Erwin Wimmer
Automated lot size 1 in large part machining
Resource optimization through the coupling of two CNC machining centers to an automated pallet retrieval store. As the first Mazak customer in Europe, Wimmer GmbH has coupled two machining centers from two different generations with different controls to an automation system. Large parts processing in batch size 1 and automation do not have to be in contradiction. With automation that fits the machine, even small batch sizes and prototype production can be economically realized. At Erwin Wimmer GmbH in the Swabian Abstatt, they have been relying on Mazak machines with perfectly coordinated Palletech automation solutions, also from Mazak, for years.
For managing director Harald Wimmer, processing batch size 1 for components up to 2 meters in diameter is part of daily business. His father, company founder Erwin Wimmer, had consistently focused on large part processing – then as now, a field in which relatively few competitors operate. The customers come from areas such as mechanical engineering, energy, drive and automation technology, container construction, or the food and packaging industry. The variety is vast; only a few workpieces are manufactured repeatedly, such as parts for turbochargers and gas turbines.
The demand of all customers is high precision. To meet these requirements, Wimmer relied from the very beginning on machines designed for highly efficient processing of various workpieces. As early as the 1980s, the first Mazak machine of the type AJV 50/80 was put into operation. "My father was very well advised by the responsible Mazak representative at that time and the machine met all requirements excellently, so the next machine was again a Mazak," recalls Harald Wimmer. "The first machine is still in our production daily cutting chips and meets the precision requirements as well as ever." In the following years, Mazak machine followed Mazak machine. Meanwhile, 14 Mazak machines are in production, the majority of which are from the FH series.These horizontal machining centers (currently referred to as HCN) are available in different machining lengths and are characterized by a robust machine construction that provides high torsional stiffness for heavy machining and highly precise finishing. In addition to the standard spindle with 10,000 RPM, a high-speed spindle with 16,000 RPM and a high-torque spindle with 8,000 RPM are also available.
"The multitude of machines provides us with great flexibility in processing," says Harald Wimmer. "Our years of experience tell us which machine is best suited for a part, whether it can be clamped during processing, or whether it is better to manufacture it in a single setup." This professional perspective on the products also indicates which type of machine should be procured next. The parts processed by Wimmer are not only large but also complex. Due to the challenging geometry of some parts, the clamping situation is often problematic. Therefore, Wimmer has the clamping tables built by a reliable supplier according to his own designs. In the measuring room, a measuring machine documents the required high accuracy of the parts in the range of less than 5/100ths. Values beyond that are measured directly at the machines.
Flexibility For A Wide Variety of Parts
Mazak machines can be automated with systems that are perfectly matched to the machines. This includes, for example, pallet changers and robotic loading, Multi Pallet Pool solutions (MPP), as well as the Palletech systems. The Palletech systems allow for a strong customization of workpieces from batch size 1 due to their modular structure and virtually limitless expandability. Wimmer decided to automate its first machine as early as 2005. In 2007, an FH-10800 was equipped with a Palletech pallet system from Mazak with 6 pallet spaces for large parts. However, the great feature at Wimmer is the integration of a horizontal milling machining center FH-8800, which has been in operation since 2007, with a 5-axis machining center INTEGREX-e-1250 V-8 acquired in 2015, via a 2-story high-rise Palletech pallet automation with 24 pallet spaces.
Like the FH machines, the INTEGREX e-series was also specially developed for the machining of large parts. The INTEGREX multifunction machines combine turning and milling operations in one machine. The complete machining of highly complex workpieces in a single setup is easily achievable on these machines. The large Y-axis travel and a powerful milling spindle enable a wide range of machining possibilities and highly precise processing.
Each of the two machines is preceded by a loading or setup station, whose control communicates with the machine controls and coordinates the workflows. The new Smooth PMC software displays the progress of the processing, the machine and tool status, and the position of the pallets on screen. Predictive processing simulations facilitate the detection of defective or missing tools as well as the flawless execution of the processing process. 'I am impressed by how Mazak has managed to connect two such different machine models with two different generations of control through the Palletech system,' says Harald Wimmer.And he emphasizes: "Our productivity and flexibility have increased enormously due to the new system, without having to compromise on quality! Thanks to the Palletech system, I can interrupt long and complex processes for urgent tasks, and then subsequently complete them without any loss of quality. The investment in this combined technology from Mazak has led to a reduction in costs per part and remarkable energy savings. Our scrap rate is approaching zero!" The state of Baden-Württemberg considered the automation solution to be worthy of an award: Erwin Wimmer GmbH is one of the 100 companies in a cluster of excellence that received an award for resource efficiency. However, Harald Wimmer is excellent not only in the field of automation: together with an energy consultant, he has optimized his entire operation for energy efficiency.
Also Exemplary in The Area of Controls
For Harald Wimmer, the Mazak-owned Mazatrol controls are another significant advantage of Mazak machines. In his company, various generations of controls are combined, all of which share the same features: easy programming and compatibility with all common programs such as CAD/CAM, ISO programs, 5-axis machining data, and 2.5D data. "The programming of the Mazatrol Smooth control directly at the machine via a touch screen is easy for all my employees to implement. This way, I have the advantage of being able to deploy them flexibly," says Harald Wimmer. "The control is also designed in such an open manner that we can enter comments and switch flexibly from one program to another. All of this saves time and nerves."
Both will serve Harald Wimmer well in the future, as he has just added a second pillar to his company. Since January 2021, the new division of tool construction has been located a few kilometers away in Weinsberg/Ellhofen. Harald Wimmer is now supported by his son Nico Wimmer, who already works at the company. He is not only a precision mechanic but also a master craftsman in mechanical engineering and a trained business administrator. This ensures the company's succession into the third generation.