MAG presents “Smart Production Systems” at EMO

Similarly, energy and environmental management as well as the careful use of resources play key roles. At EMO, MAG is focusing not only on machines, automation and the manufacturing process, but also on networking of production and supporting equipment using new communication technologies.

In Hanover this year, MAG will present new products, technologies and components that have been developed with a view to the entire production system and its environment. Martin Winterstein, responsible for Business Development and Marketing, says this about the result: “Whoever offers production systems must constantly set new standards in manufacturing technology in order to ensure maximum productivity. However, the dynamics of changing customer requirements also makes it necessary to design production systems to be flexible and find new and useful ways to integrate and network. Our “Smart Production Systems” represent powerful, streamlined and versatile manufacturing that meets the current challenges facing the manufacturing industry.”

MAG will present a wide range of product and technology innovations in a total of 13 exhibits. One of the major highlights is the new VDF 221 Cx machine series for crankshaft production featuring new turn-turn broaching and external milling operations as well as hard fine milling and hard fine finishing demonstrations. These new processing technologies offer users higher productivity and less maintenance. The modular building design is optimally suited to the component changes in the market, such as shorter product life cycles, higher demands on surface quality and demanding materials.

VDF DUS universal lathe

VDF DUS universal lathe

For machining of prismatic components, MAG will display three SPECHT® machines, each of which puts forward a number of remarkable innovations and technical data. The compact twin-spindle SPECHT 450 DUO boasts a sophisticated tool change system and a chip-to-chip time of less than 2.5 seconds as well as the ability to machine precisely thanks to the unique level of compensation in all linear axes. It offers twice the productivity without compromise, and all that with a machine footprint of only 11.2 m2. In this series, the SPECHT 600 DUO extends the success story of technology integration at MAG. Since 2011, MAG has been integrating honing and fine boring systems on CNC system machines, with significant gains with regard to processing and cost efficiency as well as flexibility. Meanwhile, a whole series of honing specifications has been established, even for plasma sprayed cylinder bores. The engines produced with the MAG process feature industry best values in benchmark tests with respect to oil consumption, blow-by and wear. At EMO, honing will be presented for the first time on a twin-spindle CNC machine system using the SPECHT 600 DUO. The SPECHT machines with integrated honing technology are well-suited for engine production as well as for suppliers, foundries and other users who require flexible 6-axis centers for milling and honing. The flexibility, one of the defining features of the SPECHT series, is also being improved: at EMO, MAG will present the first single-spindle SPECHT with Fanuc controls, the SPECHT 600.

Another product introduction comes from the MAG Mosbach plant. The newly developed Hüller Hille NBH 630 5X 5-axis machining center now makes the benefits of complete 5-axis machining available to users that rely on the robustness and productivity of the prestigious NBH Series of machines. High holding forces in the rotary axes allow for a high chip removal volume in roughing and high surface quality in finishing, both in 4-axis machining and 5-axis profiling applications. The machining center features a comprehensive accuracy package including cooling of the servo drives, ball screw nuts and gears and use of a spindle displacement sensor for determining the position deviation, providing high thermal stability and improved part quality. With large bearings and high-torque drives in the rotary axes as well as the unique Hüller Hille cassette type tool magazine, the machine offers diverse options for use, from light metal to titanium, inconel and hard cutting. An optimized work space as well as the optimization of interference conditions create the perfect conditions for 5-sided machining.

The improved Boehringer VDF 450 TM rotary turn/mill center is suited for the complete machining of round workpieces. It promises high flexibility, for example through constructive measures: with its 3-track bed, both the upper and the lower tool carriers can move without restriction around the tailstock or counter spindle. Also, operations on the main and the opposing spindle can be performed by means of the lower turret, and four-axis machining is possible from above and below throughout the complete operating range. An extremely rigid bed made of Hydropol, powerful machining spindles (main spindle with up to 5340 Nm and milling spindle with up to 380 Nm) and a generous tool magazine with up to 120 places as well as a fast tool changer with shuttle system for the exchange of the tools in working position ensure the efficiency, long-term accuracy and productivity required.

Production cell for gear wheel processing Hessapp DVT 200 vertical lathe and Modul H 250 CDT gear manufacturing center

Production cell for gear wheel processing Hessapp DVT 200 vertical lathe and Modul H 250 CDT gear manufacturing center

In order to be a real full-service gear production provider, you need an appropriate portfolio providing an integrated machining solution. For EMO, the MAG plants in Chemnitz and Taunusstein will again demonstrate their universal dominance in gear wheel and shaft machining. The Hessapp DVT 200 product premiere – the smallest representative of the vertical pick-up lathes with MAG transfer technology – joins the multi-functional Modul H 250 CDT gear hobbing center. Together, the two machines run the turning, milling, hobbing, chamfering, deburring and oil hole drilling operations in a manufacturing cell – an efficiency package for the production of wheels, hubs and other components.

MAG has a long traditon of producing extremely robust and durable machines such as the Hüller Hille NBH horizontal machining center. For users whose production conditions and applications have changed over the years, but who do not want to give up their tried-and-tested NBHs, MAG offers OEM retrofit solutions. At EMO, the experts from MAG will demonstrate the benefits of general overhaul, modernization and increase in energy efficiency by means of a Hüller Hille NB-HP 150 horizontal machining center under the slogan of “Retrofit Evolution”. Equipped with the latest control technology and efficient components, the machining center is equal to all tasks, without incurring new purchase costs either for the machine, equipment and foundation or for tools. Within the MAG business unit Service, the “Engineered Services” team offers comprehensive services for the optimization of existing systems in terms of availability and energy efficiency.

In line with the EMO slogan: “Smart Production Systems”, the engineers at MAG take many different approaches to optimizing manufacturing solutions:

  • Reductions in investment and operating costs through shortening the process chain
  • Improved machining efficiency and accuracy through complete machining of the cylinder bore and crankshaft bore in a single CNC machine and fixture
  • Increasing energy efficiency and improved working conditions through low-consumption of air and fluids, and high efficiency electrical systems, reduced use of coolant and emissions of mist
  • Production and cost optimization through the use of design and simulation tools for planning, optimization and adaptation of production tasks and processes
  • Interactive training tools for intuitive understanding and learning of product features, user interfaces and service activities

An example of the leadership role which MAG is playing with current issues such as resource efficiency is the new energy efficiency package: the combination of energy-efficient components, software and visualization can create savings of up to 30% on a machining center. Various analyses can be displayed in the visualization of the energy monitor: current and accumulated consumption, energy costs per workpiece, divided into electrical energy, compressed air and coolant consumption. In addition, the data can be accessed online on any mobile device.

Through staff training and motivation, unused reserves in production can be mobilized. With MAG University, MAG supports machine operators and maintenance personnel with an innovative, computer-based training and “trouble shooting” system (e-learning). The employees decide when, how long, where and how often they want to go through each training stage. The system-guided success control ensures the required level of knowledge has been reached and that the staff is optimally prepared and qualified for production. The already-attained goal of the new training concept of MAG is to improve production quality and plant efficiency by at least 10%.

MAG will present several other examples of this integrated approach at EMO. Technologists and sales engineers will be available to visitors in Hanover to explain the interaction between the various manufacturing options offered by MAG and work out the best solution for each application case.

Source: MAG