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REPORTAGE - K&M PRÄZISIONSTECHNIK
About Titanium, Robots, and Pyramids Two EROWA Robot Leonardo loading robots, each operating a GROB G350 five-axis universal milling center, plus a flexible and integrated workpiece palletizing system with a custom-made clamping system - K&M Präzisionstechnik in the southwestern German town of Fronreute is clearly relying on manufacturing processes that are thoroughly thought-out and exactly tailored to its needs. The highest precision to the extent that is technically feasible, perfectionism and quality without compromise - these are the standards that K&M Präzisionstechnik has set for itself. The company belongs to the Müller Group, which was established in 1991 and today consists of four independent companies with more than 100 highly qualified employees. Within the group, K&M Präzisionstechnik specializes in the production of sophisticated turned and milled parts, and is known as a relia-
ble, competent and innovative contract manufacturer. Markus Müller is the second generation at the head of the family-run business. Precision and Quality Sophisticated single parts customized according to the customer’s requirements are produced in both small and largescale batches. Typical materials include plastic and metal, e.g., aluminum, brass, stainless steel, or titanium. Its customers operate in medical technology, aerospace technology, mechanical engineering, and the electronics and sensor industries. Spinal implants as well as bone screws, nails, and implants made of titanium are but a few concrete examples of medical technology worth mentioning. Long-term partnerships have been established with many customers, two thirds of which operate in Germany, the rest mainly in other parts of Europe.
The EROWA loading robot is placed laterally on the GROB G350 and thus offers operators easy access to the manufacturing cell.
REPORTAGE - K&M PRÄZISIONSTECHNIK
Titanium and Stainless Steel „Manufacturing sophisticated parts made of hard-to-cut materials could be considered as one of the company‘s specific specialty areas,“ says Ludwig Jehle, who manages a production department at K&M. According to him, chip formation in titanium constitutes a major challenge that requires precise and empirical selection of the right tool. In addition, a special cooling lubricant must be used due to the high process temperatures. „Especially when it comes to high precision on complex geometries, things become particularly challenging with titanium. But it‘s worth it!“ The main areas of application are engine components in the aerospace industry, chassis and frames in the automotive industry, and implants in the medical technology industry. „The main motivation to use titanium is its light weight,“ reveals Ludwig Jehle. „Its specific weight is only 60% of that of steel, and it can therefore be used in any application that requires high strength at a reduced weight.“ EROWA Comes into the Picture K&M Präzisionstechnik has taken its first steps in the direction of automation at a relatively early stage. Its collaboration with EROWA dates back to 2005. „However, we‘ve intensified our efforts in this respect mainly in the last few years,“ continues Ludwig Jehle. „We acquired an EROWA Robot Leonardo in
Marc Schraudolf, machine operator at K&M, and David Estermann, EROWA product specialist for custom clamping solutions.
2014 and another in 2017. Since this last acquisition, we‘ve been working with the EROWA process control system JMS 4.0 ProductionLine.“ The goal of automation above all consists in increasing machine running times and reducing throughput times by decreasing the retooling work: „To remain competitive, we strive to continually optimize our manufacturing processes - and that means equipping the company with advanced technologies and machines,“ says Ludwig Jehle. Automation is intended to enable round-the-clock
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production - 24 hours a day, 7 days a week. „More specifically, we want to manufacture prototypes and small batches during normal working hours and let the larger batches run overnight or over the weekend.“
The EROWA UPC chuck on the machine table ensures precise positioning of the workpiece carrier.
Leonardo on GROB The two GROB G350 five-axis universal machining centers, each equipped with an EROWA Robot Leonardo pallet loader, provide a rather classical interpretation of this task at K&M. How the machines are to be used as efficiently as possible in day-to-day operation was defined together with RINK Werkzeugmaschinen. „We maintain a longstanding partnership with Hans-Herman Rink,“ explains Thomas Lüscher, Key Account Manager at EROWA, who was tasked with the project. „He is an energetic local dealer and offers competent support.“ The choice fell on the EROWA Robot Leonardo model with a magazine capacity of 32 EROWA UPC 320x320 mm workpiece carrier pallets. „The Leonardo pallet loader combined with the EROWA UPC workpiece palletizing system is an exceptionally productive and optimally matched
The fixture equipped with the self-centering vise placed at a 45-degree angle offers excellent access to workpieces during five-axis machining.
automation solution for loading the GROB machines,“ comments Thomas Lüscher. The robot features multi-level magazines and handles transfer weights of up to 120 kilograms. It thus covers a very broad range of parts. The automated gripper change also allows for two different pallet types to be used.
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„EROWA manufactured the clamping pyramids from scratch and supplied them ready for use within two months following the order.“ „The advantages they provide are remarkable,“ says Ludwig Jehle: „Unlike before, 2 to 3 times more workpieces are set up for machining on a single pallet. Implementing the 4-way clamping pyramids has thus resulted in the robot performing fewer swapping operations, the machine operating unmanned for longer periods of time, while at the same time considerably reducing throughput times. We also have additional machine capacity available for further orders. We are really satisfied with this solution.“
Loaded clamping pyramids in the robot‘s magazine are ready for their next use.
The robot is connected to the Heidenhain control system on the GROB machine via its integrated interface. This makes it very easy to program. „What‘s more, operators have very easy access to the system, and loading and unloading the magazine can be performed during operation.“ In addition, the two rotary tables on the loading station, each one with eight lockable 45-degree index positions, are helpful during setup processes. The device then automatically places the prepared pallets into an available magazine position. A further advantage is the system‘s compact and modular design. The machine tables on the machining centers are fitted with EROWA UPC chucks. „UPC chucks are the precise basis for fast and accurate swapping of the palletized workpiece carriers,“ adds Thomas Lüscher. The Pyramid The „clamping pyramids“ implemented at K&M - a customerspecific custom design by EROWA-are an innovative fixture that adds a further dimension to this combination. „We developed the idea and the design together with Hans H. Rink,“ reports Ludwig Jehle. David Estermann, EROWA Head of the Custom Clamping solutions department, goes on: „The pyramids are made of aluminum and are fastened to EROWA UPC pallets.“ Four selfcentering vises are mounted on each pyramid. The fixture fitted with self-centering vises placed at a 45-degree angle thus provide excellent access to the workpieces during five-axis machining.
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