四台格劳博五轴联动通用加工中心G750，一个可容纳120个800x800托盘的托盘存储系统，以及一座能够为四台加工中心提供刀具的中央刀库（可容纳870多把HSK-A100刀具）——这些主要特征来自于多贝玛亚（Doppelmayr）家族企业的一个互连系统。该系统用于生产由难加工材料制成的各种核心部件，以实现索道工程领域的大批量生产。
也许并没有多少人了解奥地利的沃尔福特（Wolfurt）这座小镇。位于此地的Zui大雇主——多贝玛亚拥有近130年的历史。相比于小镇而言，这座企业可能更广为人知。
对于一家传统的家族企业来说，质量、可靠、信誉以及安全等价值观深深植根于企业的经营理念之中。之如此，是因为作为索道工程制造商，多贝玛亚几乎只处理与安全相关的部件，其中所要确保的安全性在很大程度上取决于所使用的材料——由高回火锻钢制成的工件。“这种材料很难加工，”多贝玛亚机械生产部负责人NicolaySchnitzer说到，“许多机床制造商都很难成功尝试。”
以恰当的时间带来正确的工件
多贝玛亚的项目开始寻找一个互连系统，来取代现有机械设备中的两台机床，以满足不断增长的产能需求。
大体来说，有几家制造商拿到了相关组件，以确定在设计和工时研究中做出合理选择。“我们的态度和发展历史都是相对传统的，”多贝玛亚生产部门ündel在谈话中明确说道，“我们确实不想在生产中使用新的品牌。”
如此，基本的一些问题仍然存在，比如谁能提供什么？谁拥有合适的主轴？谁的机床具有理想的动态性？以及谁可以为系统提供托盘交换器？工时研究的结果是明确的。几乎每个供应商都能够为用于做出决定的参考工件提供合理的特定加工时间，但格劳博的G750通用加工中心是迄今为止Zui具动态性的机床。它可以将工件加工时间缩短45%。
格劳博五轴联动通用加工中心 G750
令人信服的格劳博G750
NicolaySchnitzer说道：“随着第二代G550五轴联动通用加工中心的投入使用，格劳博技术已经给我们留下了深刻的印象。”
工作台的运动学设计与卧式主轴相结合，使我们能够仅通过简单的冲洗和旋转循环，即可使托盘在加工后变得如此干净，以至于在托盘或工件上几乎找不到残余的切屑。这也使得冷却液的残留量降至Zui低。轻松的清洁过程节省了大量成本——对于单个托盘来说，这可能没什么大不了的，当一个周末过后，系统中有80个成品托盘，每个托盘只需要十分钟的清洁时间就可以重新用于加工，这些累计起来则可以节省很多时间和成本。
从左到右：多贝玛亚项目经理，Nicolay Schnitzer；多贝玛亚应用工程师，DominikSohler；格劳博在奥地利的代理 - Alfleth公司，Dietmar Hagspiel；格劳博区域销售经理，ChristophDemmeler。
多贝玛亚选择格劳博的另一个非常重要的原因是：G750的空间需求是所有候选机床中Zui小的。是因为机床配备了内置冷却液箱、排屑器和纸带过滤器，有助于缩短安装时间，安装空间非常紧凑；是，机床可以直接在工作区上料，这使得不需要在机床上安装额外的托盘交换器，这也意味着安装的空间需求更小。
独特的G模块设计使多贝玛亚能够实现多种夹紧方式，这需要旋转轴可以旋转到负角度的超大范围，这也是其他机床所无法做到的。“这一事实为我们提供了新的可能性来重新考虑夹紧方式和机床布局，”Schnitzer回忆道。多贝玛亚选择G750的另一个动机是：它可以从顶部装载，从而能够在自动化系统遭遇机器人故障时，仍能作为独立机床继续运行。
格劳博五轴联动通用加工中心G750的具体优势是显而易见的。其Zui令人印象深刻的特征有：
- 高稳定性（面对加工材料带来的挑战，这一点很重要）
- 动态的运动学设计，可将参考工件的加工时间缩短40%以上
- 显著减少转换和重新装夹时间（由于减少了手动清洁的工作量）
- 无需托盘交换装置，可选择直接装载
托盘存储系统和中央刀库
通过自动化提高效率和生产率也是多贝玛亚生产中所关注的重要问题。鉴于给定的结构条件，多贝玛亚的Zui终要求之一是：在一个外部托盘存储系统和一个中央刀库中，为120个托盘和大约870把刀具预留空间。G750较为轻松地解决了这两个决定性问题，因为格劳博机床可以安装在生产线中，并且可以在没有托盘交换器的情况下实现自动化。这不仅可以节省托盘交换器所需的费用，还可以对工作区域的合理进入方式保持不变，这对于处理新工件来说是一个关键点。
关于中央刀库方面，其所关注的主要是成本效益。四台G750通用加工中心各自都拥有一个带有60个刀位的换刀装置，但没有额外的外部刀具存储系统。Schnitzer说到：“就空间要求而言，在每台机床上都额外配有200个刀位的刀具存储系统是不现实的。”该系统需要实现的功能是可以容纳870把刀具的中央刀具存储系统和用于运输刀具的机器人组合。由于每台机床都有自己的刀库，其中包含60把刀具，有共计约1110把刀具可用。龙门桁架系统可根据需要将刀具从中央刀库运送给相应机床。
可容纳870把HSK-A100刀具的中央刀库使得每个工件可以在任意机床中进行加工，为整个系统带来了极大的柔性。机器人额外配备了一个背袋，以实现更加快速的刀具装卸。
“具有先进设计理念和可靠服务的动态性机床成功将我们说服。在我们的互联系统中，冷却液和切屑残留完全可以忽略，这要归功于卧式主轴和旋转工作台。与Fastem系统的连接为我们提供了极大柔性。Zui后，该设计也是一个可以为我们Zui大程度节省空间的解决方案，让我们充分利用每一平米。”
Karl-Heinz Zündel
多贝玛亚生产和物流部门经理
“通过四台互连的G750，我们将参考工件的加工时间缩短了约45%，从而实现了成本效益的Zui大化。系统操作人员当然也将会非常乐意看到工件和夹具在清洁状态下从系统中出来。拥有120个托盘空间和中央刀库的完整系统为用户提供了卓越的灵活性，可在下一台可用机床上加工任意工件。该设计也带来了十分理想的布局！”
Dietmar Hagspiel
格劳博西奥地利销售部
多贝玛亚系统的特殊之处在于，每台机床都可以使用任意一把刀具，每个工件都可以在任何机床上加工。在机床上省略托盘交换器的决定可以显著优化布局（格劳博提供了所必需的Zui紧凑的安装空间），保持了对工作区域的合理进入方式和可见性。由此带来的亮点是，由于不使用托盘交换器，格劳博机床的尺寸缩短了约一米，这在较为紧凑的空间限定下是非常有效的。
多贝玛亚集团（Doppelmayr）
多贝玛亚集团在客运和货运索道工程以及高科技内部物流解决方案方面处于质量。
全球3403名员工
8.72亿欧元销售额
位于奥地利的沃尔福特
来自全球多贝玛亚/加拉文塔（Garaventa）的15100个系统
全球50个国家/地区设有子公司或公司集团办事处
可以在96个国家发现多贝玛亚/加拉文塔索道
格劳博五轴联动通用加工中心G750
加工铝制航空航天机翼框架视频
格劳博Zui新动态
English Edition
FOUR INTERLINKED G750 GROB MACHINES SQUARE THE CIRCLE
Four G750 GROB universal machining centers, one pallet storagesystem for 120 800 x 800 pallets and a central tool magazine withover 870 HSK-A100 tools to supply the four universal machiningcenters. These are the impressive features of an interlinked systembelonging to the Doppelmayr family business for production of corecomponents of various parts made of difficult-to-machine materialsin very large quantities for ropeway engineering.
Not many know of the small town of Wolfurt, Bregenz inVorarlberg, Austria. Its biggest employer, Doppelmayr, the almost130-year-old world market leader for ropeway technologies, isprobably more well-known to many more. A traditional family companyfor whom values like quality, reliability and trustworthiness, aswell as safety, are firmly rooted in the company philosophy.
And that for good reason. As ropeway engineering manufacturers,Doppelmayr deals almost exclusively with safety-related componentswhere the guarantee for the required safety is to a great partdependent on the materials used – parts made of highly-tempered,forged steel. "This material is difficult to machine, " saysNicolay Schnitzer, Mechanical Production Department Head atDoppelmayr, "and many machine tool manufacturers have had a hardtime trying."
The correct speed for
the correct part
Project Manager Nicolay Schnitzer went hunting for aninterlinked system to replace two machines from the existing fleetof machinery and satisfy rising capacity requirements. Essentially,there were several manufacturers in the running getting thecomponent to determine the best alternative in concept and in atime study. "And this despite that fact that our attitude andhistory is relatively traditional," assures Doppelmayr ProductionDivision Manager Karl-Heinz Zündel during talks, "and we didn'treally want to use a new brand in production." Still, thefundamental questions remained, such as 'who provides what?', 'whohas the proper spindle?', 'whose machine has the suitabledynamics?', and 'who can provide a pallet changer for thesystem?'.
And the results of the time study were unambiguous. Even thoughalmost every provider was able to best the specified machining timefor the reference part used to make the decision, the G750universal machining center from GROB was by far the most dynamic.It could reduce the part machining time by 45 %.
The G750 with convincing
arguments
"With a second-generation G550 universal machining center inuse, we had already been impressed with GROB technology," admitsNicolay Schnitzer. The table's kinematics, combined with thehorizontal spindle, lets us get the pallets so clean aftermachining via a simple rinse and swivel cycle that virtually noremaining chips can be found on the unit, the pallet or the part.This reduces coolant carryover to a minimum. The savings from thesimplified cleaning process are enormous. This may not be a bigdeal for one single pallet, but when 80 finished pallets are in thesystem after a weekend and each pallet only takes ten minutes toclean until retooling can be carried out, those are big savings insum.
Nicolay Schnitzer, Doppelmayr Project Manager; Dominik Sohler,Doppelmayr Application Engineer; Dietmar Hagspiel, Alfleth GmbHRepresentative for GROB in Austria; Christoph Demmeler, GROBRegional Sales Manager (from left to right)
One more very important reason for Doppelmayr was the fact thatthe G750 required the least space of all machines presented. Forthe first part, the machine is equipped with a builtin coolanttank, a chip conveyor and a paper band filter that aid in keepinginstallation times short and the installation space very compact.Secondly, the machine can be loaded directly in the work area. Thismakes an additional pallet changer on the machine unnecessary,which in turn translates to a smaller installation space. Theunique G-module concept lets Doppelmayr implement multiple clampingsetups requiring a large swivel range of the rotary axis into anegative range, which could not have been done on other machines."This fact offered us new possibilities necessitating a re-think ofthe clamping options and the unit layout," Schnitzer recalls.Another Doppelmayr motive for the G750 is that it can be loadedfrom the top, giving it the ability to continue operation as astand-alone machine despite the automation system in the event of arobot failure.
All in all, the specific advantages of the GROB G750 universalmachining center were clear. The most impressive features were andare:
high stability (this is important due to the machiningdifficulty posed by the material)
dynamic kinematics and the corresponding reference partmachining time reduction of over 40 %
significantly reduced conversion and reclamping time (due to thelarge manual cleaning workload reduction)
the option for direct loading with no pallet changer
Pallet storage system and
central tool magazine
Increasing efficiency and high productivity through automationare important questions in production at Doppelmayr as well. One ofthe definitive requirements for Doppelmayr due to the givenstructural conditions was therefore: Making space for around 870tools in an external pallet storage system with up to 120 palletsand a central tool magazine. Two decisive points relatively easilysolved with the G750, as the GROB machine can be installed in frontof the line and can automate without a pallet changer. This notonly saves money on a pallet changer, but keeps proper access tothe work area unchanged, an important factor when working in newparts.
On the subject of the central tool magazine, the primary concernwas cost-effectiveness. Each of the four G750 universal machiningcenters has a tool changer with 60 pockets, but no additionalexternal tool storage system. "An additional tool storage systemwith 200 tools on each machine would not have been possible interms of spatial requirements," said Schnitzer.
The feature to point out of this system is thus the combinationof a central tool storage system that can hold 870 tools and arobot for transport of the tools. As each machine also has its owntool magazine with 60 tools, approximately 1,110 tools can beaccessed in total. A system of gantries transports the tools fromthe central storage system to the respective machine asrequired.
The central tool magazine with 870 HSK-A100 tools providesmaximum flexibility for the complete system, as every part can bemachined in any machine. The robot is additionally equipped with aback pouch for even faster loading / unloading of tools.
"Dynamic machines with a good concept and reliable serviceconvinced us. Coolant and chip carryover is negligible in ourinterlinked system thanks to horizontal spindles and the swivelingtables. The linking with the system from Fastem gives us maximumflexibility. In the end, this concept was also the solution thatsaved us the most space for getting the most out of every squaremeter."
Karl-Heinz Zündel
Production and Logistics
Division Manager
"With the four interlinked G750 units, we achieve maximum costefficiency by reducing machining times on the reference part byabout 45 percent. The system operators are certainly also very gladthat the parts and clamping fixtures come out of the system inclean condition. The complete system with its 120 pallet spaces andthe central tool magazine gives the customer maximum flexibilitydue to machining for every part being possible on the nextavailable machine. The perfect layout is also a very positiveside-effect!"
Dietmar Hagspiel
GROB Sales, West Austria
The particularity about the Doppelmayr system is that every toolcan be used on every machine and any part can be machined on anymachine. Deciding to omit a pallet changer on the machines allowedfor significant optimization of the layout (GROB provided the mostcompact setup space required) while maintaining optimal access andvisibility into the work area. And the highlight is: The GROBmachines are about one meter shorter without the pallet changer,which is really helpful with the relatively small spatialprovisions.
Doppelmayr Group
The Doppelmayr Group represents quality, technological andmarket leadership in ropeway engineering for passenger and materialtransport, as well as high-tech intralogistics solutions.
3,403 employees worldwide
€ 872 million sales (GJ 19 / 20)
Located in Wolfurt / Austria
15,100 systems from Doppelmayr / Garaventa world-wide
50 countries worldwide have a subsidiary or a representative ofthe company group
96 countries Doppelmayr / Garaventa ropeways can be found in