Flexible Production Solutions for Precision Components

Size: px

Start display at page:

Download "Flexible Production Solutions for Precision Components"

Maximilian Heath
5 years ago
Views:

1 Flexible Production Solutions for Precision Components 1

DVS PRODUCTION SOUTH GMBH With more than 25 years of experience in the machining of precision components

GmbH is one of the most experienced companies for classic contract manufacturing in Germany.

access to the most efficient machining technologies in the fields of turning, milling, gear cutting,

Truck wheel hubs are mass-produced at DVS Production South on behalf of the commercial vehicles industry

A highly efficient and almost completely automated production line has been realised thanks to a

Even smaller-volume turning or milling lots are manufactured economically and reliably at the Kürnbach

Digitalised series production of truck wheel hubs Own apprentice workshop High level of expertise in the

Just-in-sequence production DVS TECHNOLOGY GROUP The DVS TECHNOLOGY GROUP is made up of experienced

The DVS TECHNOLOGY GROUP has more than 1,000 employees worldwide and is one of the leading system

and sells high-precision machine tools, automation equipment and the associated services.

2 DVS PRODUCTION SOUTH GMBH With more than 25 years of experience in the machining of precision components for the automotive industry as well as for machine, tool and mould construction, DVS Production South GmbH is one of the most experienced companies for classic contract manufacturing in Germany. Flexible piece part and small batch production Membership of the DVS TECHNOLOGY GROUP facilitates direct access to the most efficient machining technologies in the fields of turning, milling, gear cutting, grinding and gear honing. Truck wheel hubs are mass-produced at DVS Production South on behalf of the commercial vehicles industry using state-of-the-art manufacturing technology on the basis of Industry 4.0 principles. A highly efficient and almost completely automated production line has been realised thanks to a driverless transport system and RFID technology. Even smaller-volume turning or milling lots are manufactured economically and reliably at the Kürnbach site near Karlsruhe/Germany. Digitalised series production of truck wheel hubs Own apprentice workshop High level of expertise in the field of powertrains 25 years of experience Custom production solutions for soft & hard machining Just-in-sequence production DVS TECHNOLOGY GROUP The DVS TECHNOLOGY GROUP is made up of experienced machining companies focussing on the turning, gear cutting and grinding technologies. The DVS TECHNOLOGY GROUP has more than 1,000 employees worldwide and is one of the leading system suppliers for machines, tools and production solutions for the machining of vehicle powertrain components before and after hardening. The following divisions make up the DVS TECHNOLOGY GROUP: DVS Machine Tools & Automation: Manufactures and sells high-precision machine tools, automation equipment and the associated services. DVS Tools & Components: Develops, manufactures and sells customised machine components, tools and abrasives. DVS Production: Series production of components for passenger cars and commercial vehicles using DVS machine tools. DVS International Sales & Service: Local DVS Contact for Sales and Service on International Markets. Machine Tools & Automation Tools & Components Production International Sales & Service Central location with excellent access to the long-distance transport network 2 3

Digitalised production of truck wheel hubs Inspired by the

0 vision, a digitalised production line has been set up at

hubs for the commercial vehicles industry.

to the high degree of automation and thanks to

Standardised component pallets developed in-house

transport systems and 4-axis lathes from PITTLER.

and information is visualised on the central computer, via

qualities of the components currently in production can be

Finished parts are measured 100% after machining and

out all the important component production data for years

Repacking and packing station for raw and finished parts Raw

conveyor washing system 5 driverless transport systems with

3 Digitalised production of truck wheel hubs Inspired by the Industry 4.0 vision, a digitalised production line has been set up at DVS Production South for the turning and drilling of wheel hubs for the commercial vehicles industry. The production line organises itself to a major extent, due to the high degree of automation and thanks to state-of-the-art information and communication technologies. Standardised component pallets developed in-house communicate per RFID technology with the driverless transport systems and 4-axis lathes from PITTLER. In order to monitor production, the entire flow of material and information is visualised on the central computer, via which the machining status as well as the manufacturing qualities of the components currently in production can be retrieved. Finished parts are measured 100% after machining and assigned a data matrix code which makes it possible to read out all the important component production data for years after production. Repacking and packing station for raw and finished parts Raw and finished parts store for the unmanned night shift 3-zone conveyor washing system 5 driverless transport systems with collision protection PLC measuring station and laser marking of the data matrix code Truck wheel hub RFID chip for communication between machine, man and FTS (driverless transport system) 8 machining islands with two PITTLER four-axis lathes and one automation cell each 4 5

Face grinding with pioneering know-how The extremely efficient

machining of the plane surfaces of flat components, which are linked

In close cooperation with the affiliated company and pioneer in the

workpiece-specific production solutions are developed which allow

The technology In the ideal case, several thousand components can be

The maximum precision of the Diskus grinding process is reflected by

Even extremely critical tolerances of the thickness dimension can be

Single face grinding Double face grinding Your advantages: The face

often used in the commercial vehicle segment for example, can be

Even especially thin components can be machined safely and reliably

4 Face grinding with pioneering know-how The extremely efficient Diskus grinding method is used at DVS Production South for the machining of the plane surfaces of flat components, which are linked with high unit quantities. In close cooperation with the affiliated company and pioneer in the field of face grinding, DISKUS WERKE Schleiftechnik GmbH, workpiece-specific production solutions are developed which allow the client to make high cost savings. The technology In the ideal case, several thousand components can be ground per hour either on one side or simultaneously on both sides. The maximum precision of the Diskus grinding process is reflected by the high evenness and parallelism of the manufactured workpieces. Even extremely critical tolerances of the thickness dimension can be met using this technology. Single face grinding Double face grinding Your advantages: The face grinding technology delivers a brilliant performance on smaller to medium-size components in particular. Yet even larger components up to 500 mm in diameter, such as are often used in the commercial vehicle segment for example, can be ground highly efficiently. Even especially thin components can be machined safely and reliably on Diskus machines without any risk of undesirable distortions. Maximum efficiency thanks to component-specific manufacturing solutions High expertise thanks to close cooperation between production and mechanical engineering companies Especially efficient technology for large unit quantities 6 7

Power Skiving efficient gear cutting. Inside and out.

to a diameter of 1250 mm and a module 7.

Depending on the order volume, a project-specific machining solution is developed together with the

With costsaving for the customer in mind, complete machining solutions are used for component

The technology Power Skiving technology is a continual, metal-cutting method used for manufacturing

The method is based on Wilhelm von Pittler s patent dating back to the year 1910.

efficient and flexible alternative for component gear cutting over the past few years.

values < 3 µm can be realised, depending on the component properties.

and surface quality possible Characteristic of power skiving is the angled arrangement of the tool

5 Power Skiving efficient gear cutting. Inside and out. DVS Production South offers efficient gear cutting solutions for rotation-symmetrical components up to a diameter of 1250 mm and a module 7. The extremely efficient technology of Power Skiving is used for this application. Depending on the order volume, a project-specific machining solution is developed together with the affiliated companies PITTLER and PRÄWEMA. With costsaving for the customer in mind, complete machining solutions are used for component manufacturing alongside combined processes. The technology Power Skiving technology is a continual, metal-cutting method used for manufacturing straight and angled internal and external gearing. The method is based on Wilhelm von Pittler s patent dating back to the year Thanks to the latest developments in manufacturing technology, the method has excelled as an efficient and flexible alternative for component gear cutting over the past few years. High gear cutting qualities of IT6 and better, all common profile and flank modifications and Rz values < 3 µm can be realised, depending on the component properties. Your advantages: Cost saving thanks to combined or complete machining of the components High gearing and surface quality possible Characteristic of power skiving is the angled arrangement of the tool axis to the component axis. This is known as the axis cross angle. This tool engagement, a defined axial feed and the coupled speed of tool and component result in a relative movement. This relative movement skives the tooth space out of the workpiece along the main cutting direction. Internal and external gearing can be cut in one single clamping with straight or tapered gear flank 3 5 times more productive than the gear shaping method More efficient and more flexible than broaching 8 9

6 Flexible production of precision components The demand for more and more flexibility in component production is increasing all the time due to the ever shorter life cycles of machines and vehicles. The machine fleet for contract manufacturing at DVS Production South is identical for the most part, which means different components can be manufactured on only one machine. Conversely, one and the same component can be manufactured on almost all the machines when larger unit quantities are required. Extremely short processing times can be realised at DVS Production South without having to modify the machining programs and without any major retooling work being necessary. Even short-term changes to unit quantities or geometries are always possible. This high degree of flexibility requires a great deal of specialist knowledge, which is why DVS Production South only deploys qualified specialists at the machines. Most of the specialists have been trained at the company

BUDERUS Schleiftechnik GmbH I.D. grinding O.

7 Direct access to DVS technologies DVS Production South GmbH is a member of the DVS TECHNOL- OGY GROUP, one of the leading system suppliers for metal-cutting processes on powertrain components. Access to the complete technology range of soft and hard machining is a special advantage for DVS Production South. Alongside the wide variety of individual metal-cutting processes available, it is the combination of processes in particular which makes the difference. Thus customised production solutions can be offered for concrete inquiries, provided certain unit quantities and run times are given. BUDERUS Schleiftechnik GmbH I.D. grinding O.D. grinding Thread grinding Hard turning DISKUS WERKE Schleiftechnik GmbH Face grinding Double face grinding Special machining PITTLER T&S GmbH Vertical turning center & Pick-up systems Gear cutting for complete machining PRÄWEMA Antriebstechnik GmbH MACHINES TECHNOLOGY PRODUCTION Gear honing Gear grinding Hobbing/Fly-cutting Chamfering Werkzeugmaschinenbau Ziegenhain GmbH Turning & Combined machining of shafts Motor spindles DVS TOOLING GmbH Tool solutions and technology support for PRÄWEMA gear honing AUTOMATION TOOLING SERVICE NAXOS-DISKUS Schleifmittelwerke GmbH Conventional grinding tools CBN & Diamond tools 12 13

Based on certification in compliance with ISO/TS 16949 and ISO 9001 and long years of experience as a partner to the

The very latest measuring technology and continual employee qualification make sustainable quality management possible.

The apprentices learn everything there is to know about their future profession as cutting machine operators, from A for

8 Based on certification in compliance with ISO/TS and ISO 9001 and long years of experience as a partner to the automotive industry, the consistently high quality at DVS Production South is the pillar of the company s philosophy. The very latest measuring technology and continual employee qualification make sustainable quality management possible. Specialist knowledge for the experts of tomorrow is taught in DVS Production South very own apprentice workshop. The apprentices learn everything there is to know about their future profession as cutting machine operators, from A for axis through to Z for zone of engagement. The high quality standard at DVS Production South is of central importance during apprenticeship training

Mitglieder der DVS TECHNOLOGY GROUP Members of the DVS TECHNOLOGY GROUP DVS MACHINE TOOLS & AUTOMATION BUDERUS Schleiftechnik GmbH www.buderus-schleiftechnik.

9 Mitglieder der DVS TECHNOLOGY GROUP Members of the DVS TECHNOLOGY GROUP DVS MACHINE TOOLS & AUTOMATION BUDERUS Schleiftechnik GmbH Innenrundschleifen Außenrundschleifen Gewindeschleifen Bohrungshonen Hartdrehen I.D. grinding O.D. grinding Thread grinding Bore honing Hard turning DISKUS WERKE Schleiftechnik GmbH Planseiten-Schleifen Doppel-Planseiten-Schleifen Sonderbearbeitung Face grinding Double face grinding Special machining DVS Universal Grinding GmbH Kombinierte Hartfeinbearbeitung für Klein- und Mittelserien Combined Hardfine Machining for small and medium size batches PITTLER T&S GmbH Vertikal-Drehbearbeitungszentren & Pick-up-Systeme Verzahnungszentren Vertical turning centers and Pick-up systems Gear cutting centers PRÄWEMA Antriebstechnik GmbH Verzahnungshonen/-schleifen Verzahnungsfräsen Anspitz-/Hinterlegungsfräsen Internal and External Gear honing Gear grinding Hobbing/Fly-cutting Chamfering WMS Werkzeugmaschinenbau Sinsheim GmbH Service-Dienstleistungen Generalüberholungen Reparatur von Baugruppen Maintenance Machine Retrofit Repairs WMZ Werkzeugmaschinenbau Ziegenhain GmbH Dreh- & Kombinationsbearbeitung wellenförmiger Bauteile Motorspindeln Turning & Combined machining of shafts Motor spindles DVS TOOLS & COMPONENTS DVS TOOLING GmbH Werkzeuglösungen und Technologiesupport für das PRÄWEMA Verzahnungshonen Tool solutions and technology support for PRÄWEMA gear honing NAXOS-DISKUS Schleifmittelwerke GmbH Konventionelle Schleifwerkzeuge CBN & Diamantwerkzeuge Conventional grinding tools CBN & Diamond tools DVS PRODUCTION DVS Production GmbH DVS Technologien in der Serienfertigung für PKW-Komponenten DVS Technologies in mass production for passenger car components DVS Production South GmbH DVS Technologien in der Serienfertigung für Nutzfahrzeug-Komponenten DVS Technologies in mass production for commercial vehicle components DVS INTERNATIONAL SALES & SERVICE DVS Technology America, Inc. DVS Sales & Service in USA, Canada & Mexico DVS Technology (Shenyang) Co., Ltd. DVS Sales & Service in China DVS Technology Europe GmbH DVS Sales & Service in Europe klimaneutral natureoffice.com DE gedruckt PRD EN-HDM 16

SynchroForm V The modular machine for geared drive components

SynchroForm V The modular machine for geared drive components 1 PRÄWEMA Antriebstechnik GmbH In Eschwege in northern Hesse, PRÄWEMA Antriebstechnik GmbH produces and develops machines for machining and