Perfectly integrated, process optimized
Darmstadt, September 2017 – To meet the increasing requirements for quality control of its precision tools and tool holders, the renowned tool manufacturer LMT Kieninger has decided to purchase another balancing machine from Schenck RoTec. The customer opted for the compact Tooldyne all-in-one system. Its scope and a few additional customized features meant it could be perfectly integrated into the production process.
The new system was required as a flexible option to cover spikes in demand, and needed to be integrated into existing processes seamlessly. Giuseppe Scarpulla, who heads up tool holder production at LMT Kieninger, says: "Apart from basic requirements such as a high degree of measuring accuracy and safety, aspects such as interconnectivity and data handling were top of our wish list". Schenck RoTec's latest, fully equipped version of Tooldyne meets these requirements.
In the German city of Lahr, the balancing process takes place immediately after assembly and prior to final inspection of the tools. Each tool is checked, ensuring 100-percent quality control. Tooldyne's lean design is suitable for a wide array of rotating tools. These may be up to 30 kg in weight and up to 600 mm in length (incl. adapter), with a maximum diameter of 400 mm. Unbalance measurement is performed in one and two planes with spindle speeds of up to 1200 min-1, delivering excellent results: the smallest achievable residual unbalance is 0.5 gmm/kg, which corresponds to just 0.5 µm eccentricity of the center of gravity.
Tooldyne comes equipped with a raft of features that are important for modern data handling. These include an Ethernet interface, statistics in CSV file format, the export of rotor data, and a balancing report. Another great advantage for facilitating system and process integration at LMT Kieninger was that Tooldyne runs on MS-Windows®. Though unusual in this market segment, many users see this as an attractive feature. "It enables us to connect the machine quickly and easily with the IT system in our production. Plus it has ensured a seamless data flow from the outset – without any time-consuming configuration work", highlights Giuseppe Scarpulla.
To optimize test report administration, Schenck has added a bar code reader at the customer's request. "Thanks to this additional feature, we can now scan the bar codes of our routing slips directly at the balancing machine and automatically transfer all order and product data into the test report. Manual input procedures are thus no longer necessary, which saves a lot of time, prevents errors and makes the process significantly more efficient", explains production manager Scarpulla.
Tooldyne has been used in Lahr for about six months now and is rapidly becoming a permanent fixture in quality assurance. "Here, everything is clearly geared toward efficiency and process reliability – from plug & play commissioning and user-friendly operation to low energy demand and minimal service effort", says the production manager.
Efficiency from A to Z
Efficiency is certainly one of Tooldyne's strong points. Take the impressive pneumatic clamping mechanism, for instance, which draws the tool placed on it into the adapter and positions it accurately. This solution developed by Schenck RoTec not only speeds up the process but also guarantees reproducible, highly accurate unbalance measurements.
The touch panel of the CAB measuring unit ensures both efficiency and ergonomics, and can be easily moved into optimum position for data input. It uses clear symbols and intuitive menu navigation.
The touch panel of the CAB measuring unit uses clear symbols and intuitive menu navigation.
Another efficiency factor of Tooldyne is its perpetual calibration. This eliminates the need for time-consuming tool-specific calibration runs before or during balancing and significantly reduces machining time. Giuseppe Scarpulla adds: "Once the tool data has been entered, we can start measuring straight away – no waiting required. Following the unbalance measurement, the machine clearly and accurately displays the correction position via a line laser. This means we are ready to continue."
At LMT Kieninger, Tooldyne is integrated into Schenck RoTec's comprehensive service and maintenance program. This includes not only quick spare parts supply but also 24/7 remote diagnosis, enabling the plant engineering firm to get an update on the state of the Tooldyne system at any time.