With a fully automatic machine in modular design Philip Hafner, which takes on measuring, assembly and labeling tasks, among other things, are the new ones Lifting rotary modules from Dr. Tretter for use. These carry out linear, rotary and positioning movements in a compact unit. Because the designers can build extremely slim, the machine works very dynamically. Users achieve fast clock speeds and high energy efficiency.

Contents

• Customer-specific production measurement technology from Philipp Hafner
  • Fast work processes required
  • Keyword: Downsizing
• Lift-turn module for dynamic processes
  • High clock rates and extremely service-friendly
  • More than just delivered
    
    

Customer-specific production measurement technology from Philipp Hafner

Philipp Hafner GmbH & Co. KG from Fellbach near Stuttgart in Swabia is one of the leading manufacturers of customer-specific production measurement technology. The family-run company can look back on a 90-year successful company history. “The demands on measurement technology have increased significantly in recent years,” sums up Ulla Böhringer, Managing Partner at Philipp Hafner GmbH & Co. KG. “Especially in the Automotive industry The tolerances on the components are becoming ever tighter, and at the same time the variety of workpiece variants is increasing.”

The Swabians' core competence lies in: tactile measurement narrow tolerance workpieces: The machines precisely record the geometry of three-dimensional parts. This is necessary, among other things, for controlled production processes. The special feature is that these systems are not located in air-conditioned measuring rooms at customers' premises, but are integrated directly into production lines.

This means that they have to perform reliably even when there are temperature fluctuations or dirty surfaces, because even the smallest deviations from the permissible values ​​can significantly disrupt the processes or lead to damage. The users predominantly come from the automotive industry. The components to be measured can be found in critical areas such as the steering, axles, engine, etc Powertrain right down to the rims in the wheels.

Philipp Hafner, for example, works at the Fellbach location 120 employees. They develop the machines, assemble them and put them into operation - always in close cooperation with the users. “With fully automated systems, the throughput times can be six to twelve months,” explains Ulla Böhringer. As a rule, these are individual solutions, more rarely also small series. The majority goes to users in Germany, up to 30% go abroad - and the trend is rising. Internationalization is playing an increasingly important role for the company.

Fast work processes required

“What sets us apart?” Ulla Böhringer doesn’t have to think about it for long. “We have a very high level of advisory competence and can develop systems that exactly meet the wishes and requirements of our customers.” This also includes a new concept of a fully automatic system – especially for pistons in internal combustion engines. Not only can she measure them, but she can also assemble piston rings, bolts and circlips, weigh the pistons, mark them with ink or laser and then check them using camera technology.

Igus linear guide as a quiet, maintenance-free alternative

“Because this is not a classic special machine for production measurement technology, we are achieving an innovative new development with this system,” explains Tim Eissele, Project Manager Construction at Philipp Hafner. The development consists of an up to 100 m long transport system with workpiece carriers. This connects individual stations that the user can adapt to their requirements and expand at any time if necessary. The project manager takes a workpiece carrier, places it on the conveyor belt and places the component, namely a piston for an automobile manufacturer, on it. “The customer expects high processing quality in an extremely short time,” he says and starts one of the stations.

The workpiece carrier is pulled into the station by the transport system via a pull-in unit and docks there. A holder moves through a hole from below and lifts the piston until it reaches the mounting position for the respective piston ring. “The system doesn’t just lift the workpiece to the appropriate height,” explains Tim Eißele. “Depending on which station it is, it has to go to a certain one Angular position positioned or rotated 360 degrees.”

Keyword: Downsizing

“Whether the respective station is assembling, measuring or carrying out other steps, the movements must be quick and dynamic in order to be able to meet the required cycle rates,” explains Tim Eißele. While researching suitable components that could carry out these movements, the designers came across the new lifting and rotating modules from their supplier Dr. Tretter from Rechberghausen, almost 40 km away.

In the modules, the spindle forms together with the torque shaft one unity. This allows you to implement both separate and combined movement sequences such as positioning, linear and rotary movements. “Conventional solutions usually require at least two elements for translation and rotation,” says Holger Schmidt, technical sales at Dr. Tretter, who is supporting Philipp Hafner on this project.

An linear guide For example, the vertical movement is implemented, a spindle axis the horizontal movement, and a rotary bearing is responsible for the rotation. "In addition, the number of components would take up much more space with a conventional system and the drives would have to be designed accordingly in order to be able to move the mass quickly," says Tim Eißele.

The lifting-rotating modules, on the other hand, require little space and the drives can be made significantly smaller due to their lower weight. Design engineers use it to implement very dynamic applications, especially in automation technology, and at the same time achieve precisely positioned movement sequences.

Lift-turn module for dynamic processes

"With the lifting and turning modules, we have expanded our range of torque ball bushings and shafts," explains Holger Schmidt. "These units transmit torques with simultaneous translation and can support them." The manufacturer technology partner combines a Ball Screw with a torque bush. As with the ball screw drive, a helical groove is ground into a solid shaft. There are also four longitudinal grooves as in the torque shaft.

Two rotatably mounted flange nuts are arranged on this shaft. A mother takes on the role of one Ball screw nut, the other that of a torque bushing. Both are controlled by one Servomotor mittels Timing belts driven. Will only the Spindle nut driven, there is a pure stroke movement of the shaft and the piston is raised. If both nuts are driven synchronously, the result is a pure rotary movement of the spindle.

High clock rates and extremely service-friendly

In order to implement the different movement profiles, the lifting and rotating modules are used just a wave necessary. If this is designed as a hollow shaft, the energy supply line can simply be routed through it. “With the lifting and turning modules, we have created a standardized way for this system to feed components from the workpiece carrier to the individual processing cells,” says Tim Eißele. This contributes significantly to achieving the required high clock speeds.

The project manager sees another very big advantage in the better accessibility for maintenance work. Compared to conventional solutions, the lifting and rotating module is slimmer and lighter. There is no need for complex mechanics. This also increases security. “We only have one spindle that goes up and down and rotates – completely uncritical in terms of mass,” emphasizes Tim Eißele. “If the structure were to weigh several kilograms, it would have to be appropriately secured.”

More than just delivered

To be able to develop such economic and future-oriented solutions, suppliers such as Dr. Philipp Hafner Petter very important. "Not only do we get decisive impulses, we can also design more efficiently," says Ulla Böhringer. Suppliers expect speed and reliability. For this the mechanical engineer needs partners whom he can rely on. To Dr. Tretter sets the specialist for over two decades. He appreciates the high quality of the products. Another advantage is the proximity. And because the lift-turn modules are particularly economical, costs are saved. This leads to a price reduction compared to the conventional solution.

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