Customers / Case Studies

Keymaker

Requirement:

Automatic placement machine for a key milling machine

The challenge:

• high process reliability and easy to operate
• precise insertion of the key bit into the clamping jaw of the machine
• double-sided milling of the key bit
• plastic-coated bow, making the piling of the keys impossible

Scope of supply:

Construction of the machine and delivery of the finished components for meanwhile 6 machines.

Device set or assembly line for the assembly of electromechanical components

Requirement:

Development of a production line for the assembly of mechatronic components on the basis of a specification book and a 3D-model of the component(s).

The challenge:

Throughput time, ergonomics, process and quality assurance are very tight.

Scope of supply:

• Mounting device for mounting and clamping
• Screen printing space for gluing
• various product mounting frames
• Clamping frame for continuous furnace
• Pressing tools
• Design of the continuous furnace

Transport racks

Requirement:

Development of a modular truck transport rack suitable for various variants, which fulfills all security measures in connection with storing, lifting, loading and transporting paper rolls up to 50 tons in weight.

The challenge:

• modularity for variants
• light in weight
• seeworthiness
• to guarantee simple, practical and safe handling as well as
• an optimal securing of the load

Scope of supply:

Development, design of 10 variants, calculations and design-accompanying documentation for CE marking.

Industrial sewing machine spare parts

Requirement:

Engineering and procurement of high-performance spare parts for industrial sewing machines, which can perform up to 6000 strokes per minute.

The challenge:

• high precision
• easy replacement by the technician without prior customisation or rework is required
• increasing the service life
• ensuring optimal functionality through 100% control
• threads must not be damaged or torn

Scope of supply:

ongoing amongst other things

• cutting knife
• thread guides
• thread catcher
• needle holder
• loop strap
• sewing foot

Housing and screw

Requirement:

• Transfer of the prototype drawing to the production drawing and procurement of the parts

The challenge:

• Precision deep hole drilling 11d, diameter H8, Ra 1.6 in both parts
• Run-out brass part
• Cost pressure

Scope of supply:

• Prototype series 10 sets
• Small series 50 sets each

Transport shafts

Requirement:

New production or repair of transport shafts

The challenge:

• Lightweight construction dm 40x1200
• perfect, long-lasting bearing seats
• 22 precisely running punctures
• Total run-out from the body of the shaft to the bearing end 0.03

Scope of supply:

• ongoing repair and new production of different variants
• Redesign for faster repair
• Bearing end quick-change system (10 minutes repair time)

Pneumatic clamping cylinder piston diameter 220, sealing system

Requirement:

• Reconstruction and improvement engineering
• fast procurement
• Customisation of the components and
• Integration into the holistic maintenance management process (IKIPM®- Performance process)
• Lifetime - monitoring

The challenge:

To completely rework and improve the existing, no longer functioning components; difficult procurement due to special requirements. (Component size, heat treatment, honing, hard chrome plating)

Scope of supply:

2 complete pre-assembled components

Worm drive

Requirement:

Housing measurement and reconstruction of the components and rapid procurement of a pair of worm shafts and worm wheels, including all bearings and seals

The challenge:

Deadline pressure and therefore zero error tolerance

Scope of supply:

• worm shaft
• worm wheel
• 4 storage and sealing systems
• flat sealing set for housing and bearing cover

Predictive Maintenance, IKIPM®- Performance process and spare parts for a production plant

Requirement:

Improve and ensure the lifetime of wear parts of a high-performance production plant within the maintenance intervals. Extension of the maintenance intervals and increase of productivity

The challenge:

Supply of optimised maintenance spare parts with extended and calculable service life

Scope of supply:

• redemption of used spare parts
• evaluation of wear patterns
• improvement engineering
• measurement protocol
• improved, customised maintenance spares
• annual report and strategy on how to proceed

Special crane / load hook

Requirement:

Development of a special crane/load hook for lifting and manipulating of particular supported cylindrical rollers

The Challenge:

• Very slide but adequate firm construction design incl. PU covering
• Manipulation protection in any position
• Extensive technical documentation

Scope of supply:

• 6 coated special hooks
• Legal / statutory documentation
• Prototype intitial tests and periodic tests

Miniature cross table

Requirement:

Development and delivery of a 44-part miniature group of components with a total weight of 12.9kg for uptaking and shifting of a sensor inside a cubus (d6xw6xh9mm) 

The challenge:

• repeat accuracy and shift accuracy less 0.01
• rapid divisibility from the ground plate
• free of mechanical clearance and rigidity during operating
• as low weight as possible
• exact miniature scales for metering with partition 0.2
• robust and practical design because of frequent changes of the sensor

Scope of supply:

• development, construction
• production, mounting and initial operation of 3 group of components

Spoiler support plate

Requirement and solution:

• Re-engineering of broken spoiler support plates and winglets of a racing car that were loaded with 250kg of wind pressure during racing. Aircraft grade aluminium was used. All edges have been rounded and polished by hand.

Challenges:

• High vibrations cause stress cracks
• Very high moment load on the lower fastening eyes due to 250kg of wind pressure acting on the winglets
• Lightweight construction requires high-strength material
• Redesign of the rather complex logo to facilitate producing it by stencil

Scope of supply:

• 4 sets of support plates and winglets
• Redesign, production and surface finish
• Pre-assembly

Air Quality Measuring Machine

Requirement:

• Modernization of a 30-year-old measuring machine
• Manufacture and assembly of 4+9 units in 3 months
• Maintain market price
• Modern and contemporary design

Challenge:

• Reduce the cost of complex, expensive welded components and parts
• Replace obsolete components
• Improve the accuracy and reliability of the handling system
• External footprint dimensions including packaging: 800x1200 mm for air transport
• Existing sensors and filters must remain in use
• Suitable for various climate zones
• Manufacture and testing of a prototype is not possible due to time constraints

Scope of delivery:

• Reverse engineering, design
• Procurement and assembly
• 13 systems