Series production

Better than complete processing

JUNKER experts must take into account further basic conditions: Calculate the target tact time of the grinding process, including the loading and unloading time, based on the original planned annual production, actual production shifts, and machine availability statistics. The person in charge of the JUNKER Group's automotive division project commented on the last successful project: “With the extensive experience in the efficient grinding of CBN grinding technology, JUNKER has proposed a solution for the overall machining. But this solution It doesn't help us achieve our goals, because it's followed by a significant increase in total equipment investment. In contrast, cutting-in and end-grinding are separated, and then all contour grinding will save even more. Cost. Through a series of tests on the drive shaft, we determined that the program can guarantee product quality and the production process is quite stable."

For the first expansion of the transmission shaft with an annual production capacity of 400,000, the customer has adopted two independent production lines: one production line for two drive shafts (manual transmission and automatic transmission) consisting of two “Jumat5000” The /50s" CBN cylindrical grinder is cut and ground, and three "Quickpoint 3000/60" HSG cylindrical grinders (see Figure 3) are used for profile grinding. Another processing line for the production of two output shafts consists of three “EJ50” straight-cut circular grinders, one of which is cut into one and the other two grinds.

Nordracher JUNKER workshop: part of the grinding machine being installed in a drive shaft project, including the workpiece logistics conveyor

The project demonstrates the ability to transform original equipment suppliers (OEMs) into technology suppliers within the framework of existing partnerships and cost control principles. A project leader of JUNKER once said: "In order to enable EJ50 grinding machines with only one wheel head frame to process two different lengths of output shafts, JUNKER has followed the two spindle types of the project in the design of the product. The corresponding design adjustments have been made so that the same grinding wheel set can be used for machining, and the integrated wheel set can be used to adjust the grinding wheel set to the correct position. The Jumat and Quickpoint grinding machines can rotate the workpiece one week because of the B-axis. Convenient and fast positioning of two different sets of grinding wheels."

Fast workpiece loading and unloading and logistics control with chip

In order to achieve a shorter tact time, it must be achieved by means of an efficient grinding process. The cutting process is carried out by an electroplated grinding wheel that does not require dressing, and the contouring is done by means of a ceramic bond CBN grinding wheel that has been trimmed in the machine. On the other hand, the workpiece changeover time must be included in the beat time, and the advantages of JUNKER's built-in loading robot solution are highlighted here. When the external loading robot has to wait for the grinding process to end until the loading window can be opened, the built-in loading and unloading robot has used the W-clamp to feed the next workpiece to the vicinity of the spindle. Due to the extremely high rigidity of the machine, the loading and unloading robot does not have any influence on the grinding process. Built-in online measurements ensure product quality and process safety.

In addition to machine tool usage, machine dressing frequency and time required are also factors that affect annual production. In the case of plunge grinding, the service life of the grinding wheel is close to 20,000 drive shafts, so that only two to three grinding wheel sets can be replaced in one year, and the time required for dressing can be reduced to 30-60 by means of the reloading aids on the machine. minute. In order to eliminate interference with the most flexible production concept, the machine also deliberately installed a workpiece carrier equipped with an RFID chip. Before the workpiece is fed into the machine, the drive shaft type and machining status information will be confirmed, and if necessary, the top position of the tailstock, the machine settings used for the grinding wheel set, and the NC program will be modified. Before the program is turned on, the plausibility test of the rated and actual values ​​of the geometric parameters of the drive shaft will be carried out again. Once the deviation occurs, the drive shaft will be sorted. After processing, the stored data in the workpiece carrier chip needs to be updated.

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