including a completely paperless process utilizing the ToolBoss and Zoller Tool Management System, automating the facility with ABB or FANUC robotics, and/or incorporating Midaco pallet changers and balluff chip IDs. "The things that I see down there [at the Partners in THINC facility] can benefit us at RCR," said Grimes. "The technology of the THINC control is limitless now with the PC-based control. We need this technology to keep us at the top of our game."

There's no better example than the spring race at Richmond International Raceway in 2003. The difference between 1st and 36th place on the starting grid was 0.387 seconds. "That's why that operation is here - to gain that 1/10th of a second. It's all about the performance on the race track. If we don't continue to improve, we can't improve on the race track."

According to Grimes, the new Okuma machines with the THINC control will allow them to adapt to changing technologies faster and more efficiently. "We need to have equipment to handle what we can do with the Car of Tomorrow. By having all of this equipment in house, it allows us to do more things internally - and confidentially - in order to give us a more competitive edge on the race track."

Technology is at the heart of the RCR and Okuma Partnership, and Grimes considers Okuma number one in the machine tool industry. "They are the forerunner in the market of machine tools and continue to improve with their new PC-based control (THINC). Everyone was in shock and awe at IMTS 2004 when both the cylinder head manufacturing process and the THINC control was revealed. Okuma keeps us current in technology to help us implement new methods of machining that will allow us to make parts we've never been able to make before."

"RCR continues to need to keep that confidentiality and to have the competitive edge…that's why Okuma is here. We have to have the competitive edge to win races, to win championships to take care of our sponsors and to keep our drivers happy. When they win, we eat!"

RCR is on the fast track to upgrading its shop in order to win more races, not only through their partnership with Okuma, but now with Partners in THINC. "The value of Partners in THINC is that it's a one-stop store now….not only a store, but where you can actually touch, feel, smell, and look at end results," said Grimes. "You can give them your parts and drawings and say ‘make this for me - show me how it's going to work on my stuff.' As a result, we saw our water pump pulley being made on the Multus with an ABB robot. The LNS barfeeder was running our caliper mount studs. That's pretty impressive to see your parts being made when you walk through someone else's doors."

As a result, some of what RCR has seen at Partners in THINC may change its strategies regarding technology in the future. The partnership with Okuma will continue in order to keep up with the multiple engines and teams they provide for each week. It will also help keep its drivers' dreams alive for the NASCAR NEXTEL Cup Race to the Chase and the ultimate prize of winning a championship.

"For us to be number one in this industry, we have to have the support from the number one people around the world. Our partnership and possibilities with Okuma are second to none."