Issue 2016 // 01

Aiming high with UnionChemnitz

Top News: UnionChemnitz present in China with two offices // New Heidenhain control TNC 640 // AMS Arneburg invests in second PCR 150

Thanks to the 12 m X-axis, the PCR 150 is capable of machining XXL crane components at Gothaer Fahrzeugtechnik.

The specifications of a modern caterpillar crane are impressive: the strongest one in the world with lattice jibs can lift 3,000 t. It is used in the manufacture of power stations, refineries and wind power plants. It reaches a maximum lifting height of 245 m and an outreach of 196 m. This combination of size and strength demands an exceptionally stable and light construction. This is achieved by the use of fine-grain structural steel.

The components for such XXL cranes are manufactured at Gothaer Fahrzeugtechnik GmbH in Gotha, Germany. The core competence of the family-managed company is the manufacture of lattice masts for mobile and caterpillar cranes. Numerous renowned crane manufacturers, such as Liebherr, have their lattice components produced at Gothaer Fahrzeugtechnik.

Mechanical machining is keyFrom material cutting and welding to mechanical machining and painting, each pro-duction step is handled by the 400 employees in Gotha. “The more precisely each single crane component fits, the faster a crane can be assembled on-site,” CEO Jens Schwabe explains. Mechanical machining therefore plays an important role in the company. After the welding process, an exact fit can only be achieved through mechanical machining. Compensating the inevitable welding distortion by means of heat would impair the stability of the crane components to a great degree. Absolute precision when boring and milling the workpieces is therefore paramount.

“The largest crane components we manufacture are 12 m long, 3.20 m high, 3.60 m wide and weigh 30 t,” Jens Schwabe says. The floor-type boring mill PCR 150 with a boring spindle diameter of 150 mm made by UnionChemnitz turned out to be the ideal solution for the machining of the crane components at Gothaer Fahrzeugtech-nik. The machine, which is equipped with a 10 x 3 m floor plate and a 12 m X-axis, has been in operation in Gotha since 2009.

Its additional highlights: a hydrostatically guided RAM that can be extended 1 m, a fully automatic tool changer and an integrated rotary and traversing table. “The RAM and the boring spindle of the PCR 150 allow for machining up to a depth of 1,700 mm inside the workpiece, that is beyond the middle of the workpiece. The component is then flipped to machine the other side,” Frank Winter, head of work preparation at Gothaer Fahrzeugtechnik, explains. The precision required for these machining processes is guaranteed by the robust design of the PCR 150 with a strongly ribbed column, as well as the fully automatic RAM sag and column tilt com-pensation and the longitudinal compensation of the boring spindle.

Successful investment for highest securitySince the PCR 150 has been commissioned in 2009, the boring mill works in two or three-shift operation. “Investing in the PCR 150 has been the right decision,” says Frank Winter. “We are absolutely satisfied. The RAM design is great and a big advantage in terms of stability. The price-performance ratio is convincing, as well.”

The last step in the production of a lattice mast at Gothaer Fahrzeugtechnik is paint-ing. After cutting the material, welding and mechanical machining, this step, too, is performed at the company itself. When the finished lattice mast components for mobile and caterpillar cranes leave Gothaer Fahrzeugtechnik, they become the foun-dation of the secure transport of parts that weigh up to 3,000 t at construction sites around the world – thanks to the united expertise of crane construction specialist Gothaer Fahrzeugtechnik and UnionChemnitz.

Precision machining of large crane weldments at Gothaer Fahrzeugtechnik with a PCR 150

Events: IMTS in Chicago, USA from September 12 - September 17, 2016 // AMB in Stuttgart, Germany from September 13 - September 17, 2016

CommunICaTIonS

Editorial

Dear readers,

With a history that spans more than 160 years, UnionChemnitz is well aware that the key to long-term economic success lies in technological development of existing and new products. A central slogan in the area of product development that currently dominates the headlines in many trade magazines, technical contributions and trade fairs is “Industry 4.0”. Not only the German government and umbrella organizations in the industry promote this topic in many projects; there is also a wide range of international works on this issue.

Industry 4.0 as an approach to boosting innovation in the German industry addres-ses two areas. On the one hand, ideas regarding wireless interconnection of sensors and actuators in machine systems are explored and brought to industrial use. On the other hand, the term “internet of things” encompasses efforts aimed at enabling single elements, such as motors and machine elements, to communicate indepen-dently and interact according to specific situations. The goal of both approaches is to increase the productivity of machines, facilities and entire plants.

However, the basic orientation of many research and development projects has to be questioned. Complex software interfaces, intelligent sensors and whole smart factories are frequently developed without regard to the market requirements and potential customer benefit. German projects and enterprises in particular are increas- ingly tempted to connect and digitalize anything and everything and strive for the technological maximum. However, the question should always be: what do custo-

mers require at the moment and in the future, and which affordable added value can be achieved in production with the help of Industry 4.0?

UnionChemnitz, too, has been involved in Industry 4.0 for quite some time and par-ticipates in various research projects. Yet, for UnionChemnitz, the benefit for the customer always remains the focus of attention. This includes increasing machine availability, maintaining long-term machining precision and improving the produc-tivity of the facilities. In order to capture the specific requirements of the boring mill and the production environment, fast and direct contact with our customers is essential. Only the combination of this knowledge and current technological devel-opments can form the basis for UnionChemnitz’s orientation in this field.

Regarding the manifold future developments in the area of Industry 4.0, it remains to be hoped that the undertakings begun with much energy and enthusiasm do not only explore the ivory tower of technology, but yield solutions for production technology that can be utilized economically in close cooperation with customers and suppliers.

Dr. Benedikt Sitte

China: reliable HerkulesGroup service

UnionChemnitz present in China with two offices

Selling machines all around the world requires fast and uncomplicated com-munication between the manufacturer and the user across the continents. De-spite email and telephone, language problems and time differences can result in misunderstandings and delays that waste valuable time. As an example: if users require service in China, in the worst case they might have to wait for several hours until the manufacturers in Europe start their working day and react to questions. Shipment of spare parts around the world then results in long delivery times and therefore machine downtime.

This is not the case with UnionChemnitz. Since becoming a member of the Herkules-Group, UnionChemnitz is present in China with two locations. The advantages for customers in China: local contact persons and prompt service.

In Beijing, the competent team of the WaldrichSiegen Beijing Representative Office is the first contact for any queries of UnionChemnitz customers, as well. All employ-ees have been trained at the German production units of the company group. Stefan Elze is the head of the office. He and his employees have many years’ machine tool experience.

The Chinese service unit of the HerkulesGroup, German Machine International Trad-ing (GMT), is based in Jiaxing near Shanghai and is also responsible for UnionChemnitz. From here, highly skilled engineers provide service to the Chinese market. They guarantee prompt, top-quality service in the areas of spare parts, repairs, assembly and after sales with short travelling distances and delivery times for Chinese custom-

Uncomplicated and prompt service for UnionChemnitz customers in China – here in Dalian.

unionChemnitz Communications

ers. Of course, communication takes place in the local language and invoicing takes place in the local currency. Regular training ensures that all employees are on top of technological innovations and capable of reacting quickly on-site. GMT is headed by Arno Knipp, who like Stefan Elze looks back on a long career in the HerkulesGroup.

At GMT’s 6,400 m2 production site in Jiaxing, around 30 employees manufacture high-quality machine components for the Chinese market. The well-equipped ma-chine inventory comprises three portal milling machines, two horizontal boring mills, four lathes, a vertical lathe, two grinders, a machining center and a 3D measuring system by Zeiss – all made in Germany. The employees have also been trained in Germany and work according to German quality standards.

Customers who decide to acquire a boring mill or a travelling column mill by Union-Chemnitz do not only receive outstanding machine technology, but also excellent, local service.

unionChemnitz Communications

AMS Arneburg invests in second PCR 150

New machine increases efficiency

New Heidenhain control TNC 640

Complete range of boring mills available with new control

UnionChemnitz will offer the new Heidenhain TNC 640 as an option for all machine types in the future. Besides Siemens and Fanuc, Heidenhain controls are operated in boring and milling machines by many companies. Noteworthy customer benefits are their workshop-oriented programming with graphic support, as well as a user-friendly operating concept with a wealth of field-proven cycles.

The previous Heidenhain control iTNC 530 only allowed for the combination of bor-ing operations and turning operations, as for example with a high-speed rotary table or a facing head, to a limited degree. Heidenhain has now expanded the otherwise successful concept to include a comprehensive integration of turning technology.

Another advantage of the TNC 640: thanks to a new 3D simulation graphic with ex-ceptionally high attention to detail, the operator is able to judge the machining result before the actual machining process. A new concept for working with parallel axes allows for a compensational movement or balancing of the position display of the parallel axes Z and W, which are typical for boring mills. Operating and programming the new control do not require an additional training period. Machine operators who have experience with the iTNC 530 can easily switch to the TNC 640.

New TNC 640: comprehensive integration of turning technology.

PCR 150: precise machining of large workpieces.

“The definition of quality: when the customer returns” – this saying is affirmed by the follow-up order of a boring and milling machine which UnionChemnitz received recently by Arneburger Maschinen- und Stahlbau GmbH (AMS). A boring mill of the type PCR 150 by UnionChemnitz has been in operation there since 2007, machining components in the areas of materials handling and crane technology, energy tech-nology and coal and steel industry. After many years of witnessing the machine’s performance and precision, the company decided to invest in a second PCR 150 in order to further increase capacity and machining quality. The new PCR 150 will replace an older UnionChemnitz boring mill of the type PC 130.

The new horizontal boring and milling machine with a spindle diameter of 150 mm is designed for complete machining of large workpieces with an X-axis of 8 m and a Y-axis of 4 m. Boring and milling units can be attached automatically with the help of a transportable pick-up station.

As AMS Arneburg is a contract manufacturer for the engineering industry, an efficient work process in its production is crucial. In order to save time and money during the installation, the fundament of the PC 130 is adjusted to the new machine by the UnionChemnitz experts. The existing floor plate is expanded, as well. In addition, the PCR 150 is equipped with a rotary and traversing table DV 25 with a clamping area of 2,500 x 2,500 mm. Thanks to this new investment, AMS Arneburg now has two high-performance, cutting-edge boring mills at its disposal.

The first machine that UnionChemnitz has equipped with the new Heidenhain TNC 640 control, a table-type boring mill of the type TC 110, is already in operation suc-cessfully. In addition, the TNC 640 will be available in the complete boring mill range as an option (see above). Within the next months, a floor-type boring mill PCR 150 with a TNC 640 control will take up operation at the Estonian company AS REMEKSI KESKUS, a manufacturer of steel constructions for industrial facilities.

The fully hydrostatic machine with a boring spindle diameter of 150 mm will machine welded constructions with a length of up to 25 m and a height of up to 4.5 m. In order to ensure efficient and flexible production, the machine is equipped with two floor

Integrated turning function with TNC 640

plates. These are arranged to the left and right hand side of a rotary and traversing table with a clamping area of 3 x 2.5 m and a maximum load bearing capacity of 45 t. This configuration allows for flexible machining of large, long workpieces on the floor plates and prismatic housing parts on the rotary table. With the help of an automatically interchangeable facing head, the machine is able to perform turning as well as boring and milling operations. The facing head control is fully integrated into the new machine control. The machine takes full advantage of the turning functions of the TNC 640, which are supported by a large number of turning cycles.

PCR 150 with new Heidenhain control for AS REMEKSI KESKUS

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UnionChemnitz News

Issue: 2016 // 01

Publisher:

UNION Werkzeugmaschinen GmbH

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Corporate Communications

Flexible solutions for demanding housing components

First floor-type boring mill PCR 180 // KCU 150 for maximum precision // PCR 150 with integrated turning function

The first floor-type boring mill of the type PCR 180 with a boring spindle diameter of 180 mm will take up operation at JSC “Ko-peysk Machine-Building Plant”, the largest Russian manufac-turer of machines and compo-nents for the mining industry, in the beginning of 2017. Machin-ing housing components for the mining industry requires maxi-mum machining accuracy.

In order to achieve that, the new PCR 180 is hydrostatically guided in all axes. The machine traverses 8 m in the X-axis and 3 m in the Y-axis. With a perfor-mance of 84 kW and a torque of 5,520 Nm, it reliably masters even heavy-duty machining tasks with a high material re-moval rate. An orthogonal mill-ing head, manufactured within

UnionChemnitz makes it to the semi-finals

Seven athletes made their way from Chemnitz to Sonthofen in the Alps on January 30. Con-trary to its reputation as a calm holiday haven, the atmosphere at the annual HerkulesGroup Football Cup in the picturesque Bavarian region was far from tranquil that weekend. Assem-bly technologist Stefan Lauck-ner, start-up engineers Kevin Eberlein und Sven Hübler, as-sembler Steve Herbst, plan-ning engineer Kirill Zelter and apprentices Tobias Knauth and Norman Weckert took up the sporting challenge this year,

accompanied amongst others by CEO Christoph Thoma and President Dr. Benedikt Sitte. Twelve teams from all German locations of the group com-peted for the victory – but the tournament was about more than a title. “Not just the play-ers; the other employees and presidents of the companies, too, share the excitement each year,” Stefan Lauckner explains.

The tournament is not what you would generally expect from a company cup – the level of the players ranges as high as

the fourth German league, and total commitment is a matter of course. “We did well, con-sidering we are leisure foot-ballers,” says Stefan Lauckner. “The other teams, by contrast, have many players from higher leagues – and in this tourna-ment, everyone gives every-thing.”

In the group stage, Chemnitz was able to win several very competitive games, for exam-ple against the hosting team RSGetriebe. They were only de-feated in the last group match

against Herkules Meuselwitz, the victor of the 2014 tourna-ment. Chemnitz entered the knock-out stage as runner-up. The opponent: HerkulesGroup Services, who had remained un-beaten so far. With a level score of 1:1 the outcome of the game remained open until just before the end. Finally, Enrico Bali-jaj scored the winning goal for HerkulesGroup Services. They went on to the finals, but were beaten in overtime by Herkules Meuselwitz, who won the cup for the second time.

Team effort at the HerkulesGroup Football Cup

High-speed rotary table with interchangeable turning tool holder.

the HerkulesGroup, machines the housings with great flexibil-ity and precision.

The PCR 180 is equipped with an automatic tool changer with 40 pockets. Another advan-tage: two floor plates allow for the machining of one work-piece while the next is being set up – a significant time-saver.

Boring, milling and turningThe Russian Tomsk Vakhru-shev Electromechanical Plant, JSC (TEMZ Tomsk) has or-dered two machines as part of a new production chain for housing components: a planer-type horizontal boring and mill-ing machine with an integrated facing head KCU 150 and a boring mill of the type PCR with a boring spindle diameter of

The HerkulesGroup Football Cup is an opportunity for the employees to share an expe-rience outside of the offices and production facilities, to get to know each other and thus strengthen the communication between the companies. Be-sides arts and culture, sports is a central part of the social com-mitment of the HerkulesGroup – from staff events to youth devel-opment.

150 mm. The planer-type bor-ing mill is characterized above all by outstanding machining precision.

The PCR 150 is equipped with a high-speed rotary table, al-lowing for vertical turning of the components in addition to precise boring and milling op-erations. An interchangeable turning tool holder, a new de-velopment by UnionChemnitz, provides for additional flexibil-ity. Both boring mills will ma-chine pump housings for the oil and gas industry in the new production facility.

When arts student Stefan Schwar-zer received the advancement award of the arts festival “Bege-hungen Nr. 8” in the town of Chem-nitz, Germany, UnionChemnitz had just been integrated into the HerkulesGroup. Following the tra-dition of the Herkules Group to support artists from the respective regions, I contacted Stefan Schwar-zer and acquired his 204-part instal-lation “Groggy” – single drawings of the characters in the computer game Street Fighter II. Since then,

The artist Stefan Schwarzer

the works can be seen in the can-teen of UnionChemnitz.

In March of this year we met again – in Leipzig, Germany on the occa-sion of the vernissage of his exhi-bition “La Habana – Umbruch auf Raten” (“La Habana – Change in Installments”). After scholarships in Stuttgart, Germany and Havana, Cuba the artist works in Armenia at the moment. We will hear more from him in the years to come.

Marita Thoma

Twelve teams from all German locations took part in the HerkulesGroup Football Cup.

Artists Christian Zabel and Stefan Schwarzer; Marita Thoma and Gökben Beyazgül.