MMS Technologie SKF LubriLean - Deutsche Messe AGfiles.messe.de/cmsdb/D/001/23112.pdf · 2010. 4....
Transcript of MMS Technologie SKF LubriLean - Deutsche Messe AGfiles.messe.de/cmsdb/D/001/23112.pdf · 2010. 4....
MMS TechnologieSKF LubriLean®
Ralf Domrös Dipl. Ing.Product Manager MQL
E-Mail: [email protected].: +49 (0) 30 72002- 398Fax.: +49 (0) 30 72002 – 345Mobil: +49 (0) 160 9729 2551
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Inhalt
SKF – Lubrication Systems Germany AG1
2
3 Anwendungsbeispiele
MMS Technologie
SKF LubriLean Product Features4
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1SKF – Lubrication Systems Germany AG
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SKF – Group
World wide Comprehensive industry knowledge
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BERGER VOGEL s.r.l.
SKF LubSysFRANCE S.P.A.
SKF LubSysHockenheim
SKF Lubrication Systems Germany AG
Berlin
SKF LubSys USA
SKF LubSys Japan
SKF LubSysNEDERLAND B.V.
Centralized Lubrication for Machine Tools
Coolant Pumps
MQL – Minimal Quantity Lubrication
Truck- und Off-Road-Lubrication
SKF Vert riebsnetz weltweit
Company
SKF Berlin
SKF Hockenheim
Sales+Service Centers
Group, total
Foreign countries
Employees
457
904
150
22
275
Turn over 2008: 170 Mio. €
SKF Lubrication Systems Germany AG, 2008
Lubrication of Windmills
Lubrication of marine engines
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Hockenheim
Berlin
MühlheimSKF GmbH
SKF – Lubrication Systems Germany AG
Berlin: Headquarter
- Production of all parts
- assemblyapprox. 450 employees
Hockenheim:- assemblyapprox. 140 employees
Subsidiaries:- Newport News, USA- Osaka, Japan- Saumur, France
2MQL Technology
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Trockenbearbeitung mit MMSNassbearbeitung
Stark verringerte UmweltbelastungStark verringerte Umweltbelastung
Geringe Gesundheitsrisiken
(Haut- u. Atemwegerkrank.)
Geringe Gesundheitsrisiken
(Haut- u. Atemwegerkrank.)
Umwelt-Aspekt Kosten - Aspekt Gesundheits-Aspekt
Verringerungder
Hauptzeiten
Einsparung KSS-Anlage und KSS-Aufbereitung
Motivationsfaktoren für die Trockenbearbeitung
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interne ZuführungPartiklegröße 0,3 µ up to 1µ
externe ZuführungPartiklegröße 15 µ up to 40 µ
Werkstück
Example
Principle Principle
Example
Interne und Externe Aerosol Zuführung
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Internal and External Aerosol Supply
Turret Lathe Machine
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SchmierstoffBehälter
KoaxialschlauchIntern Öl, Extern Luft
Düse
Air
Oil
Covering air stream
Particle size
15 - 40 µm
Dosierter Schmierstoff wird in einer Sprühdüse durch Druckluft zerstäubt. Dabei entstehen Mikrotröpfchen, die mit der Trägerluft ohne Nebelbildung zur Reibstelle gelangen.
Prinzip der Externen MMS
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Prinzip der Internen MMS
Drehdurchführung
Spindel
Werkzeughalter
Werkzeug
Schmierstoff
Aerosol
Aerosolerzeuger
Zuführung
Kugelhahn
UFZ.U00-009
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Vario VarioSuper DigitalSuper1
InterneMMS
ExterneMMS
Info Info 1-2-Kanal
Info Info Info Info MonitoringInfoBsp Bsp Aufb AufbAufb Aufb
VarioPlusSmart Basic
Überblick der VOGEL LubriLean MMS Produkte
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Tools
Engineering
Schmierstoff Werkzeugmaschine
MQL-SystemLubriLean®
- Staub- Öl- Späne
Absaugung
Spindel
Dry Cuttingwith MQL
MMS Gesamtsystem
3Application examples
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Improvement of Environmental Issus using MQL
Coolant
MQL
*
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Berechnungsbeispiel
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Improvement of Environmental Issus using MQL
*
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1. Long-run test with MQL
2. Convincing results
Retrofitting with MQL at 7 lathe machines
Total cost saving:
Costs for: Coolant MQL
Improved environment
maintenance:oil:compressed air:cost of transportation:
Total costs/year:
Savings/year:
177.305 EUR35.461 EUR
---
1.655 EUR
214.420 EUR
44.326 EUR5.319 EUR11.820 EUR
473 EUR
61.938 EUR
214.420 - 61.938 = 152.482 EUR
- Significant drop of the oil consumption from20 000 Litre to 500 Litre/year- Dry workpieces- Less health hazard- Less interrupt for cleaning offilters, tanks, leakages etc.- Improved environment- No waste disposal costs- Dry chips- Less damage of the environment- Equal production time
Roller bearing steel 100Cr6, roughness of surface Ra < 0,5 µmCutting-off operation with Oil as coolant.
Source:
Cost Savings: MQL vs. Coolant
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1) GM Nodular Cast Iron Billets (Crankshaft Iron)2) Machine Tool Builder: Ingersoll CM Systems3) Tool: Sumitomo Carbide MQL drill4) 6.00 Dia Tool5) MQL-System: SKF LubriLean VarioSuper6) Lubricant: Vogel LubriOil7) Air pressure = 7.5 Bar (108 PSI)8) Depth of cut = 100mm [4"] //(17 Times Diameter)9) Tool Life distance = 108.5 Meters
10) Tool life distance for test at Mack Trucks 220 Meters
VarioSuper
Customers with same application:Mack Trucks Inc. (Volvo Group), Toyota
Deep Hole Drilling in Crankshafts
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Drilling Balance Holes in crank shafts
1. Machine Adaptation2. Excellent Chip Formation3. No Thermal Effects4. 14mm Tool 5. Up to 2.5 x D6. Tool life increased 150%
VarioPlus
Balance Hole Drilling at Ford USA
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VW Engine Plant Salzgitter
• 22 stations with LubriLean® Vario• Fully automatic refilling• Tool life increased by as much as 50%
Engine Block Production with Vogel LubriLean®
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Series Production of Connecting Rod‘s
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Success Stories – GROB-WERKE GmbH & Co KG
First order of 18 Digital Units (UFD10-021) (for 18 Grob machine Centers) which will be installed at Volkswagen Salzgitter for Cylinder Head works.
70 cent Einsparung pro Zyliderkopf
UFD10-021DigitalSuper 1 MQL System
Quelle: fertigung 08/2009
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Tool: � 3,25 mm; straight grooved
Material: AlMgSi1
RPM: 18.000 min-1
Feed: 3.780 mm/min
Length of drill: 150 mm
Depth of hole: 70 mm
Approximately 500 holes without wear
Tool supplier: Gühring
BZ 500 L LubriLean DigitalSuper 1
New engine block transfer line of Grobfor
DaimlerChrysler Mannheimequipped with Vogel LubriLean
Transferline of Grob with SKF LubriLean
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Workpiece: - Cylinder-head of row 6 cylinders truck engine
Machine: - 8 “G-Modules” of GROB equipped with 8 DigitalSuper units- 1 Transferline of GROB equipped with 3 DigitalSuper units
Ø-Range: - 8-30mm
Applications: - drilling, deep-hole-drilling, boring, monting, tapping and reaming
Source: GROB
MQL at DaimlerChrysler Plant: Mannheim
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MQL Unit: LubriLean DigitalSuper1
Machine Tool Center: DMC 160
Material: Inconel®
Application: Tapping (1/4 inch to 2 inch)
Depth: 20 - 40 mm
Tapping of Threads in Inconel® at Volvo Aero
13 Machine tools equipped with LubriLean MQL-Systems DigitalSuper
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MQL Cutting of Airplane Parts
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Main results:
Reduction of liquid consumption:
- Previously: 3 liter/day
- Currently: 0,5 liter/day
- 83%
- Increasing of rollers output:
+ 10%
EHS!
New Tool holder
MQL Process at Roller Channel 2, SKF Gothenburg
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Main results:
Reduction of liquid costs: 97%
� Cost Payback: 0,67 year
MQL with SKF LubriLean at SKF Cage Factory in Gothenburg
Example for a short Payback of Investment in MQL
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previous today
Saving Potential using MQL instead of Coolant
Oil consumption: 1 l/dayCoolant consumption: 80.000 l/day
Coolant loss: 150 l/day
Traditional Milling with coolant Milling with MQL
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wet
MQL
Time saving
Turned parts
0 5058%
59%
49%
48%
45%
82%
70%
78%
37%
73%
45%
24%
Mounting flange BK 3.18
Guide rod KFA 1.20
Mounting flange DS-4E.04
Housing SP 9.31
Holding device BK 6.104
Mounting flange AZ7
Valve body 873-780-004
Delivery plunger PFP-90.02
Housing PFP-90.12
Head PFP-90.01
Plate KFE-25.01
Pump spindle MS-40980
Operation time (wet)100%
Time savings at Vogel production by using MQL
4SKF LubriLean Product Features
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• Product features• Pressure reservoir with integrated aerosol generators• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter � 0,5 mm• Integrated control system for automatic control of aerosol • quantity and quality• Profibus as standardized interface with machine tool• Startup and diagnosis possible via PC
• Applications- for turning, drilling, milling, tapping, broaching, deep drilling, etc.
- high-speed spindles- machining centers and turning cells- complex production processes in flexible manufacturing
• Integrated topping-up device• Meets HPC standard
Digital1Super - Product Features
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MQL Process Monitoring of LubriLean DigitalSuper
Analoge pressure switch
Digital display
Flow-Sensor
Oil level switch
Aerosolsensor
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Customer requirements• Inline and online monitoring of aerosol supply• Teaching of operating conditions
Unique position feature• The only MQL-monitor on the market• Integrated into DigitalSuper MQL-system• Can be operated as a stand alone device
Schedule / Status• series start 09/2006
Aerosol Monitoring System for MQL
AM1000 Aerosol Monitor
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• Product features• Pressure reservoir with integrated aerosol generators• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter ≥ 0,7 mm• Adjustment of air and oil quantity via machine tool’s SPC• Filling level monitoring with capacitive sensors (2 points)• Automatic topping up possible• Applications: - turning, drilling, milling, tapping, broaching
- multispindle units- high-speed spindles
VarioSuper - Product Features
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• Product features• Pressure reservoir with integrated aerosol generator• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter ≥ 1,5mm• Manual adjustment of air and oil quantities• Manual adjustment of supplementary air for dilution of aerosol• Filling level monitoring (4 Points)• Automatic topping up possible• Applications: - turning, drilling, milling, tapping, broaching
- multispindle units- high-speed spindles
VarioPlus - Product Features
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• Product features• Pressure reservoir with integrated aerosol generator• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter ≥ 2mm• Manual adjustment of air and oil quantities• Manual adjustment of supplementary air for dilution of aerosol• Filling level monitoring possible• Automatic topping up possible• Applications: - turning, drilling, milling, tapping, broaching
- multispindle units- high-speed spindles
Vario - Product Features
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Smart - Product Features
Product featuresOil and air feed via coaxial lines
Aerosol generated at nozzle outlet
Reservoir sizes 0.3, 0.5 and 0.7l2 separately meterable outlet ports (via oil choke)
Extensive range of lines and nozzles available
Can be fastened to machines with magnetic clampsUsed for simple production processes
- sawing techniques
- model construction, training- simple milling, turning and drilling operations
Entry-level unit for external MQL
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Smart - Application
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• 3 liter reservoir capacity
• Oil and air feed via coaxial lines (up to 20m)
• Aerosol generated at nozzle outlet
• up to 8 outlet ports can be switched, independently or in groups
• Extensive range of lines and nozzles available
• Filling level monitoring possible
• Autom. topping up possible
• Applications - sawing- simple milling, turning and drilling
• operations - broaching- forming- oiling jobs
• Product features
• All outlet ports can be separately regulated by hand (oil choke and atomizing air)
Modular system for external MQL
Basic - Product Features
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Basic - Application
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