• Product and volume flexibility for agile production systems
Eislingen – The entry of the thermal coating of cylinder bores into volume production can no longer be halted and plants and processes suitable for series are offered by the collaborative partners MAG and STURM. This broadens the work sequences in the production plants by a further process building block which must also be flexibly integrateable in the process chain according to the customer specification. Nothing has changed on the previous tasks for these modern production systems: capability for "2 + 1 strategy" (2 types of workpieces in parallel operation on the plant and allowance of the tool capacity for a further workpiece type) as well as the reconfigurability of the plant after the product phase out of the workpieces for which the plant was originally designed.
The coating process especially may initiate a change in thinking in the procurement strategy. This is installed at the beginning of the process chain in the production plant in most cases but some manufacturers also do this in the later fine machining area. Thus it could be quite possible that a new product is going to change the order still used today and will have to deal with a well-designed production line.
The SPECHT® range is known for its use in series production where durability, precision and productivity are required at the highest level.
The product range is already distinguished from the competition machines with its axle arrangement thus supplying the significant advantage for robustness and manufacturing quality. The integration of the engine spindle in the X and Y axes as well as its connection to a frame stand offers a maximum rigidity of the machine structure in all machining positions compared with mobile stand variants. For the production of automotive components such as cylinder blocks and cylinder heads, long bore rods are required for the crank shaft and camshaft bores as well as long bore tools for the oil duct machining. A workpiece method enables the required Z stroke.
Contrary to the Z axis position with the spindle as quill or protruding slide, with SPECHT® , the spindle remains in the position of maximum stiffness. This "jig boring principle" is the concept for success for the highest machining quality with universal application in all processes.
With the introduction of the adapter plate, a support plate for the customer workpiece with a uniform interface to the devices on the machines and standardized pick up sites for the automation, MAG has developed an ultimate workpiece flexibility for agile manufacturing systems which is now used as a standard solution. The adapter plate also takes over the function of cells between a transport pallet. With an integrated data storage medium, information is available to the workpiece type and all production data at each position of the system.
With the integration of the honing technology in the SPECHT® series, an adjusting spindle with electromechanical pull rods is used with which, by means of cutting compensation, the highest precision can be achieved with many other adjustable tools through the defined control in addition to honing. MAG provides here a full value alternative to conventional honing machines with in-process measurement of workpiece geometry.
Options for the honing machines: Linear drives, measurement during the machining, software for the generation of the measurement-controlled machining process and the adjusting spindle for workpiece cutting control.
Agile production systems by MAG are based on the parallel process and enable volume flexibility through the further integration of capacity machines in the respective operation. The process flexibility is also guaranteed through the design of the SPECHT machinery. If the customer decides on the use of 5-axis machines, he has a workpiece flexibility available for any possible future workpiece type. The parallel process, in particular, is a guarantee for the high availability and thus a prime asset utilization.
Dr. Manfred Berger
MAG IAS GmbH
Salacher Straße 93
Tel: +49 7161 805-4900
Fax: +49 7161 805-2630
MAG is one of the leading suppliers of customized production and technology solutions with locations in Germany, the USA, China, India, Hungary, Great Britain and Switzerland. The Group combines traditional brands from the international machine tool industry such as Boehringer, Cross Hüller, Ex-Cell-O and Lamb. Since 2005, a global production specialist has developed with one-of-a-kind knowhow and an outstanding technology basis. The Group offers tailor-made solutions for the automotive and utility vehicle industry and their suppliers.
MAG supplies machine tools, manufacturing systems and services including turning, milling, honing, systems integration, automation, software, maintenance and repair, retrofitting. e-learning as well as core components for machine tools. As an industrial supplier, MAG offers complete solutions including machining technology, process capability, system configuration and full turnkey systems. The broad understanding of technical production problems and a close partnership contribute to the sustainable reduction of production costs in the target industries.