Gearbox manufacturer Kordel relies on the GARANT Setting Bench SB1 for quality inspection
Up to 90 dial gauges are set daily
Kordel Antriebstechnik GmbH has equipped its gearbox production with a Pallet handling system and thus the current shortage of skilled workers Compensated to a certain extent. As a result, it was necessary to improve quality assurance. without sacrificing precision and process reliability. The Hoffmann Group provided the solution with a new method for the digital data transfer of measurement data from the measuring equipment to the horizontal Setting device.
Dirk Strotmann's employees have to use up to 90 dial gauges at the cord Antriebstechnik GmbH on a daily basis. Even with a horizontal This is time-consuming with 12 to 15 different components per day. Thereto In the past, typos and transposed numbers have repeatedly led to Problems. Since the company no longer enters the data manually, but directly from the Comparison medium digitally reads into the presetting device, this source of error is banned.
The family-owned company Kordel Antriebstechnik GmbH produces around 325,000 gearboxes for industrial trucks, agricultural machinery and construction machinery and the with an exceptionally high level of vertical integration for the industry. Around 25,000 Parts are manufactured and assembled in-house – every operation, such as heat treatment, is covered. Dirk Strotmann heads the department Machining of housings at the main plant in North Rhine-Westphalia Dülmen-Rödder. His task: the production of transmission parts and gearbox housings. For this purpose, he has 16 machining centers at his disposal. Several four-axis machines and turn-mill centers as well as a deburring cell in which the housings are post-processed, are part of its machinery.
Decreasing batch sizes
"An order typically has a batch size of 5 to 30 parts. We manufacture but only four parts, if that's what someone wants," says Strotmann. "A lot of customers are now repeatedly ordering smaller quantities instead of placing a large order. place. "So we have to convert more often and also change the reference measuring equipment for Readjust quality controls more frequently. That's why we have created for the area Housing production purchased horizontal setting devices some time ago", reports Strotmann.
Automated set-up, increased clock frequencies
In order to increase the degree of automation in enclosure production, Kordel In 2019 in Dülmen and in 2018 at the Jawor site in Poland, Liebherr installed the PHS 1500 Pro pallet handling system and adapted it individually to its needs. In Dülmen and Jawor, the increasing shortage of skilled workers was the decisive factor for the Automation. The system was designed with two strings in order to achieve particularly high clock frequencies. Both lines consist of a material storage system and a production system, each with a storage and retrieval machine, and communicate permanently via the common master control with each other. They are designed for up to six machines. Currently, there are five identical ones at each of the two locations Machining. The system supplies the machining centers in which transmission parts are produced. made of cast iron and aluminium, drilled and milled, with material – from the warehouse to the machine and back again. The quality controls should be based on the cycle rates of the automated system, without sacrificing quality assurance to have to do.
Accelerated quality assurance
Dirk Strotmann asked himself whether repeated calibration of dial gauges with the same data could not radically simplify data entry. He asked the Manufacturer of its horizontal setting device for a solution – without success: "The didn't manage to do that, and it was the same with three other providers. I have then the measurement technician from the Hoffmann Group, Marcel Haufe, on my problem addressed," says the master machinist.
"That was an interesting question, which I would like to ask at my next appointment with our product manager," recalls Marcel Haufe. "For the Development of new product ideas, we are happy to take up the wishes of our customers. That's why our product managers are very open when a customer has a specific needs." In fact, there was now hope for Kordel as well.
About six weeks later, the news came that a solution had been found. The Hoffmann A few months earlier, at the EMO 2019 trade fair, Group had launched the new horizontal GARANT Setting Bench SB1 presetter introduced.
This makes it possible to display the data of the Print the measurement, including the date and time, on a self-adhesive label and thus mark the measuring device. By scanning the QR code on the label the device automatically adjusts to the measured values stored there – this creates a plus in process reliability and shortens the effort required for repeated calibration. In addition, the GARANT Setting Bench provides a tolerance calculator for because drawings within the framework of the ISO fit systems often only contain the tolerance class (e.g. H7). The tolerance calculator shows, for example, the Dimension 90 H7 is the maximum and minimum permissible dimension (90.035 and 90.00 mm) and the Average value 90.017 mm. The user now selects the appropriate dimension. One There is no need to look up the table book. This saves time and reduces additional costs. Type error.
Digital data entry, increased process reliability
Digital data entry, increased process reliability The three-month practical test was carried out to complete satisfaction: "With the GARANT Setting Bench, calibration is really quick," explains Strotmann. "Our Employees can now keep up with the extreme clock frequencies without stress and the Process reliability has improved. Since we measure the same measurements over and over again, bring the application of the measurement data to the dial gauges and the reading by scanner a real advantage." Only if the article master changes and a new dimension is added to the assortment, a dial gauge must be readjusted and the associated label can be printed. At Kordel, this task is performed by the foreman. He marks daily, which dial gauges are used and takes over the first one for new measurements. Calibration of the dial indicators. To do this, he types in the dimensions on the touchscreen and prints the new Remove the label on the label printer and stick it on the tool. The exact values specifies the computer-aided quality assurance system (CAQ) for it.
Easy for everyone
Since the dial gauges have to be checked regularly during a shift, At both ends of the 45-metre-long production hall, Dülmen has a GARANT Setting Bench SB1. Six employees use the devices per shift. At Kordel, work is carried out in three shifts from Monday to Saturday morning. After The GARANT Setting Bench SB1 in Dülmen was very well received by the employees In January 2021, Kordel ordered two more for the plant in Poland, where the Large-scale production. "There is a great shortage of skilled workers in Jawor and we have to train many new employees. With the Setting Bench this is very fast and process reliability is guaranteed," reports Strotmann.
The GARANT Setting Bench SB1 has been in use at Kordel for over a year now. Strotmann is still enthusiastic: "The device is incredibly useful and the Operation is child's play." The new GARANT Setting Bench SB1 has become a significantly increased process reliability and significantly reduced work stress among the workforce. Also from the customer service of Hoffmann Group, he is impressed. "They listened to our request, they took it seriously developed a solution and implemented it in a timely manner."
Get In Touch