Cost pressure: In France, an accessory factory producing automotive turbocharger seals changed the workpiece from the past stamped part to the current welded narrow band part through the conversion of the processing technology, which reduced the material cost by 140%.
Executive summary: The accessory industry is facing a rapid flow of mergers. In this process of merger, the company must have a good mental preparation to exert its technical skills and create new values ​​better. In this regard, the medium-sized manufacturer of press-bending components usually faces the question of which technology should be prioritized: whether it is a follow-on connection process that will soon be performed or flexible stamping-bending technology. Many companies have their own technological advantages, but some companies dare to risk the process conversion - and thus achieve success.Examples from the automotive industry. Manufacturers have realized that in the face of the saturation of the market, and intend to win customers first by expanding the variety of models. In addition, in the last 10 years, the product life cycle of the automotive structural series has almost been reduced by half, which has led to further expansion of variants of automobile models and production equipment. Therefore, production must be flexible, so that manufacturers are increasingly trying to modularize their processing units. More and more development tasks and the processing of complex components are increasingly being transferred to the accessory production plant, which leads to the profound restructuring of the supply system of the accessory parts. Therefore, in the future, the accessory production plant will have more of its own power in the development of mass production equipment and in production and assembly. Whoever wants to survive in this industry must continue to invest: at the business level of the company's employees. However, we must also invest in technological innovation.
The current situation encountered by the accessory production plant is also reflected in the company's 50-year history of enterprise development at the Bihler Machine Tool Plant (Halblech). The company has grown by producing simple springs and stamping-bending parts. Over time, due to the experience accumulated over the years, highly complex components that can be assembled directly are manufactured on Bihler's automatic machines with extremely high quality, high production efficiency and very low one-piece costs. Become a norm.
Can no longer accept more material consumption Not so long ago, a French auto parts manufacturer decided to end its struggle with rising material costs. As a manufacturer of turbocharger seals, in the past, they produced such components using only presses. The parts are punched from the wide-band steel plate and then processed into the final product through other processes. This processing process results in considerable material consumption. The consumption of this material has proved to be unprofitable. In addition to the ever-increasing one-piece cost, the punching process also affects the quality of the seal because the texture of the board material can be broken, reducing the strength of the seal. Based on this actual situation, the accessory production plant requested Bihler to develop a processing technology to greatly reduce material consumption through this process, and secondly to significantly improve the quality of the components.
These two goals drive designers to work with great enthusiasm. A simple and proven reliable solution was proposed to replace the seals that were hitherto punched out of wide strips. At present, a narrow metal band is formed into a ring, punched, laser welded and then marked. This may sound simple, but it requires practical know-how and careful preparation, especially regarding the welding process. In this respect, first of all, there is no empirical data, so trials must be conducted in order to master the technology. In this way, a sample of the product was produced and the sample was tested in order to determine all necessary parameters. It also determines the forces that affect the quality of the weld and the dynamic loads that will be absorbed by the weld.
Comprehensive processing: According to the plug-and-play concept of the slogan, all machining processes can be realized on the machine via a digital control system via a servo drive.
Six different functions integrated on a single robot For laser applications, two types of lasers from Trumpf, a process technology partner headquartered in Ditzingen, can be used, and the company promises to provide an economical solution for machining seals. The advantage of a laser is that it has excellent focusability, resulting in a smaller heat affected zone. Therefore, the time-consuming and costly follow-up processing can be omitted in this processing example. Since laser welding can use higher welding speeds, it can further increase the production efficiency and improve the safety of the welding process compared with the traditional welding process.
High-tech applications: Trumpf's Nd-YAG lasers and marking lasers are used on multi-function machines, eliminating the need for subsequent processing.
The innovative machining process, which includes individual steps such as feeding, spheronization, cutting, stamping, welding and marking, is converted into a full CNC machine system called Bimerie. NC technology is precisely the high-end technology if it is an efficient process, but it is a common technology for multi-function automata. According to the plug-and-play concept, all machining processes can be flexibly implemented on such a machine tool system via a servo drive via an NC system. Therefore, a machine such as Bimerie is suitable for both high-volume, low-batch processing and high-volume, high-efficiency machining. In the parts factory in France, for the workpieces such as seals, the machine tool system can realize three kinds of seals of different specifications by replacing pre-adjusted function modules for spheronization, cutting, stamping and welding. Since the individual processing steps are separated in spatial position, the individual tools can be seen clearly and accessible to the tool, which is particularly convenient for the operator to perform maintenance and repair work, and the operator no longer provides a continuous combination. Mold.
Today, for the French company, the process of converting from pure stamping to an innovative integrated manufacturing process adds significant value to economic efficiency. The first is to save a lot of materials. Compared with Bihler's process, the manufacturer originally consumed 2.5 times more material. In terms of material prices, the current price per ton of material has changed within five digits. This makes it easy to calculate how much savings potential there is in the consumption of materials. The second is the obvious improvement in product quality. Because spheronization is carried out with a narrow strip of steel, the texture of the material is not broken, thereby increasing the material strength and the stability of the material. For the use of seals in the high temperature range, these are two particularly important criteria.
Multi-variety production: Various types of plug-in terminals for integrated processing on multi-function machine tools.
The innovative process from the connection technology area should be said to be the second example. In this industrial field, accessory manufacturers certainly demand higher and higher prepayments for its customers. Here, only manufacturers that can provide high-quality products and are more economical than their competitors can survive. This is especially important for competitive capabilities when multiple processes are required to process complex components.
Here, whoever disperses the various processes on multiple machine tools has to think twice about overcoming these important shortcomings. A German manufacturer of plug-in terminals has such an experience. Various processes such as pre-stamping, electroplating, bending, and assembly used in the processing of the plug-in terminals of this factory were dispersed on different machine tools and presses. The use of such processing methods will increase the handling and operation of the workpiece. Cost, more time lost and quality loss.
Quality assurance: The insertion depth of the plug terminal and the distance between the terminals are finally detected using an inspection station equipped with two cameras.
It is always worth rethinking the machining process. Even in this case, the technical transformation is worthwhile to the customer. The first is related to winning time and improving quality, but it is also related to flexibility, because the equipment can be simply and quickly converted to different Specifications Plug terminal production. Should you finally go back to stamping - is bending technology a better processing solution? It must be honest to say that the efficient stamping process also has its strengths. However, the two examples of application described should be said to be very clear about the potential of stamping-bending technology. It should lead to reconsidering and experimenting with unique processing techniques to effectively cope with conventional production. Increased pressure on the process. In this regard, integrated processing technology provides decisive processing capabilities. Through the saving of materials, time, and cost, as well as the improvement of production efficiency, this processing technology has finally increased the output value significantly. It cannot be denied that for simple components and extremely high stamping tonnage, the comprehensive processing technology is not comparable. Efficient stamping process. However, the integrated processing technology is an economical solution to the future situation of the parts manufacturer mentioned at the beginning of the article and the situation clearly demonstrated by the two application examples.Electric portable screw air compressors are widely used in mining, hydropower, urban construction, shipbuilding and other industries. With the advantages of portable screw models, they are more consistent with lightweight, miniaturization of the development trend of screw compressors. New type electric portable screw air compressors have greater breakthroughs in terms of system and configuration than the traditional ones. They have achieved high efficiency, high stability and low energy consumption. It is more easy to operate and more convenient to maintain.
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