Welch Gardner Denver

The product range is constantly being adapted to new markets, such as the rapidly growing so-called botanical ingredients market, which includes the production of pharmaceutical raw materials from cannabis plants like CBN and CBD. The main facility of Gardner Denver Thomas GmbH is located in Memmingen, Bavaria. In the Ilmenau plant, pump parts are manufactured in a two-shift operation, which are then processed into the final product on several assembly lines. Production manager Patrick Hoyer and quality supervisor Erik Berger, together with their team of long-term employees with extensive know-how, ensure that these parts are always available in the correct high quality and quantity. To remain future-proof, old machines in the machinery are continually replaced with new, more powerful ones. The latest addition is a Mazak 5-axis machining center model INTEGREX i 250H-ST.

Andreas Ringer, long-standing Mazak area representative in Thuringia and a competent contact for those responsible at Welch, translated the requirements into the appropriate machine series INTEGREX i-H. His consultation resulted in exactly the machine configuration of an INTEGREX i-250H ST that was optimal for production at Welch.

It took a long time for the INTEGREX i-250H ST to find its place in production due to the pandemic. Time that Patrick Hoyer knew how to utilize well: "Our project team worked for over a year to prepare the implementation of this new machine as optimally as possible. Many different components had to be newly integrated, so we prepared and simulated more than 70 programs in advance using software. After the commissioning of the new machine, we were able to smoothly transition to producing and releasing the first parts on the new machine in no time. Due to pendulum machining, our setup time was reduced by about 20%, and the runtime savings are around 15%. As a result, we are able to increase our capacities and shorten production times. "This means that we can respond faster to customer inquiries while maintaining the quality of our products. The investment in this new machine is part of the long-term growth strategy for the Ilmenau location".

The INTEGREX i-250H ST is equipped for the necessary high flexibility and performance in turning and milling processing of complex workpieces in a single setup with high-performance main and counter spindles with 8-inch chucks, each capable of 4,000 min-1 and 30 kW. The machine features an integrated compact milling spindle with Capto interface with a milling capacity of 12,000 min-1 and a lower turret with 9 tool positions, allowing for 5-axis simultaneous machining with two tools. The tool magazine at the back of the machine is equipped with 112 tool positions. The generous 300 mm stroke of the Y-axis and a B-axis with a swivel range of 240° ensure unrestricted contour machining. The machine at Welch also has a programmable chuck pressure regulation at the main spindle and the counter spindle.

 

Machine and Automation Perfectly Coordinated

In the development of the INTEGREX-i-H series, the steadily increasing demand for automation solutions due to the shortage of skilled labor and growing cost pressure was kept in mind. But also the desired productivity increase from many users. For this reason, the machines were designed with a straight front, while the tool magazine is located at the back. The operator has the best access to the magazine area there. The new arrangement provides improved access for front-mounted automation systems such as articulated robots, as well as for side-mounted bar loaders installed like those from Welch. A discharge device with a parts catcher mounted at working height ensures easy removal of the finished parts.

The processed materials include aluminum, various stainless steels, high-strength alloys such as EN AW 6082, and difficult-to-machine plastics such as PP, PVDF, PTFE, and PEEK. These plastics have properties such as high electrical conductivity, high chemical resistance to acids and solvents, and low flammability to provide protection in explosive environments. "Our products must meet very high requirements. The consistently high processing and surface quality is extremely important in the medical technology sector,” says Erik Berger. "The INTEGREX meets all these requirements with ease." A significant contribution to this is made by the SmoothAi control system, which Patrick Hoyer had already prepared intensively for in advance, allowing him to fully leverage its capabilities from the start.

 

SmoothAI Control - Artificial Intelligence Ensures Continuous Process Optimisation

The SmoothAi has a variety of auxiliary functions, such as Smooth Machining and Virtual Machining, which significantly reduce setup time, especially during workshop programming. With the 3D Assist function, workpiece drawings (Step, Iges, Parasolid) can be loaded, and the elements automatically marked by feature recognition or manually selected by the operator can be directly transferred into the Mazatrol program.

With Virtual Machining, the machining process can be simulated even before the first cut, allowing for checks on possible contour violations or interference contours. The control system offers an automatic cutting data check, independently corrects programming errors, and suggests the best milling path. When setting up a workpiece, the 'Cutting Adviser' function is available, which intelligently identifies program sections where important parameters such as speed, feed rate, and cutting depth can be adjusted before the first cut. The function also allows for the visual representation of machining data such as tool utilization, machining volume, cutting load, and processing time.

"For our product range, up to 5000 different components are required," explains Patrick Hoyer. "At our site, we regularly process around 200 different recurring workpieces with diameters between 20 and 50 mm in batch sizes of 50 to 200. All tool data is created via the control system and can be uploaded through a network. A notes function, where important information for operator changes can be recorded, ensures smooth processes. Thanks to the excellent interplay between machine and control, we generate a real added value for ourselves. With a Mazak machine, everything just works!"