Equipment

Company facilities:

Equipment (machinery and equipment)

 

1. Planning und Engineering

 

Planning und Control

  • ERP-system with AS-400 hardware and interconnected workstations by intranet
  • EIS (ARUBA)

Engineering Foundry

  • CAD-workstations with SOLID-WORKS-software
  • Solidificationsimulation-software MAGMA SOFT

Engineering machine-shop

  • CAD-workstations with SOLID-WORKS-software and OPUS-NC software for CNC-programming and tool-engineering

Drawing / Datafile-control in QA-department

  • Controlling customer-files and specifications by dedicated software “Smar Team”.

2. Foundry

 

Moulding equipment

  • Automatic moulding line with vacuum molding process, made by Künkel-Wagner Flasksize 1050 x 780 x 300/250 mm, Theor. capacity 110 moulds/h with automatic pattern-change-system; 0,8 min/change, With channel-type NF-induction furnace/casting unit, capacity 2,5 t, made by Junker; Pouring weight up to appr. 240 kg/mould.
  • Mechanical moulding line GV 5,5, made by Zimmermann Flasksize 1400 x 850 x 500/500 mm; Effective capacity 80 moulds/shift Casting weight up to 450 kg/mould
  • Sand plant 1 continuous sand mixer, capacity 100 t/h, made by Künkel-Wagner and 1 Multi cooler by Simpson
  • Prototyping with 1 continuous sand mixer up to 10 t/h capacity

 

Core shooting department

  • Coldbox core shooters made by Röper, H6,5; H40
  • Coldbox core shooters made by Laempe, L20-40; L40; L65; L100 (2x)
  • 2 sandmixers, capacity 5 t/h each; made by Laempe

 

Melting plant

  • Liningless hotblast cupola oven, made by Kölsch-Fölzer; capacity max. 20t/h
  • 4 x 6-t NF-induction furnaces by Junker
  • 1 NF channel-type induction holding furnace, effective capacity 45 t, made by Junker

 

Grinding/fettling department

  • 2 continuous shot-blast ubits including conveyer-tracks, made by Agtos and Berger
  • 1 CNC-grinding tool “Robomat” for flywheels and brake-discs, made by Reichmann
  • 2 grinding robot Koyama 500 TTi
  • manual fettling workstations

 

Painting

  • 1 Paint line for hydro-paint including conveyer and drying tunnel with integrated paintspray-booth for standard- and non-standard coatings
  • 2 paintspray boothes for preservation and/or painting

 

Pattern shop

  • 1 Measuring machine by Stiefelmayer, 2550 x 1500 mm

 

Quality Assurance in the Foundry

  • 1 Spectrometer “SpectroLab LAVM 12” for automated spectographic analysis, made by Spectro
  • 1 Spectrometer GS 1000, made by OBLF
  • 1 Handheld XRF S1 Titan, made by Quantron
  • 1 Microscope RMA5, made by Ratenow with DSLR Canon 650D
  • 2 Brinell-hardness testing machines
  • 1 draw bench with digital transducer
  • 1 Pendulum impact testing machine
  • 1 3-D-Scanner ATOS II Triple Scan, type GOM
  • Ultra-sonic testing units by Krautkrämer
  • Crack detection and dye penetrant technique
  • Several Lab-instruments for water based chemical test
  • Buehler EcoMet 300 pro, semi-automatic grinding and polishing machine
  • WDE 500 Cycles-CNC-lathe, made by Wagner

 

 and  3. Machining Department

 

Production of Housings

  • 1 Horizontal CNC-machining centre Nbh 290, x = 1.460, y = 1.250, z = 1.200, made by Hüller-Hille
  • 1 Horizontal CNC-machining centre Nbh 290, x = 1.400, y = 1.000, z = 1.200, made by Hüller-Hille
  • 1 Horizontal CNC-machining centre Nbh 230, x = 1.200, y = 1.000, z = 1.200, made by Hüller-Hille
  • 2 Horizontal CNC-machining centres Nbh 6+, x = 1.050, y = 800, z = 1.000, made by Hüller-Hille
  • 1 Horizontal CNC-machining centre Nbh 170, x = 800, y = 800, z = 800, made by Hüller-Hille
  • Production cell housing consisting of 1 Horizontal CNC-machining centre Nbh 230, x = 1.200, y = 1.000, z = 1.200, made by Hüller-Hille and 1 Horizontal CNC-machining centre Nbh 800, x = 1.400, y = 1.100, z = 1.400, made by Hüller-Hille included a pallet storage system (12 places) made by Kirchgässner
  • 2 Horizontal CNC-machining centre Nbh 170, x = 1.000, y = 800, z = 1.000, made by Hüller-Hille linked by a pallet storage system (24 places) made by Fastems
  • 2 Horizontal CNC-machining centre Nbh 230, x = 1.200, y = 1000, z = 1.200, made by Hüller-Hille and 1 Horizontal CNC-machining centre Nbh 170, x = 1.000, y = 800, z = 1.000, made by Hüller-Hille linked by a pallet storage system (38 mashine pallet places and 68 material pallet places) made by Fastems
  • various means for leaktesting
  • 2 cleaning systems

 

Flexible machining system for machining flywheels up to ø500 mm/150 mm high and max. 60 kg weight

  • 1 DVT500 Pickup-lathe made by Hessapp
  • 2 DBZ vertical CNC-machining centres made by AXA
  • 2 articulated arm robots made by Kuka
  • 1 ring-gear press made by Hengstebeck and Eich
  • 1 half-automatic balancing machine, by Hoffmann
  • 1 packing station

 

Flexible machining system for machining flywheels, brake discs and other rotation symmetric parts up to ø540 mm/150 mm high and max. 90 kg weight

  • 4 CNC automatic lathes fitted with manipulation robots
  • 2 vertical CNC machining centres fitted with manipulation robots
  • 1 Horizontal machining center for circumferential machining
  • 1 Automatic ring-gear press with torque control
  • 1 Automatic marking machine with computer-controlled data transfer
  • 1 integrated automatic balancing machine, by Hoffmann
  • preservation units

 

High volume flywheel production-transfer line ø450 x 120 high

  • 4 lathes, by Diedesheim
  • 2 Multi spinle drilling/threading machines, by Diedesheim
  • 1 Ring-gear press
  • 1 Automatic static/dynamic balancing machine, made by Schenck
  • 1 preservation unit

 

Production Cell for the machining of rotation symmetric parts up to ø800 mm

  • 2 CNC lathes, by Hyundai Wia
  • 1 vertical machining center made by Cincinatti
  • 1 semiautomatic balancing machine, made by Cimat

 

Production Cell for the machining of rotation symmetric parts up to ø500 mm

  • 2 CNC lathes, by Hyundai Wia
  • 1 vertical machining center made by Cincinatti
  • 1 static balancing machine, made by Schenck
  • 1 articulated arm robot made by Kuka

 

Flexible workshop for small lotsizes (<100 pcs) for rotation symmetric parts up to ø800 mm

  • 2 CNC-lathes, by Hyundai Wia < ø800 mm
  • 1 CNC vertical machining centre, by AXA
  • 1 Dynamic balancing machine, by Schenck
  • 1 Static balancing machine, by Schenck

 

Assembly hall

 

Quality Assurance in the Machining Department

  • Air conditioned measuring room for measuring of products
  • 1 CNC-measuring machine, x = 2.000, y = 1.200, z = 1.000, made by LK
  • 1 CNC-measuring machine, x = 2.000, y = 1.200, z = 1.000, made by Nikon
  • 1 CNC-measuring machine Aberlink, x =600, y = 800, z = 600
  • Air conditioned room for measuring and calibration of gauges
  • 1 length measuring instrument, Mahr ULM 600E
  • 1 Dial indicator test device, Mahr 865E
  • 1 Rockwell-hardness testing machine, made by Wolpert
  • 3 interconnected PCs used for gauge control

 

Tooling Department

  • 1 Tool grinding machine
  • 1 Universal milling machine CNC –   2 Vertical drilling machines
  • 2 Computer controlled tool measuring and setup units
  • 1 Bandsaw
  • 2 conventional lathes
  • 1 cycle-CNC-lathe
  • 1 machining centre

 

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