LaserControl at Playmobil.
As the company approaches its 40th anniversary, some 2.6 billion Playmobil numbers currently inhabit the planet. Many brand-new figures are released each year, positioning high demands on the in-house mould store. To accomplish optimal efficiency in unmanned, automated procedure, Playmobil’s many machining centres have been using LaserControl determining systems of Blum-Novotest already for 15 years.
” For Playmobil numbers, hundredths of a millimetre count,” says Attila Britting, head of Playmobil’s internal mould shop in Zirndorf near Nuremberg. “The goal in building the injection moulds is to produce completed plastic things that need virtually no rework– which is essential in view of an everyday manufacturing of about 10 million individual components as well as over 100 million numbers a year. As a result, the mould splitting up should likewise be a high-precision procedure, so that there are not any burrs on the individual parts or the ended up number.”
And also not least, the moulds are defined for very high volumes, manufacturing runs of 200,000 to 300,000 pieces from one mould are no rarity. The needed efficiency can just be achieved by partly automated production along with the normal two-shift operation. So a selection of makers works over night on ready work. To implement these work, several of the machining centres are equipped with pallet changers and tool publications with the capability to hold as several as 120 devices. The machines even maintain running unmanned over the weekend. The Blum-Novotest systems are mounted in the machining area of the automated DMG five-axis machining centres.
BLUM laser determining system in the Playmobil mould-making shop
BLUM laser measuring systems assist geobra Brandstätter to create injection-moulding tools efficiently and in top-notch
After every tool adjustment, the laser immediately determines the length as well as distance of the device before machining, and also after machining checks for breakage and also wear. Therefore, our skilled workers no longer need to pre-set the device in the pre-setting gadget. A brand-new tool is merely shrink-fitted into the owner as well as gauged at machining speed after fitting. This guarantees that the device data in the maker is correct, mathematical errors or data reading blunders can no longer occur. Additional functions include high-speed automated settlement for the thermal expansion of the entire maker as well as for spindle variation. Incorrect device information can have pricey consequences such as malfunctioning tools, rejects, or equipment deduction. A spindle damaged by a collision will certainly set you back a minimum of 18,000 Euros to replace.
Without a monitoring system to identify worn or damaged tools, automated production is hardly possible. The LaserControl system’s damage screen makes sure that busted device discovery runs immediately after every machining step. Depending upon the programs, the machining centre can after that either trade the device for a double or inform the on-call service team, who can log in to the maker online and also monitor the workshop with a web cam. At Playmobil, as lots of as 4 of the trick tools are kept in the device changer, which suggests that the automated overnight tasks run extremely reliably.
We mainly use steel with a high chromium web content since it reveals the least wear during the large volume manufacturing large. It does create substantial device wear during cutting, nonetheless. That is why it is really essential to watch on the running times of the private devices. The BLUM laser gauging systems do this effectively.
Blum-Novotest makes it possible for the several shot mould to be produced in supreme top quality.
In the manufacture of highly complicated injection-moulded devices, hundredths of a millimetre count: All solitary parts are precisely matched to each other.
High-precision measurement in a dirty atmosphere presents a significant difficulty, and also air conditioning is essential to the manufacturing process. To secure the optical system from being dirtied, the determining system is mechanically sealed from the coolant by a pneumatically operated shutter piston during machining. The revolving device is additionally cleansed with pressed air before gauging in order to ensure that the dimension is not hindered by swarf, dust or cooling down lubricating substances. During measurement, a stream of barrier air provides protection versus dirtying.
The LaserControl systems have actually absolutely been their cash’s well worth at Playmobil. The systems are almost maintenance complimentary; as well as, after greater than ten years in continuous procedure, the seals resemble new. Most importantly, however, the experts have actually never been pulled down by the laser systems and have experienced only good things in terms of solution, also. “We have had only good experience with BLUM lasers– and also we conserve functioning time since there is no requirement for pre-setting”, Marco Mendl, group leader CAD/CAM/NC, sums up. “The precision of the LaserControl systems is remarkable, too. Based upon our experience, its repeatability is within less than 2 thousandths of a millimetre. As well as for us, one point is for sure: Without the BLUM laser systems, this degree of automation would certainly not be feasible.”
Based in Zirndorf near Nuremberg in the Franconia area of southerly Germany, geobra Brandstätter GmbH & Co. KG is the supplier of Playmobil, and also because of this Germany’s biggest plaything supplier. The Brandstätter Group operates production facilities in Germany, Malta, Spain and the Czech Republic. It uses more than 3,700 individuals worldwide, as well as in 2012 produced complete sales of 591 million Euro. At the heart of the multi-award-winning plaything idea are the 7.5 centimetre tall Playmobil figures, which are marketed in over 30 historical and also modern-day themed series to greater than 80 nations throughout the world. Approaching their 40th wedding anniversary, there are presently some 2.6 billion Playmobil figures occupying the planet. Together with costs plaything quality ‘Made in Europe’, given that the year 2000 the ingenious organization has actually likewise been manufacturing LECHUZA state-of-the-art plastic planters.