Although it is believed that the ModuleLine system (MLS) developed and produced by Heller is just another type of flexible production system for processing polyhedral parts, in the view of Bernd Zapf, who is responsible for developing this machine system, MLS is not just existing. Some changes have been added to the system, but a new flexible production system.
At present, the demand for automotive products fluctuates greatly, new models are continuously introduced, and the product development cycle is getting shorter and shorter. Automakers hope to find such a production and processing solution: they must have the basic production efficiency of the automatic production line, but also Flexibility in flexible production systems. Of course, investment costs are also a key consideration for automakers.
In fact, the manufacturing cost of a part depends not only on the investment cost of the production line, but also on many other factors, such as operating costs, maintenance costs, and the cost of adding equipment to the later stage. For example, an automobile manufacturer believes that it may take 10 years to recover an investment in a production line. In order to achieve this, they must use the 80% to 85% index to achieve overall equipment efficiency (ie OEE, OEE = equipment availability). × production capacity × quality). Therefore, in the large- and medium-sized mass production of powertrain components, in view of the changing needs of production, automobile manufacturers are considering the investment in automatic production lines, but also consider the use of flexible production processing systems.
Modular composition
When talking about the MLS system solution, Vincent Trampus, vice president of sales for HELLER's US business unit, explained that the system designed primarily for powertrain component production can be seen as either an automated production line or a flexible production system.
The basic element of the MLS system is a processing module consisting of machine tools. The small footprint is one of the advantages of the MLS system. These machines include: Single-axis machine tools MC 10 and MC 20 with a spindle stroke of 630 mm and 800 mm respectively. The machine is relatively compact and has a width of only 1.8 m. The MCT 10 is a twin-spindle machine that is integrated into a two-axis machining center based on the MC10 machine. The MC 200 is a reinforced version of the MC20 machine. It can be equipped with a 4:1 gearbox and can generate a torque of 800 Nm. Use a large size tool to boring the cylinder or crankshaft and milling the top surface. MPC machines are designed with multi-axis machining heads. Other auxiliary equipment includes tool magazines, tool changers and workpiece changers, all of which are common to machine tools. In addition, there is a trunnion device with a rotary table consisting of two additional axes (A and B), combined with the three basic elements of the machine, the MLS system has a commissioning card. 5-axis and pentahedron processing capabilities. More importantly, the MLS system can also be set to wet processing, dry machining or micro lubricant processing (MQL) by using different types of spindles.
The automation system is an important part of the MLS system, mainly in the automatic transfer of parts and the transfer of tools. The system uses a linear motor drive, the power transmission of the motor uses contact rails, and control signals are sent over the air. Thanks to the unwound towed cable, this design not only minimizes maintenance requirements, but also facilitates further expansion of the production system when needed.
Investment cost and production capacity
Compared to automated production lines, the structural advantages of MLS systems are reflected at the beginning of the project. That is to say, the production capacity of the automatic line is the production capacity of its existing production equipment, and the production arrangement can only be solved by the existing automatic production line. The initial investment in planning an automated line is considerable. However, a project usually takes several months, or even a year or more, to achieve a given production capacity, which means that the equipment is always under production capacity. run. However, the initial investment cost of the MLS system is 1/6 compared to the automated production line. Each workstation on it, including the automatic part transfer system, can be installed. Once the production process is determined, additional equipment can be installed if additional equipment is required.
Figure 1: MC10 Machining Center
But it doesn't mean that MLS is different from other machining center-based production systems. Mr. Trampus said that in the case of an elevated loading system, it has been proven by practice that some of the system's processes seem to be implemented more than the MLS system. It is expensive and complicated. This is because, for an overhead loading system, the entire expected automation device is purchased. The advantages of the MLS system are not limited to this. If a flexible production system is used and compared to an MLS system that produces the same capabilities, the MLS system can save an average of 37% of the floor space. Overall, if the system has an annual production capacity of 50,000 parts, the MLS system can help users save 18%.
Figure 2: The automated system for transferring workpieces and tools is driven by a linear motor without cables that are prone to wear.
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