LaserControl at Playmobil.
As the firm approaches its 40th wedding anniversary, some 2.6 billion Playmobil figures presently populate the planet. Numerous brand-new numbers are released annually, putting high demands on the in-house mould shop. To accomplish maximum performance in unmanned, automated operation, Playmobil’s countless machining centres have actually been utilizing LaserControl measuring systems of Blum-Novotest already for 15 years.
” For Playmobil figures, hundredths of a millimetre matter,” claims Attila Britting, head of Playmobil’s internal mould shop in Zirndorf near Nuremberg. “The purpose in developing the shot moulds is to create finished plastic items that need essentially no rework– which is essential because a day-to-day manufacturing of around 10 million individual components as well as over 100 million figures a year. Consequently, the mould separation must likewise be a high-precision operation, to ensure that there are not any burrs on the private parts or the completed figure.”
And not least, the moulds are specified for incredibly high volumes, manufacturing runs of 200,000 to 300,000 items from one mould are no rarity. The needed efficiency can just be achieved by partially automated production along with the normal two-shift procedure. So a selection of devices works over night on prepared tasks. To execute these work, several of the machining centres are furnished with pallet changers as well as device publications with the capability to hold as numerous as 120 devices. The machines even maintain running unmanned over the weekend break. The Blum-Novotest systems are installed in the machining area of the automated DMG five-axis machining centres.
BLUM laser determining system in the Playmobil mould-making store
BLUM laser determining systems help geobra Brandstätter to produce injection-moulding devices effectively and also in premium
After every tool change, the laser immediately gauges the size and span of the tool prior to machining, and after machining look for breakage and wear. Thus, our skilled workers no more need to pre-set the device in the pre-setting tool. A new device is just shrink-fitted into the owner and also gauged at machining rate after suitable. This ensures that the tool information in the equipment is proper, numerical errors or data analysis mistakes can no longer take place. Further attributes consist of high-speed automatic payment for the thermal expansion of the entire device as well as for pin displacement. Inaccurate device information can have expensive effects such as faulty devices, denies, or equipment standstill. A spindle harmed by a collision will set you back at the very least 18,000 Euros to replace.
Without a monitoring system to identify used or damaged tools, automated manufacturing is hardly possible. The LaserControl system’s damage screen guarantees that damaged tool discovery runs instantly after every machining step. Depending upon the programming, the machining centre can then either exchange the tool for a double or inform the on-call service staff, that can visit to the maker over the Internet and check the workshop with a cam. At Playmobil, as many as 4 of the trick devices are kept in the tool changer, which suggests that the automated overnight jobs run really dependably.
We primarily make use of steel with a high chromium web content since it reveals the least wear throughout the large volume manufacturing big. It does create significant device wear during cutting, nevertheless. That is why it is extremely essential to watch on the running times of the private tools. The BLUM laser determining systems do this extremely well.
Blum-Novotest allows the several injection mould to be created in supreme top quality.
In the manufacture of very intricate injection-moulded tools, hundredths of a millimetre count: All single parts are precisely matched to each other.
High-precision measurement in a dirty atmosphere positions a major obstacle, and cooling is vital to the production procedure. To secure the optical system from being dirtied, the gauging system is mechanically sealed from the coolant by a pneumatically operated shutter piston during machining. The turning tool is also cleansed with compressed air before measuring in order to make sure that the measurement is not impaired by swarf, dirt or cooling lubricating substances. During dimension, a stream of obstacle air provides defense against staining.
The LaserControl systems have genuinely been their money’s worth at Playmobil. The systems are almost upkeep complimentary; as well as, after greater than one decade in continual operation, the seals look like new. Most of all, however, the specialists have never been pulled down by the laser systems as well as have experienced just good things in regards to solution, too. “We have actually had only good experience with BLUM lasers– and also we conserve working time since there is no need for pre-setting”, Marco Mendl, team leader CAD/CAM/NC, summarises. “The precision of the LaserControl systems is astounding, also. Based on our experience, its repeatability is within less than two thousandths of a millimetre. And also for us, something is for sure: Without the BLUM laser systems, this level of automation would not be feasible.”
Based in Zirndorf near Nuremberg in the Franconia area of southern Germany, geobra Brandstätter GmbH & Co. KG is the manufacturer of Playmobil, and therefore Germany’s largest plaything manufacturer. The Brandstätter Group runs production centers in Germany, Malta, Spain and also the Czech Republic. It uses more than 3,700 people worldwide, as well as in 2012 generated total sales of 591 million Euro. At the heart of the multi-award-winning plaything concept are the 7.5 centimetre high Playmobil numbers, which are marketed in over 30 historic and contemporary themed collection to greater than 80 nations throughout the world. Approaching their 40th wedding anniversary, there are currently some 2.6 billion Playmobil numbers inhabiting the earth. Together with premium toy high quality ‘Made in Europe’, given that the year 2000 the innovative service has likewise been manufacturing LECHUZA top-quality plastic planters.