As a system supplier for OEM customers and in the context of the 2015 European machine tool trade showed EMO in Milan MAG again unveils several development highlights under the motto: “come and see tradition of innovations” and presents the performance of these products and technologies for efficient assembly. Among those the new BOEHRINGER 221/226 Cx for crankshaft machining and the SPECHT machining centres, which have proven themselves in automotive manufacturing. Moreover, the subject of Industry 4.0 occupies a central position.
The new product series BOEHRINGER 221/226 Cx is specially designed for the new generation of crankshafts for compact drive units with a progressive performance portfolio. With higher milling performance for harder materials and crankshafts with optimized bearing diameter to reduce fuel consumption, the series pioneeringly covers the requirements in an excellent manner. The compact design paired with optimum service accessibility allows for these machines to be integrated into the production plant with minimum space requirements. MAG introduces the BOEHRINGER 226 CM, a longer machine variant for the new 6-cylinder in-line engines crankshafts,
which provides significant investment benefits for the operator, in addition to the technical innovations.
Boosted operating comfort
Not only do modern machine tools have to be capable of manufacturing productively and efficiently; both ease of operation and maintenance as well as environmental aspects are of increasing importance. From this point of view, MAG has carefully examined the established Boehringer-Series for crankshaft machining. The result is a compact, modular machine with great ease of use.
“Designing a machine in a manner that notably simplifies operation and maintenance also affects productivity due to decreasing non-productive times,” explains Martin Billerbeck, Leader of the technology rotary parts, at MAG. The new concept Cx includes the three types of machines for milling, turn broaching and turning, all according to the same modular principle: the machine bed with a spindle, steady rest slide, same linear guide rails, always the same ball screws, etc., only the tool carriers differ depending on the type of machining. As a consequence, preventive maintenance becomes much easier; the customer only has to put one spindle in stock in order to be able to exchange it in case of failure of one of their MAG machines.
Increasing the size of the spindle head from size 8 to 11 as well as more solid spindle bearings have lead to more overall stability. As a result, the machine precisely manufactures from the first crankshaft on, without timeconsuming precision optimizations. The machine bed itself consists of an environment-friendly, recyclable mineral cast with high material damping. Integrated cast strips optimally conduct the occurring forces into the bed. In addition, the vertical bedslide reduces the moving load and the slant bed ensures an optimum flow of forces. Dimensional stability during brief temperature fluctuations is achieved by the high thermal inertia. Although so far there are no comparative figures – the CNC crankshaft machines still is too new to the market – a better yield and longer tool life are to be expected due to the high stability which prevents chatter marks and improves surface quality.
Another highlight at the new CNC crankshaft machines certainly is the three-stage gear. It brings more torque to the machine, which directly impacts productivity. “Previously it was driven with a braked drive because the torque of the old 2-stage transmission was insufficient,” says Martin Billerbeck of the customer projects.
Access to everything
An essential aspect for the machine’s design has been operator friendliness and maintainability. On the one hand the worker should be able to operate the machine optimally, on the other hand maintenance should be simplified by making all serviceable parts more easily accessible. Therefore, ease of use had priority in the entire process of cladding. “We have put emphasis on functional machine design – what’s the use in having a nice sliding door without function,” says Martin Billerbeck. The sliding door is designed in a way that allows it to be opened by loosening three bolts, so that the entire engine room is easily accessible, and from the left and right at that. A lateral
service entry allows maintenance personnel to quickly access all of the components – the cover can be moved without having to dismantle anything.
The working space is designed for optimum chip fall and suitable for dry machining. The disposal of the chips is much easier now: The generously dimensioned chip conveyors are mounted beneath the machine. The machine interior is resistant against flying chips and designed for optimal chip fall, so that chips cannot accumulate. There are flat recesses in the bottom plate, so that the chip conveyors can be lifted above the bottom plate by use of a handle. A positive side effect: the elimination of the chip conveyor at the machine’s outside results in its footprint at 4m being one meter shorter. The compact design includes the optimal preparation of machines to be used in the system – in an assembly line the units can be arranged with only 800mm of spacing. And finally, the energy container (fluid power and electrical cabinet) is centrally and compactly mounted on the rear of the machine. It is also more accessible now. The operating ergonomics are accommodated by the fact that all control panels are vertically motor-adjustable according the height of the machine operator. If, in addition, using a handheld terminal is desired (e. g. for the portal) a corresponding plug is found directly on the control panel. Also, there is an interface available for the operating device of the loading manufacturer.