To define an angle heads’ optimum time of maintenance in crankcase manufacturing, MTU Friedrichshafen uses the BENZ operating hours counter. The digital indicator supports MTU Friedrichshafen in carrying out preventive servicing more efficiently and in reducing possible disruptions in the production process – e.g. caused by the breakdown of units – to a minimum.
Haslach i.K., 23.10.2014. In crankcase manufacturing machining with precision to the nearest hundredth is an absolute must. This places high demands on the technical features of the tools used. Parameters such as concentricity, stiffness etc. directly influence the machining quality of parts. Tools that are used often or in diverse processes have to be checked and serviced regularly to guarantee their functionality and precision. But when is the right time to do it?
Precisely that is the question Ricci Martin, responsible for tool planning at MTU Friedrichhafen’s crankcase manufacturing, asked himself. MTU Friedrichshafen GmbH, a core brand of Rolls-Royce Power Systems AG, is one of the world’s leading suppliers of large-bore diesel engines with an output power of up to 10.000 kW. The engines are used in trains, ships, emergency power generators or in agriculture. Those engines are characterized by being extremely robust, having low fuel consumption and favorable emission values. Until a raw part turns into a ready for assembly crankcase, 3 machining centers and 7 different settings are necessary. During the fully automated machining, tools mill the surface of the work piece. Therefore, MTU Friedrichshafen relies on BENZ angle heads.
Due to the amount of angle heads and the resulting frequent tool changes the operation times of the angle heads could have only been monitored via the machine control, investing enormous research and documentation efforts. That is why MTU sent their angle heads to BENZ’s service department quite regularly, even if an angle head was only rarely used. This less than ideal situation forced Ricci Martin and the technology specialists from BENZ to look for an easier solution to monitor operation times. The result is a digital operating hour counter that is directly integrated into the angle head’s housing. As soon as the spindle starts turning, the counter gets activated. Users benefit from fast and exact data of an angle head’s operating time, directly at the unit – a requirement to strictly monitor the unit and to implement efficient and preventive maintenance. “Thanks to the operating hours counter we know at once if an angle head achieved the recommended operating time”, Ricci Martin describes this technology’s advantages. “We are able to better plan inspections and to avoid possible failures in our production process.” For him it is clear that all MTU angle heads will be upgraded with the new counter. “In the future, an operating hours counter for sure will become a standard feature. It is an easy but comfortable solution that reduced our expenditure on testing and maintenance significantly.”
More than 30 years of experience in developing and producing CNCmachine tool accessories make BENZ GmbH Werkzeugsysteme one of the leading system partners in the Metalworking-, Woodworking and Composites Industry. The sophisticated product portfolio reflects high quality and innovative precision engineering. It includes static and live tools, exchangeable units, such as angle heads, multi spindle heads, modular quick change systems and large drilling heads, as well as 2-axis CNC-NC heads. The combination of modern management and advanced, innovative engineering has transformed this traditional tooling company with over 250 employees into an innovative, growing enterprise. Clear organizational structures, yet room for creativity allow efficient and quality-oriented processes. For many years, the concept of “innovation”, “precision” and “passion” has been applied in daily operations, which is reflected in the company’s products.
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