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Complete 01/2023 EN

Complete 01/2023 EN
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Complete 01/2023 EN

Product catalog summary
Editorial Overview
The document explores the challenges and opportunities faced by WFL Millturn Technologies in the context of global crises such as the pandemic, supply chain disruptions, and climate change. It emphasizes the company's commitment to sustainability and digitalization, highlighting initiatives like expanding photovoltaic systems and implementing digital solutions to enhance production efficiency.
Key Sections
  • Automation and Innovation: WFL focuses on automation solutions, including mobile and articulated robots, to improve production flexibility and efficiency.
  • Technology Expertise: The document showcases WFL's expertise in complete machining, particularly in internal machining and deep hole drilling, highlighting their capability in producing complex components like crankshafts and parts for small power plants.
  • Success Stories: Features success stories such as Renk GmbH's use of MILLTURNs for vehicle transmission parts and SSI Schäfer's warehouse lift system integrated with SAP for improved efficiency.
  • Software Solutions: WFL offers a range of software solutions for machining processes, including programming tools, collision prevention systems, and energy-saving technologies.
  • Customer Service Insights: An interview with Roland Steingress, Head of Global Customer Services, discusses the importance of customer satisfaction and the dynamic nature of after-sales service.
Conclusion
The document underscores WFL's commitment to innovation, customer satisfaction, and technological advancement, positioning itself as a leader in the complete machining sector.
Overview
The document discusses the innovative automation solutions provided by FRAI Robotic Technologies, a subsidiary of WFL, and highlights the importance of customer service and training within the company. It also covers the success story of Renk GmbH, a leader in transmissions for military vehicles, and their collaboration with WFL for machining solutions.
Key Sections
  • Customer Service and Training: Emphasizes the importance of direct customer interaction to understand on-site issues and the need for training new and existing staff to enhance skills.
  • Automation Solutions by FRAI: Describes FRAI's role in developing flexible robot systems and the benefits of automation in production, including increased productivity and efficiency for both large-scale and small batch productions.
  • Innovations in Automation: Discusses the evolution of automation from fixed transfer lines to flexible line chains and individual cells, highlighting the integration of intelligent software for automatic tool and device replacement.
  • mobileCELL Solution: Introduces mobileCELL, a hybrid solution combining AGV with robot cell construction, offering flexibility and efficiency in production by allowing autonomous operations.
  • Success Story of Renk GmbH: Details Renk's use of WFL's Millturn machines for complete machining of transmission parts, emphasizing the importance of programming and simulation in production efficiency.
Technical Insights
  • Automation Benefits: Automation solutions provide continuous productivity with minimal effort, suitable for both large-scale and small batch productions.
  • mobileCELL Advantages: Offers a mobile solution that enhances competitiveness by allowing autonomous shifts and reducing intralogistics costs.
  • Machining Efficiency: WFL's Millturn machines enable complete machining of complex parts, reducing the need for special clamping devices and allowing for economical production even in small batch sizes.
  • Programming and Simulation: Utilizes Siemens NX CAD-CAM for programming, ensuring accurate simulations and reducing collisions during production.
Conclusion
The document highlights the strategic importance of automation and customer service in modern manufacturing, showcasing FRAI's innovative solutions and Renk's successful implementation of WFL's machining technology.
Overview: The document discusses the integration of advanced machining technologies and automation solutions in manufacturing processes, particularly focusing on the use of WFL Millturn machines for complete machining tasks. It highlights the benefits of these technologies in terms of efficiency, productivity, and safety.
Key Sections:
1. Machine Specifications and Capabilities: Machines with a 3000 mm center distance include a built-in pick-up magazine for long boring bars. This setup reduces the need for multiple machines and external suppliers, significantly cutting lead times and operational sequences.
2. Efficiency and Automation: The introduction of automation solutions from FRAI Robotic Solutions has enhanced the production efficiency of workpieces like planetary gears. The automation allows staff to focus on more demanding tasks, optimizing machine utilization.
3. Maintenance and Monitoring: Renk has an in-house maintenance team for repairs and uses a universal machine data acquisition system for predictive maintenance and condition monitoring, collaborating with Siemens for a consistent solution across plants.
4. Deep Hole Drilling: WFL MILLTURN Technologies offers specialized tools for deep hole drilling, providing advantages over traditional machines. The process is fully automated, with easy correction of hole center deviations using WFL measuring cycles.
5. Historical Context of Linz: The document also provides a historical overview of Linz, from its Roman origins as Lentia to its development through various historical periods. It highlights archaeological findings and the cultural significance of the city.
6. Complete Machining for Small Power Plants: WFL MILLTURN Technologies is involved in the complete machining of components for small power plants, ensuring high precision and meeting stringent tolerances for energy technology applications.
Overview: The document discusses advanced machining processes and logistical improvements in manufacturing, focusing on the production of components for small power plants and the modernization of storage systems.
Machining Processes:
  • Generator Shafts: The document details the machining of generator shafts using the MILLTURN technology, emphasizing the precision alignment of welded-on bars and the automated measurement and correction of welding errors. The process includes various operations such as milling, boring, and grinding, with significant savings in setup time, machining steps, and overall machining time.
  • Crankshafts: Complete machining of crankshafts is highlighted as an efficient alternative to traditional methods. The MILLTURN technology allows for reduced machining operations, minimal setup, and improved process reliability, particularly beneficial for small series and prototype production.
Technologies and Innovations:
  • MILLTURN Technology: This multifunctional machining center is used for various operations, including milling, turning, and in-process measuring, providing flexibility and precision in manufacturing.
  • SSI LOGIMAT® Warehouse Lifts: The document describes the implementation of these lifts to optimize storage space and increase picking efficiency. The integration with SAP allows for direct control without additional interfaces, enhancing operational efficiency.
Logistical Improvements:
  • Warehouse Modernization: The installation of SSI LOGIMAT® lifts has significantly increased storage capacity and picking output, freeing up floor space and reducing reliance on staff availability.
  • Process Optimization: The project led to further optimizations, such as tool stations on lifts and a centralized label printing station, reducing the need for multiple shifts.
Innovation and Future Directions:
  • EuProGigant Project: This initiative aims to enhance data sovereignty and communication in production through a European data cloud environment. WFL is a key partner, contributing to the development of smart data use in manufacturing.
  • Component Matching: The document discusses efforts to ensure functional assembly through precise component matching, reducing the need for goods inward inspection.
Introduction
This document discusses advancements in production processes, focusing on infrastructure savings, component matching, and the evolution of internet data infrastructure. It highlights the EuProGigant project and deep hole drilling technology.
Infrastructure and Component Matching
The document emphasizes the importance of efficient testing infrastructure shared by suppliers and customers to speed up assembly processes. It introduces a component matching service that ensures compatibility between components from different suppliers, enhancing production efficiency through digital processes.
New Generation of Internet
The EuProGigant project envisions a new internet generation with extensive data and digital services. This system allows users to search for data similarly to using a web browser, with a focus on data sovereignty and mutual trust.
Faster Value Creation
Digital tools are crucial for simplifying and accelerating production processes. The document discusses the implementation of digital monitoring for tools, processes, and machines, ensuring machine availability and workpiece quality.
From Testing to Implementation
The document outlines the transition from research-related testing to implementation, focusing on "perfect component matching" and integrating experiences from the Gaia-X development.
Perfect Component Matching
This section describes an automated comparison of parts considering tolerance deviations, optimizing assembly grouping and reducing manual installation time and rejects.
Project Partners
The EuProGigant project involves 16 partners from Austria and Germany, aiming to increase energy efficiency, reduce production costs and CO2 emissions, and enhance productivity and turnover by 2025.
Deep Hole Drilling Technology
The document details deep hole drilling challenges and processes, including gun drilling and BTA processes. It highlights the advantages of WFL MILLTURN machining centers in handling deep hole drilling with precision and efficiency.
Technology and Innovation
The document concludes with a focus on complete machining processes, automated measurements, and the flexibility of machining steps, emphasizing the passion for technology and innovation.
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Catalog excerpts

Complete 01/2023 EN-1

The complete machining magazine SUCCESS STORY | Complete machining of parts for vehicle transmissions INNOVATION | A new level of added value – EuProGigant ALL EYES ON | Innovative automation solutions by FRAI Robotic Solutions The digital MILLTURN For a smart use of production data.

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Complete 01/2023 EN-2

Linz changes Linz has an eventful past, which has shaped the city distinctly. Not only the first half of the 20th century brought massive changes to Linz's history, the city's development already started in antiquity. Find out everything about the history of Linz in this

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Complete 01/2023 EN-3

Dear valued customers, dear readers, makework. There is only one machine tool that turns, mitts, drills and performs with the highest precision: A MILLTURN by WFL. The current crises caused by the coronavirus pandemic, disrupted supply chains, inflation, the energy crisis as well as climate change are all posing huge challenges for us. These crises are resulting in shortages of a wide range of resources such as raw materials, energy, components and parts. Crises always bring opportunities with them too and act as drivers of innovation, as so many changes take place with regard to things like...

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Complete 01/2023 EN-4

The perfect software solution for any type of machining Programming and simulation BEHIND THE SCENES Achieving our goals with renewed vigour Interview with Head of Global Customer Services Roland Steingress Innovative automation solutions by FRAI Robotic Technologies SUCCESS STORY: RENK GMBH Complete machining of parts for vehicle transmissions Transmissions made by Renk GmbH set armoured vehicles in motion and generate huge levels of drive torque. ALL EYES ON Deep hole drilling in the complete machining centre LINZ OVER THE YEARS Lentia - the Roman Linz Celtic fortifications were built in the...

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Complete 01/2023 EN-5

WFL SOFTWARE SOLUTIONS THE SUITABLE SOFTWARE SOLUTION FOR EACH AND EVERY MACHINING TASK

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Complete 01/2023 EN-6

Achieving our goals with renewed vigour Setting sail with service – new management brings breath of fresh air We really value customer satisfaction, loyalty and quality. n sailing, it’s important to remain steady and, above all, reliable. Consistently good performance means that no road is too long and no wave or problem too big, even in stormy times. By constantly working on yourself and developing, you’ll never stray from the planned course. Teamwork is absolutely essential here, as it brings the high performance required in order to reach your goal. The WFL Service department has always been...

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Complete 01/2023 EN-7

co-workers to have a chat. I introduced myself and tried to find out what the current situation was, where there was untapped potential, and where there were any issues. I absorbed these findings and planned my next course of action. How can the flow of information be improved, where is there even more potential, how can we make our processes more reliable, and which systems can help us? These were my initial thoughts and tasks, so to speak. One of my biggest concerns was to ensure smooth, friendly, fast and above all technically adept teamwork. What does your typical day look like? ‘Business...

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Complete 01/2023 EN-8

Who or what comes to mind when you hear the word ‘successful’? One way of measuring success is in euros. That’s definitely an important aspect when setting our objectives. In another vein, employee and customer satisfaction is an important contributor to success. To this end, we have a larger project with Salesforce in our pipeline. This will focus on generating customer satisfaction and making our interactions better/winning back former customers and fostering these ‘new’ relationships. It also aims to build up many loyal customer relationships and ensure that they are satisfied for the long...

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Complete 01/2023 EN-9

Innovative automation solutions by FRAI Robotic Technologies utonomous production methods have long been used by automotive manufacturers, the aerospace industry and mould construction companies to produce equipment for machine tools. Other sectors with less of a focus on automation are now showing increased interest in this area, above all due to the possibility of introducing autonomous night and weekend shifts. Depending on the customer’s requirements, WFL and FRAI use automation solutions such as articulated robots, automated linear and area gantries and even mobile robots for automated workpiece...

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Complete 01/2023 EN-10

SUCCESS STORY: RENK GMBH Complete machining of parts for vehicle transmissions Armoured vehicles need huge levels of drive torque to get going. In order to deliver the necessary propulsive force, manufacturers rely on transmissions from Augsburg-based Renk GmbH, the specialist in fully automatic transmissions for heavy tracked military vehicles. And wherever top performance is required, you can be sure that solutions from WFL are not far behind. But first things first… Roughly 60% of all parts to be machined for vehicle transmissions are rotating parts, practically all of which can be produced...

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Complete 01/2023 EN-11

EFFICIENCY THROUGH AUTOMATION To boost efficiency even further, Renk has successfully deployed automation solutions from FRAI Robotic Solutions on two machines. From left to right: Wolfgang Neukäufer – Foreman, Complete Machining; Martin Wimmer – Head of Production, Vehicle Transmissions; Stefan Müller – Production Manager, Vehicle Transmissions. ing devices are thereby rendered unnecessary, as workpieces are clamped on the Millturns by either standard jaws or a few special jaws with a three-jaw chuck. A critical factor in determining the productivity of a machine is its programming, which is...

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Complete 01/2023 EN-12

any length position and that you can sometimes find that there is a workpiece in the way, but that hasn't been an issue for a long time now," jokes Wimmer, looking back on those early days. Machine data acquisition is a topic of growing importance at Renk. To this end a system is already in use that displays the respective status of the machine via a dashboard. As it is important that the same solution can be used in every plant, Renk has opted for a universal solution that is not dependent on any one machine builder – and like with CAD-CAM, there is a close collaboration with Siemens here as...

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