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Company
I N F O R M AT I O N F R O M T H E C O M PA N Y Edition II . November 2005 Company To all customers, persons interested, shareholders, employees and friends of company Company 1 To all customers, persons interested, shareholders, employees and friends of company Products 2-4 C 20 UP – the production set RS – Perfect automation Users 5-7 Hermle machines tested in practice Group 8 Founded a new international subsidiary Dynamic Collision Monitoring (DCM) Dates 1 Euromold Frankfurt 30. November 02. December 2005 hall 8.0 - stand K 152 NORTEC Hamburg 25.-28. January 2006 hall A1 - stand A1.302 METAPRO Brussels / Belgium 15.-18. February 2006 TechniShow Utrecht / Netherlands 14.-18. March 2006 hall 12 - stand A010 METAV Munich 04.-07. April 2006 House-exhibition Gosheim 26.-29. April 2006 Die and Mold Shanghai / China 08.-12. May 2006 Metallobrabotka Moscow / Russia 23.-27. May 2006 METAV Düsseldorf 20.-24. June 2006 For more participations in trade fairs by Hermle, please go to www.hermle.de We look forward to seeing you! Ideas instead of lamenting – that’s what makes an organisation successful? It seems that lamenting is currently the most popular virtue in Germany. But lamenting only creates a negative view of everything and everybody, and certainly does not create any new ideas. Especially in times, in which organisations taking on the function of a role model are needed – and this not only with regard to record sales, but also with regard to added value and orientation towards returns – it is critical to show people that successful ideas and concepts can indeed be realized in Germany. However, concepts and ideas cannot simply be copied from one organisation to the next, and may also not simply be generically prescribed to organisations by third parties (politics, organisations, unions, which already interfere with the concerns of companies way too much). Not only must they be carried by all involved – management, owners, employees, works council, even by customers and suppliers, but most importantly, they must also be understood. Communication between persons involved must be fair and open, however the organisation will always come first, and inevitably this also includes the jobs. Continuous process optimising in all areas is required. To achieve this individual areas must be closely related, and harmonise with each other. Opportunities for quick decisions are necessary, not to forget the human factor. Unfortunately, the capital that is represented by service oriented and motivated employees is often not properly recognised by organisations. Employees who identify themselves with their organisation, are sick less often, work more efficiently, are more career oriented, and contribute their own ideas and concepts to the organisations in the form of improvement suggestions (for an internal employee suggestion system); it is “their organisation.” This results in new ideas and concepts that can often be expressed for the organisation in hard cash. An additional factor which should not be underestimated are well trained employees who were already integrated into the organisation structures as apprentices and who are continuously qualifying themselves in further education programmes. The individual working time models that are demanded everywhere, and often already implemented years ago, must match the organisation, and also be realistic. It makes little sense to force a working time concept of a large corporation onto a small business. Employer/works council agreements must guarantee the desired degree of flexibility between management and employees. In this regard the key concern is “what matches our organisation.” A balanced manufacturing depth custom-tailored to the respective organisation, the fair treatment of suppliers, and the outside representation are all issues of a positive company philosophy. With regard to the products, we may not rest on our laurels, but instead must consistently expand our technical competitive edge over others, and re-live our German virtue of “let’s roll up our sleeves, and get to work.” We must strive forward using the notion of “we”, and not the “I”. A little annotation on the side: Manager bashing certainly won’t get us far, either, on the contrary, it separates us all the more. Those who do not agree should take a look at abroad – after all, that’s where most of Germany’s customers are – we are, after all, world champions in exporting. What I wish to see are new concepts and ideas for us all, not only coming from organisations, but also from all involved in the work process, in order to continue to keep Germany competitive. Sincerely, Dietmar Hermle Management board spokesman The compact production system C 20 UP ADVANTAGES OF A UNIQUE MACHINE CONCEPT LARGEST WORKING AREA RELATIVE TO THE INSTALLATION SURFACE UNIQUE AXIS CONCEPT SHORT CHIP-TO-CHIP TIMES ON ACCOUNT OF INTEGRATED TOOL MAGAZINE COMPLETE TRANSPORT AND FOUNDATION-FREE ERECTION CONSISTENT MODULAR DESIGN FROM THE STANDARD MACHINE TO THE FLEXIBLE MACHINING CENTRE 2 The highly productive machining centre C 20 UP with pallet changer PW 160 with pallet storage, ICS plant and additional tool magazine ZM 43. The pallet changer with pallet storage can hold up to seven pallets at a space required of only 4.5 m2. Management software is fully integrated into the machine control. The accessibility to the working area for manual workingsteps, such as set-up or placing of individual parts, is retained completely. The manually moveable roof top element for crane loading and the discharge chute with drawer for chips and cooling lubricant are but only smart details. F Feed force F Reaction Working area Traverse X-Y-Z: 600-450-450 mm Rapid linear traverse X-Y-Z : F Reaction Linear acceleration X-Y-Z : 45 m/min. 6 m/s2 Main spindle drive F Milling force Speed: 10000, 16000 or 40000 rpm. Torque: up to 200 Nm Main power: up to 32 kW Tool changer (pick-up) Magazine pokets: Chip-to-chip time*: 30 approx. 4,5 s Control Heidenhain: Siemens: Ideal power transmission through three staggered guideways with central drive iTNC530 S 840 D * (chip-to-chip times were determined in accordance with VDI 2852, sheet 1 in a 3-axis design) Products PALLET CHANGING SYSTEM PW 160 PALLET STORAGE SYSTEMS HERMLE PALLET CLAMPING SYSTEM CUSTOMISED PALLET VERSIONS RETRACTABLE ROOF TOP SECTION FOR CRANE LOADING FEED CHUTE WITH DRAWER Pallet changer PW 160 Pallet dimensions: 320 x 320 / Ø 400 mm 400 x 400 / Ø 500 mm Number of pallets with 4-fold storage: 7 pallets Transport weight per side (incl. pallet ): max.160 kg Repeating accuracy <0,01 mm 3 HIGH DEGREES OF FREEDOM IN THE WORKING AREA VERY HIGH TABLE LOAD (UP TO 300 KG AT HIGHEST PRECISION) NO CHIP COLLECTION ON THE TABLE (TABLE SWIVELLING) SWIVELLING AXIS A AND ROTARY AXIS C ARE IN THE COMPONENT (U SHAPE) WIDE CHEEK SPACING RESULTS IN A VERY LARGE COLLISION CIRCLE NC-controlled swivelling rotary table Pallet dimensions: 320 x 320 / Ø 400 mm 400 x 400 / Ø 500 mm Swivel range: +/- 115° Speed - rotary axis A: 25 rpm. Speed - rotary axis C: 25 rpm. Maximum table load: 300 kg Pallet clamping system: 3-fold Products Perfect Automation Robot solutions for the C series Robot cell RS for the all-automatic loading and unloading of pallets and components For manufacturers, whose processing centres have a 7 days a week production run in multiple shifts, automation is becoming an issue of increasing importance. Parts handling is mainly performed via pallet exchangers, or external handling systems. For example, if the components are processed on the 6th side, or if any chamfering, grinding, washing, etc. is to be done, several process steps can be performed at the same time in just one setting. - All-automatic loading of pallets and/or parts means the system can be projected for flexible pallet handling, as well as for direct component handling - Can be extended to a flexible manufacturing cell, or to a flexible manufacturing system - Inexpensive transport and simple installation by means of “hook-ready” designs of the machine, and also of the robot cell - Can be used 7 days a week in multiple shifts - Integrated software for flexible order management - Further processing of the components on the 6th side and/or chamfering, grinding, washing, monitoring, inspecting, testing, etc. - Customer-individual gripper and/or double gripper solutions 4 - Set up location for loading and unloading also during the manufacturing process (parallel to core time frame) - Customer-individual component/pallet storage - Four transport weight classes 6, 16, 30, or 60 kg - High system competence by only one manufacturer The robot removes the component processed from 5 sides, and simultaneously inserts a new blank workpiece “double gripper effect” Demo robot cell for the 5-sided machining with subsequent processing on the 6th side(separating, grinding, camera monitoring, and shelf storage for various different components) HSC milling cutters are on the rise Users Hartmut Lorenz (Programming Manager), Daniel Eckel (Machinist/Operator), and Hans-Martin Sauerwein (Work Preparation and Resource Planning) in front of the C 30 U and the C 1200 V / C 1200 U HSC milling cutters are on the rise As if … cost-effective or more profit-oriented manufacturing was no longer possible in Germany! This is true especially for organisations dealing with more than one production process and manufacture the tools for the same, but also offer additional equipment. Dealing with development, project management, manufacture and service of tools for the production of diecast parts for the past 25 years, Heck + Becker GmbH & Co. KG at D-35232 Dautphetal is such a technology company. Founded in 1936 and employing 190 people today, the renowned specialist Heck + Becker is, of course, also in aggressive competition worldwide with regard to technology and economy. For this reason, the 130 technicians involved with the production are continuously provided with the latest production facilities. Heck + Becker puts particular emphasis on a modern machine outfit, thus continuously ensuring highest quality across the entire in-house production. The approximately 50 CNC machines in use include lathing, milling, eroding, and grinding machines, with 15 of them being classified as HSC systems. Since the year 2000, this also includes 4 (3 + 1) processing centres of the Type C 1200 V and U, with the aid of which large size and heavy inserts, sliders, frame components, as well as other large-scale parts made of tool steels and heat resistant steels (1.2343) with up to 50 HRC are manufactured, or processed completely. These components can be up to 1,200 x 700 mm in size. For the essentially complete processing in one setting, large milling heads are utilized as well as 1 mm small milling cutters or boring tools. All C 1200 machining centers, are equipped with high-performance spindles for speeds of up to 16,000 rpm., and with Heidenhain controls of the type TNC 430. According to Hartmut Lorenz, Programming Manager, and Hans-Martin Sauerwein, responsible for work preparation and resource planning at Heck + Beck, good results have been achieved with the machining centers by Hermle, especially with regard to processing accuracy, general technical availability, and the service for the machines used in 2 shifts. Consequentially, the company Berthold Hermle AG also received an inquiry when the acquisition of a quick, high-performance machining centre for the flexible manufacture of small parts and cores was considered. In this regard, Hans-Martin Sauerwein remarked as follows: “We have performed a strict selection process among the competitive products, and have always defined the same sample parts, working conditions, as well as parameters. By means of the absolutely same programs, infeeds, tools, spindle speeds, and finally measuring of the parts, we were able to determine a clear favourite in the end, which was the new, highly dynamic machining centre C 30 U by Hermle.” Hartmut Lorenz adds: “In contrast to some of the competitor products, the C 30 U is equally fast in all axes, provides multiple component and tool setting possibilities due to the special axis concept, and is characterised by high crash safety thanks to the forging core design in the spindle unit.” The machining centre C 30 U by Heck + Becker has an NC pivoting/round table with torque motor in the C-axis and with a diameter of 630 mm, which is capable of receiving components with a weight of up to 800 kg. The practical, large swivel range of +30° to -115° supports the 5-axis/5-sided complete machining on the basis of the flexible setting of standard/special tools. Hartmut Lorenz summarises: “We develop the NC programs externally, perform tool and processing simulation tests, and carry out only improvements on site. Together with the factory-installed equipment on the C 30 U for the measuring of the tools, for the control of broken dies, and a calliper, process-safe working into the night is possible, particularly since we have also made provisions with regard to coolant facility and chip disposal”. 5 3D component of a diecast tool with deep cavities, completely manufactured on a C 30 U Ideal setting of the tool and/or component for difficult processing situations www.heck-becker.com Users Manufacturing time reduced 5-axis manufacturing cell at MAN B&W consisting of a C 30 UP with pallet exchanger and 15-pallet storage 5-axis milling cutters reduces manufacturing time by 50% 6 Compressor wheels with diameters between 120 and 450 mm While the high-speed and 5-axis simultaneous processing has long been established in the areas of tool construction and mould making, as well as in single item production, there are still reservations with regard to series production. However, these have been proven unfounded, and actually only serve to hinder the utilisation of advanced manufacturing technology. However, those who can appreciate the 5-axis processing have a considerable edge as opposed to the competition, and are able to better stand their ground on the markets. This also applies to the company Augsburger MAN B&W Diesel AG, which as the worldwide leading manufacturer of large-scale diesel engines for sea vessels and power plants offers a broad spectrum of two- and four-stroke engines with ratings of up to 97 MW per engine. Additionally, the company is at the forefront for diesel power plants and turbochargers. Being part of the MAN group, the MAN B&W Diesel Group employs nearly 6,700 persons in Germany, Denmark, England, France, the Czech Republic, and China. In the plant Augsburg 2,200 persons are working on the development and manufacture of four-cycle diesel engines with ratings from 450 and up to 23,850 kW. 250 of these employees are part of the turbocharger area, which accommodates the manufacture of the mechanism, and therefore the complete processing of compressor wheels. As a Senior Vice President, Ralf Großhauser is responsible for this area, who is being supported, especially for the manufacture of the turbochargers, by Uwe Stecklum, Department Manager for Production and Logistics. Both agree that the latest production facilities must be utilised for the production of housings, small parts, and mechanisms. The only manner in which to further increase the turbochargers’ efficiency, and satisfying all economic concerns is the production of perfectly manufactured components. MAN B&W Diesel highly expects substantial ratio effects especially of the high-speed, or the 5-axis simultaneous processing, which is why a 5-axis highperformance machining centre of the type C 30 UP was purchased in the spring of 2004. Ralf Großhauser says: “In this area we are mainly working in three shifts, or extend hours into Saturday afternoons, and begin work on Sunday evenings at 10 pm. The production of the mechanism plays a key role, which does not allow any production downtimes. It is therefore important to select the machines, and of course also the tools, very carefully. In particular, the machines must have a high technical availability and longterm accuracy”. And Uwe Stecklum added: “We have performed milling tests with different tendering parties, and obtained very different results. The Hermle machining centre C 30 UP with the 28,000 rpm. spindle and the pallet exchanging system was able to convince us from the beginning, and we also received very competent and practical support. Thanks to the pallet system we are able to automatically produce with minimal manpower, and utilise the system to a maximum in every aspect”. The high-performance machining centre C 30 UP for the 5-axis complete processing of compressor wheels was equipped with a pallet storage system in addition to the pallet exchanger, which Ralf Großhauser justifies as follows: “The enormous performances of the machining centre C 30 UP lead to a very high rationalisation effect with the actual chip removal. This has caused the component dwell times, or the component changeover cycles, respectively, to become substantially shorter as opposed to before. In order to be able to convert this system into an operation with minimum manpower, a certain operation queue must be provided for”. According to Uwe Stecklum, the main focus in this regard is not on efficiency, but instead on reproducible accuracy. “With the highest of processing quality we concentrate even more on performance, and thanks to the C 30 UP we see ourselves in the position of fully meeting all quality and productivity requirements. The performance of the C 30 UP lead to a reduction of the compressor wheel processing times by 50% based on the 5-axis processing on an older machining centre”. www.manbw.com Complete processing Users The machine operator takes on the project settlement beginning with CNC programming to the production and to quality control Milled titan blades (Ti6Al4VGr5) 7 Sulzer Innotec 5-axis complete processing in production The company Sulzer Innotec at CH-Winterthur has a highly capable infrastructure and technological resources for the 5-axis/5-side/ 3D milling processing. Services offered range from the development, component modelling, and CNC programming to the single item and series production on processing centres of the type C 800 U. Sulzer Innotec does not manufacture their own products, but fully concentrates instead on the development and manufacture as integrated or combinable and compatible service(s). In detail, this may be pure milling processing services, complete manufacturing orders, including CNC programming, or even complicated technology development orders. The latter are often based on feasibility studies, and end, for example, with the implementation of the milling technology, as well as the support of the same in the customers’ plants, who wish to produce the parts themselves at a later time. The “make or buy” decision can be made by each customer on the basis of his/her own cost structure and product/manufacturing strategy, as well as based on expanded possibilities and higher efficiency in cooperation with Sulzer Innotec. Many of the requirements in practice are covered in the area of the universal 5axis complete processing on the high-performance model C 800 U processing centres. Due to the variable axis position of the component to the milling spindle, the 5-axis milling technology “by Hermle” accommodates the economic complete processing in one or few settings. Furthermore, the 5-axis machining centers cover boring processes, 2-, 3-, Simultaneous fivefold-milling of a inversely constructed impeller and 4-axis milling processes, 4- and 5-axis simultaneous milling processes, as well as the milling of rounded contours. The fact that the obtainable accuracies and surface qualities are very high, as well as reproducible, is made clear in the complex practical example of “Milling processing of complex components, such as turbine blades made of hard to machine titan material in one setting”. The turbine blades are equipped with a clamping base that is removed after milling. The processing is done in the form of 5-axis simultaneous milling of the turbine blade and 5-axis multiple side milling of the actuator axis. The Move in program, tests are performed in three blade channels angular, as well as positional accuracy of the drive shaft to the free form surfaces is ensured by means of precise milling in one setting. In changing clamping settings on the other hand, this could be ensured only at an extremely high effort due to the difficult free form surface referencing. However, production times may also be positively influenced with the 5-axis milling cutters. By way of optimised accessibility to the component interior surfaces, and the nearly free blade angle of the milling tool for critical processing, the production times can be reduced significantly, the tool life of the tools can be notice- Plunge milling as a roughing process with long tools ably increased, and the surface quality can be drastically improved. However, according to Sulzer Innotec the 5-axis milling not only offers the potential of optimising the quality and reducing costs, but is often also the only economic possibility for manufacturing complex components, prototypes, or small series with high demands made of stability, geometrical accuracy, general accuracy, and surface. www.sulzerinnotec.com Group H l W ld ide In order to reinforce our engagement in upcoming markets, we have founded an additional subsidiary, namely Hermle World Wide Export AG, in short: WWE AG, at Baar in the canton of Zug in Switzerland. The goal of this subsidiary will be the export of Hermle Products to the CIS (Commonwealth of Independent States) in a first step. Additional markets may also be targeted by WWE AG. Hermle + Partner Vertriebs GmbH Oymühlenstraße 29a - D-87466 Oy-Mittelberg Phone +49 (0)8366 988007 Fax +49 (0)8366 987129 e-mail [email protected] Internet www.hermle-partner-vertrieb.de Hermle-Leibinger Systemtechnik GmbH Daimlerstraße 14 - D-78532 Tuttlingen Phone +49 (0)7461 96628-0 Fax +49 (0)7461 96628-398 e-mail [email protected] Hermle WWE AG Managing Director Heinz Bischof Zuger Strasse 72 CH-6340 Baar (ZG) Phone +41 (0)41 768 51-51 Fax +41 (0)41 768 51-50 e-mail [email protected] Hermle (Schweiz) AG Rheingoldstrasse 50 – CH-8212 Neuhausen Phone +41 (0)52 67400-40 Fax +41 (0)52 67400-41 e-mail [email protected] Internet www.hermle-schweiz.ch Hermle Nederland B.V. Molièrelaan 176 – NL-5924 AN Venlo-Blerick Phone +31 (0)77 3961761 Fax +31 (0)77 4641070 e-mail [email protected] Internet www.hermle-nederland.nl Parallel to the above, another company, namely Hermle Vostock GmbH, or also known as Hermle East, was founded in Moscow. There, we will install a showroom soon, in order to work the CIS market even more intensely. Verkaufsbüro Belgien Martin Coun Meldertsestraat 55 – B-3545 Halen Phone +32 (0)13 5563-83 Fax +32 (0)13 5563-84 e-mail [email protected] Hermle Machine Co. LLC 5100 West Franklin Drive – Franklin, WI 53132, USA Phone +1 414 421-9770 Fax +1 414 421-9771 e-mail [email protected] Internet www.hermlemachine.com ALWA-HERMLE S.r.l. Via Papa Giovanni XXIII 9-b – I-20090 Rodano (MI) Phone +39 02 95327-241 Fax +39 02 95327-243 e-mail [email protected] Internet www.alwa.it Hermle Österreich Rudolf Fluch Sportplatzstraße 31/2 – A-8712 Proleb Phone +43 (0)3842 83377 Fax +43 (0)3842 82410 e-mail [email protected] 8 Dynamic Collision Monitoring (DCM) The advantages and necessity of such a monitoring function are obvious. Modern processing centres enable increasingly higher accelerations and travel speeds. At rapid traverses of, for example, 60 m/min, the axis travels by 1 m in one second! Even the technician with the quickest reaction is hardly able to prevent a potential collision by pushing the emergency stop button. Additionally, the axis movements during the manufacture of complex mould components that are processed with 5 axes, cannot be predicted. Although the NC programs necessary for this purpose are mostly generated in CAM systems, which avoid a collision of tool, or tool holding fixture and the component, the machine components located within the working area are usually not taken into consideration. Even with external machine simulation one can never be sure that the machine conditions (e.g. clamping position) will be exactly as were simulated. In a worst case scenario, a collision won’t be recognised until the part is being processed on the machine. In these cases the iTNC 530 dynamic collision monitoring will relieve the technician’s burden. In case of a potential collision, the control will interrupt processing, thereby creating increased safety for operator and machine. Machine damage and resulting costly downtimes can be avoided. Shifts with no manpower become safer. The key advantages of collision monitoring not only can be utilised well in the automatic operation of iTNC, i.e. during the execution of an NC program in the program execution full sequence operation. Monitoring is also possible in the manual operating modes: If, for example, the machine operator is located in the working area during the setup of a component on “collision course” with a module, this will be recognised by the iTNC 530, and the axis movement is stopped by means of a warning or error message. However, one collision must be permitted by DCM: The collision of the tool with the component! After all, a component needs to be processed. Alexander Schiestl Föhrenwald 35 – A-6105 Leutasch Phone +43 (0)5214 20272 Fax +43 (0)5214 20377 e-mail [email protected] v Hermle Ceská Republika Jaroslav Novácek Svermova 349 – CZ-39102 Sezimovo Ùstí Phone +420 (0)381 276278 Fax +420 (0)381 276221 e-mail [email protected] Martin Skukálek Podhájom 1365/164-73 SK-01841 Dubnica nad Váhom Phone +421 (0)424 441888 Fax +421 (0)424 441886 e-mail [email protected] Hermle China Shanghai Representative Office A 8158, Jiahua Business Centre 808 Hong Qiao Road, 200030 Shanghai, P.R. China Phone +86 21 6447 9495 Fax +86 21 6448 0223 e-mail [email protected] Beijing Representative Office 28# Beisan Huan Dong Road Chao Yan Distric 100013 Beijing, P.R. China Phone +86 10 64405196 Fax +86 10 64405216 e-mail [email protected] Hermle WWE AG Zuger Strasse 72 CH-6340 Baar (ZG) Phone +41 (0)41 768 51-51 Fax +41 (0)41 768 51-50 e-mail [email protected] iTNC 530 now also processes DXF data DXF data created on a CAD system can now be opened directly on the iTNC in order to extract contours with the click of a mouse, and store them as plain language dialog programs. The DXF format is widely known and is supported by all popular CAD and graphics programs. This applies in particular to the DXF format R12 (also known as AC1009). This is reason enough for HEIDENHAIN to support just this format. After the DXF file has been read into the iTNC via the network or the USB stick, you may open the file like an NC program by way of the file administration. The iTNC takes into consideration, from which operating mode you have started the DXF converter. DXF files usually contain several so-called layers (levels), with which the designing engineer may structure and organise his drawing. With the aid of layering technology, the designing engineer arranges diverse elements, such as the actual component contour, dimensioning, guide and design lines, hatchings and texts. In order to have as little redundant information on the monitor as possible with the selection of the contour, you can suppress any redundant layers contained in the DXF file with a click of the mouse. For this you will need the control panel with touch pad, or an external pointing device. A special feature with the contour selection at a later point: The iTNC can select a contour outline even if the designing engineer has saved the same on different layers. It becomes especially comfortable where the definitions of the component reference point is concerned. The drawing zero point of the DXF file is not always located in such a manner that you may use it directly as a component reference point, especially if the drawing contains several elevations. The iTNC therefore provides a function with which you can shift the drawing zero point to a useful location by simply clicking on an element. www.heidenhain.de IMPRINT Published by: Maschinenfabrik Berthold Hermle AG Industriestraße 8-12 – D-78559 Gosheim Editorial work, concept and layout: Udo Hipp Phone +49 (0)7426 95-0 Fax +49 (0)7426 95-6110 e-mail [email protected] Internet www.hermle.de Photos Inspirations Ganter, Heidenhain, Hermle AG Printed Druckerei Fecker – Albstadt-Ebingen This information is not binding. We thank the editors and publishers for permission to use published technical papers and user reports.