Heller company uses brand-new plan to satisfy the auto industry requirement to the more flexible system that be like labour. Brand-new " system of ModuleLineSystem (linear module) " inside includes automation job technological process considered taller productivity. Want you to share double leg only enough leave to sit on the floor with respect to can firm quietly -- such figure ground explained the general manager of Heller company, Manfred Maier flexible treatment system " MLS(ModuleLineSystem) " this one brand-new the jumping-off place of plan, this system is used at machining the cubic spare parts among engine and gear-box. A leg represented a car to make the client of the industry, that is to say, these OEM companies and one class supplier abandoned multitask automatic machine bed, chose so called mixture solution since 90 time; Another leg represented the market of general purpose machine tool in independent machine tool. With machining center (modular system) for the foundation, heller company is located in above successfully surely two domains, but avoid the interior that draws on more and more complaining that bring about to grow increasingly packs charge. "The client is in technology square and the requirement always is varied, " Maier says, "On one hand, they ask cutting unit can be used highly, want to provide very good automation performance for batch production, achieve inferior sheet thereby the purpose of cost; On the other hand, they ask to own the cutting tool library with huge amount, want to offer good preparative job for batch production, its size range of pipe bent wants to be able to enclothe all sorts of component completely. Henceforth, the application that we want to be these two respects hammer and tongs offers the solution that did not complain. " the jumping-off place of MLS system originates the frame condition that auto industry changes ceaselessly, more and more the innovatory cycle of the class, product range that expands ceaselessly, greater and greater cost pressure. The program field of vision of automobile industry is less and less, the security of the program is lower. The equipment that how can you let plan today is 8 can be manufacturing requirement still satisfied after coming 10 years? How can you make investment safety the biggest change? "Adjustability " it is panacea the cubic spare parts in using many special machine tool to machine engine and gear-box commonly, such ability are amounted to so far inferior sheet cost. However, because the work number of original plan changes ceaselessly, the yield of equipment became an issue. Because of the geometrical appearance of the spare parts, the side effect that workpiece machines the change of flow and causes is more and more apparent also. Manufacturing process often is disturbed, worst circumstance falls to need to add a product line newly even, existing perhaps product line cannot continue to use at all. "On the machine that who is willing to cannot be used in one caboodle to continue to work? Even if mixture solution of before a few years, build on automation line equipment, although this rebukes equipment had undertaken as far as possible optimizing according to the demand of auto industry, but also cannot solve the problem in the future well. Accordingly, we decide to develop a kind of brand-new plan to mix the user in manufacturing efficiency flexible the requirement that changes two aspects is uniform rise. " Maior says. Graph the extreme that 1 consecutive stock sheds, rely on new-style automation system, workpiece and cutting tool are machining module automation system to decorate in the center of in MLS system, make its core part (graph 1) ; Workpiece and cutting tool are decorated machining module both sides. Can carry freely. The control system of MLS system (graph 2) can be judged automatically, carry work well and truly to this machine tool. Compositive the flowing labour that the workpiece library in MLS system mixes is carried can ensure all the time every machine tool (although this machine tool is returned,processing work) already all had made the preparation that receives next work. As a result of machine tool and automation system each other depart, machine module to be able to offer the time of makings to choose successive job certainly by oneself with this. Systematic solid some is flexible this one characteristic can make the user can implement 3 kinds of changes in actual production: The work measure that implements a plan can increase, decrease, perhaps change treatment content automatically according to the change of workpiece circumstance. The first kind of case can expand through increasing additional machine tool the function of MLS system. Workpiece management also can satisfy bigger crop requirement through expanding linear module comes further. The requirement is stricter, but however more the situation that often produces is measure of ceaseless reductive work. Below this kind of circumstance, need machines what measure certainly content to come off from this system, reoccupy at processing other work. For example: Below current condition, arrangement MLS system is used at machining the cylinder lid of 4 crocks of gasoline engine. And the growth that manufacturing task forecasts demand of next treatment derv engine; The diesel engine part that this equipment in the system will select to accord with him job ability undertakes machining. Final. Shed order to change operation order according to the content of different measurement workpiece. In MLS system, system but expansibility and workpiece but union is removing expansibility: The system can expand what carry work to press order to perhaps run paralell is aberrant. Have the aid of this kind of adjustability (the effect that graph 3) future invests depends on conditional ground the workpiece amount that calculate whether with the workpiece of single contract in actual condition the amount agrees, why will planting obtain on degree consistent. In the meantime, also will stem from no longer henceforth flexible the consideration that turn comes obligate productivity. The price of single work affects direct, front the core dimensions of batch product line. About lifecycle benefit optimization manage was discussed at 10 o'clock what can install is flexible change MLS system to pass compositive the machining center of the hard usage that understands through carrying out check test and verify will satisfy various requirement, odd rod for instance machining center MC-10 and MC-20 collect become double rod machining center MCT1O, perhaps combine the module of MC200, MPC200 and MP200 together collect to become its to have the new system of special function. Of the machine tool modular the design makes the converter that MLS system can use all sorts of cutting tool and work in the round, unit of cutting tool library, base, machining center and odd axis machine tool. Even workpiece of such as cleanness, measure workpiece and working procedure waits in carve characters on a seal of the laser on workpiece can agile ground is compositive go up in MLS system. Heat of cast-iron lathe bed keeps apart the structure of upside of machine tool of machine tool structure of entire firm and need of servo electric machinery and lower tall hardness pillar guides hold the stiffness that design of shape of a flight of stairs considered Z axis way. Also considered cutting tool and workpiece are had in Z axis direction identical those who raise litre of height is constant condition. Secured the main shaft that decorate and the clamping apparatus that are used at feed to ensure those who machine quality but repeatability. The feed means on all axial can use ball guide screw selectively linear perhaps electric machinery. Fewer dimensional demand and the automatic feed orgnaization that link through conveyer belt and dragon mast photograph or Composite equipment photograph is compared, the space that the MLS system place that reachs identical process capability needs is reduced significantly. Its reason consists machining center cover an area of and accumulate lesser, module both sides needs 2 millimeter to be able to arrange automation system each in the center of. Craft of 5 type treatment is opposite craft of 5 type treatment and craft of treatment doing type cutting power and cutting trends character raised a frame requirement that contrasts economy: It is in top rotate speed 16000 turn / below the circumstance of cent, power cannot exceed 40kW(HSK-100) greatly most, the time that start is the longest cannot exceed 0. 3 seconds, 60 meters cannot exceed the most quickly with quick stroke on all and linear axial / cent, acceleration cannot exceed 8 meters greatly most / second 2, the steep drive on A axis and B axis direction also must satisfy the requirement in the future. The equipment of craft of treatment doing type needs the lock keeps harmonious and consistent, maintain the freedom that cuts bits to slide, external Z is uranous, rising head treatment, the container that cut bits and the metal that exceed 60 degrees of banking angle are enclothed must ensure the unobstructed of a bits, and cannot appear the phenomenon that cuts bits to twine. System of cutting tool management places the circumstance with shorter and shorter time to fall in cutting tool outfit, should improve facility total productivity is about to reduce the time that change a knife. MLS system uses double ungual chuck no longer, decorate cutting tool library directly however in workpiece upper part, use fast pedrail chain to carry cutting tool to main shaft (graph 5) . The alone installation process of cutting tool is little at 3 seconds, reduced the job to plan time. Make cutting time interval OK thereby achieve 2.
4 seconds. System of cutting tool switch was replaced with a few accessary functions that live, for instance encode of clean cutting tool, cutting tool and cutting tool blemish are controlled. Of machine tool main shaft decorate a form basically to make the free length of cutting tool OK and choose the cutting tool library of outfit to be united in wedlock together, it is OK to make the length of MLS system use broach the biggest thereby achieve 800 millimeter, the diameter of milling cutter can achieve 330 millimeter greatly most. System of cutting tool management places the circumstance with shorter and shorter time to fall in cutting tool outfit, should improve facility total productivity is about to reduce the time that change a knife. MLS system uses double ungual chuck no longer, decorate cutting tool library directly however in workpiece upper part, use fast pedrail chain to carry cutting tool to main shaft (graph 5) . The alone installation process of cutting tool is little at 3 seconds, reduced the job to plan time. Make cutting time interval OK thereby achieve 2.
4 seconds. System of cutting tool switch was replaced with a few accessary functions that live, for instance encode of clean cutting tool, cutting tool and cutting tool blemish are controlled. Of machine tool main shaft decorate a form basically to make the free length of cutting tool OK and choose the cutting tool library of outfit to be united in wedlock together, it is OK to make the length of MLS system use broach the biggest thereby achieve 800 millimeter, the diameter of milling cutter can achieve 330 millimeter greatly most. Workpiece management system -- FlexFlow MLS system has perfect, the workpiece management system of commutation diversity. Strong link was not used to use a kind of flexible workpiece feed and workpiece to allocate an orgnaization however between machining center. Linear module achieved the workpiece switch rate of 10 seconds less than, included take out work from workpiece library, edge slideway feed (graph 4) , carry again picture " silent lackey " on the changeover stage of same job (graph 6) . The workpiece that expects the system realized only station equipment sends feed in the center of. Graph gate of 6 workpiece pass in and out: Be located in the join orgnaization between treatment module and central workpiece memory -- " silent lackey " , changeover time makes the operation with complex equipment handy requirement less at the drill with 10 handy seconds. All manufacturing strategy and memory of ministry of violet urgent the way to deal with a situation are in control system, need 8 pushbutton to be able to operate whole platform facility conveniently only. "IPM " process supervisory system is compositive workpiece monitoring (include work damaged is monitored and workpiece overload is monitored) , machine tool collision is monitored, leather belt wears away monitor, , function of ball guide screw is monitored, adjust according to machining process and workpiece circumstance main shaft is actual the function of power. Medium video photographs MLS system to be able to monitor sightless at ordinary times process in real time even like the head. The configuration management function that the system controls in the center of is returned can show the state of place Yo equipment clearly come. Convenient maintenance the choice of machinery and electric component considered the following wear away. The main shaft in automation system was used brand-new the direct drive means of development, the name is " Help " in drive system (include: Hydraulic pressure part, electric power part, lubricant part uses a part compatibly) all sensor and carry out implement, control and automation system (of Xi Menzi " Solution Line " system) decorate in in hind, and marked outside electric control ark ground marks come out. One person is lost expensive solve what all problems consider installation after service to answer speed, the machine tool of Heller company and automation component arranged a contact only. The advantage that invests charge above makes Heller company justifiable by believe, with at present already some plan photographs are compared, it is in order to machine the cubic spare parts of dynamical assembly exemple, this system that they develop is in whole lifecycle is average and OK save the investment of 30% . CNC Milling
CNC Machining