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7/30/2019 Projekt_MAN Crank Case
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M AN N uremberg , Germany
6 -cylinder crankcasemanufacturing system.
Customer Report
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Customer Report M AN N uremberg , Germany
The D20 project.The new heart of the TGA.
Nuremberg,
Summer 2000
After four years of development,
MAN engineers have completed the
prototype of a new generation of
6 -cylinder diesel engines. The inno-
vative project is called D20.
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6 -Cylinder Crankcase Pr oduction Line
Increasing demands on performance and fuel con-
sumption and stricter emission controls require manu-
facturers of commercial vehicles to draw on innovative
technologies. The R&D division at MAN broke new
ground with the development of the latest generation
of TGA engines. Expectations of the D20 project are
high: more power and longer intervals between
maintenance, at the same time reduction of weight,
fuel consumption, pollutant and noise emissions. For
the first time a vermicular graphite casting (GJV 450)
was used as material for the crankcase. In addition to
product and process development the project required
a state-of-the-art production system.
Phase 1:Specificat ions
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Customer Report M AN N uremberg , Germany
Innovat ion through co-operat ion:
engineering par t nership providesaddit ional t ime and cost advant ages.
Nrtingen,
October 2000
HELLER received the assignment
to develop a detailed process layout
for the D20 crankcase. Close co-
operation had a positive influence
on the development process.
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It is necessary to ever excel in product and process
technology to remain the innovative leader in a field. To
keep the innovative edge, MAN and HELLER project
teams started to work together early in the prototype
phase. HELLER design engineers contributed extensive
product and process know-how and the MAN team
added in-depth knowledge of the product. Because of
the close collaborat ion and simultaneous engineering
the time until start of serial production was reduced by
several months and a number of innovative ideas could
be incorporated in the development process. A system
partnership was forged that opened up innovation
potential and assured MAN a competitive lead.
Phase 2:Engineering
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Customer Report M AN N uremberg , Germany
HELLER system solutions ensure a maximum level of
dependability and planning reliability. Experienced pro-
ject engineers will answer any of your quest ions through-
out all phases of a new project, from the preparation
of the performance specification to the development of
an optimum process chain, including system layout,
successful commissioning of the system and achieving
production t argets.
However, HELLERs co-operation is not restricted to
the layout of the production technology. HELLER also
supports the customer in questions of production-
friendly workpiece design, material flow, design of
clamping fixtures or material handling between the
operations. Today, simultaneous engineering involves
computer-based modeling of the complete process
from raw to finished part. This has the advantage that
modifications can be quickly and easily integrated into
the ongoing development process. As a result, the
development period to the actual start of production
can be significantly shortened an important factor
when time is money.
HELLER makes sure customers are kept up-to-date
with the latest trends in production technology so they
can concentrate on their production. Partnership with
HELLER guarantees customers innovation ability for a
lasting competitive edge on the world market.
Process technology made to measure:syst em part nership wit h HELLER unlocks
innovat ion pot ent ial.
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Customer Report M AN N uremberg , Germany
Nrtingen,
January 2001
On the computer 20 different layout
versions are modeled, based on avail-
able space and planned production.
A short way from model to reality:computer -aided layout design speeds up
decision-making process.17 16 15 14 13 12 11 10 9
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6 -Cylinder Crankcase Pr oduction Line
Integrating a system into an existing structure is
subject to different requirements than building a new
facility. The MAN plant in Nuremberg had several areas
within the facility available for the production of the
D20 crankcase. In a shor t time, HELLER's layout
experts were able to submit alternative layouts to MAN
by using efficient CAD systems. Special software tools
determined the required machine capacity based on
planned production volume. In this process, various
combinations and automation options of special and
serial machines are considered as well as alternative
manufacturing concepts using various machine types.
The ideal solution for MAN was a combination of 18
machining centers of the model range MCH 400 and
4 FST (Flexible System Transfer Lines) and single
machines from other suppliers.
Phase 3:Layout planning
8 7 6 5 4 3 2 1
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Customer Report M AN N uremberg , Germany
Nuremberg,
September 2002
Modular building blocks for the D20
project are beginning to take shapein HELLERs final assembly shop. All
system components of the manu-
facturing line successfully pass the
required acceptance tests a pre-
requisite to meet the high expectations.
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6 -Cylinder Crankcase Pr oduction Line
Detailed planning of each process step during the deve-
lopment phase resulted in time savings that benefited
machine configurations and process trial runs. In case
of the D20 crankcase, installation of three machining
centers with three clamping positions was sufficient to
test run the NC programs and to verify the required
process capability. The remaining fifteen MCH 400
machining centers were shipped to MAN after geome-
trical acceptance. Because of this positive experience,
MAN released the transfer systems for shipment after
they had passed the function tests and trial machining.
Fine adjustment for maximum process capability, a very
time consuming process, was completed at the MAN
facility.
The extensive machining competence of the project
engineers contributed to saving time on the project.
At the Nuertingen plant, HELLER is able to machine
prototypes required by MAN for t rial tests before
commissioning of the manufacturing system. For this
purpose, the machining content of the special-purpose
machines (FST) was transferred to a machining center.
Phase 4:M achine configurat ion
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Customer Report M AN N uremberg , Germany
Nuremberg,
January 2003
HELLER installs the first machines
in the former turbine building. Five
months later pilot production star ted.
One hundred and fifty units will be
manufactured by the end of the year.
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6 -Cylinder Crankcase Pr oduction Line
The hybrid production system applied to the MAN
project assures efficient installation of each machine
and fast commissioning of the complete system. It is
based on HELLER's highly modular system components,
characterized by standard basic machines and flexible
assemblies. This is the reason that HELLER manufactur-
ing systems can easily be extended without major invest-
ments. If an increase in production volume creates a
bottleneck in a production area, HELLER can easily solve
the problem with alternatives from its modular range.
In addition to twin-spindle machines and turret head
solutions, dynamic packages are available for enhancing
the performance of existing machines.
Phase 5:Commissioning
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Customer Report M AN N uremberg , Germany
Two steps to full performance:integrated process measuringguarant ees highest qualit y.
Nuremberg,
April 2004
The new MAN manufacturing
system goes into production. It is
planned to increase production from
14,0 00 cases in 2004 to 55,000
units in 2007.
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6 -Cylinder Crankcase Pr oduction Line
It was planned to ramp up production at MAN in two
steps. In the first step, the system had been laid out
for a production of 30,000 units. In the second step,
production was gradually raised to the required
55,000 units.
To achieve this goal, only the capacity of the machining
centers for the intermediate operations had to be
increased. Due to their high flexibility, the transfer
systems are scalable according to requirement. To
ensure maximum reliability of the system in high-
volume production, finish-machining is performed using
in-process gauging. Integration of the measuring tech-
nology into the final step of the process chain allows
to compensate for any wear effects that may occur
during pre-machining and to ensure consistent part
quality in batch manufacturing.
Phase 6:Start of production
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Customer Report M AN N uremberg , Germany
Nuremberg,
June 2005
The D20 project moves full speed
ahead, all sales forecasts have been
exceeded. MAN decides to implement
step 2 earlier than planned.
The product
The outcome of the par tner ship between HELLER and
MAN was remarkable. The new D20 engine generation
surpassed all expectations and the projected sales
volume was already exceeded in the first year. This
comes as no surprise considering the improvements
made on the engine: a 25 % reduction in engine
components and a weight reduction of 100 kg are a
quantum leap in heavy engine design. Significantly
reduced pollutant emissions ensure that all existing and
future exhaust emission standards are met. To ensure
this, the engine is equipped with common-rail techno-
logy, exhaust gas recirculation and a special mainten-
ance-free filter. As a result, maintenance intervals were
extended to 120,000 km and fuel consumption was
cut by more than 5 percent.
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6 -Cylinder Crankcase Pr oduction Line
HELLER a r eliable par t ner forbest results.
The manufacturing system
4 Flexible System-Transfer lines (FST) with
4 6 single and double machining stations each
18 machining centers MCH 400 with direct loading
1 stand-alone FST
Washers, Alfing cracking system
Lift-and-carry-system for automation of FST
GSA overhead gantry loaders for automationof the MCH 400 machining centers
The process chain
Step 1 (1 st and 2 nd FST): pre-machining of
cylinder head and oil pan face, pre-machining of
cylinder bore, deep hole drilling and pre-machining
of crankshaft bore
Step 2 (MCH): milling (using angular milling head),
deep hole drilling, multispindle machining
Step 3 : intermediate washer
Step 4 : cracking of crankshaft bearings, machining
of oil holes in 3 rd FST with integrated head changerand TBT gun drilling unit.
Step 5 (4 th FST): finish m achining of crankshaft
bore and thrust bearing, machining of front faces,
machining of cylinder bore (2 spindles), milling of
cylinder head joint faces
Step 6 : deburr ing/ assembly
Step 7 : washing
Step 8 : final inspection
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Customer Report M AN N uremberg , Germany
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6 -Cylinder Crankcase Pr oduction Line
Development and implementation of the manufacturing
line for the machining of the D20 crankcase was only
one aspect of the successful system partnership
between Gebr. HELLER Maschinenfabr ik GmbH and
MAN Nutzfahrzeuge AG in Nuremberg. HELLER also
took on overall responsibility for the planning and
commissioning of manufacturing lines for further key
components of the 6-cylinder engine generation.
Meanwhile, the complete machining of the cylinder
head is performed on HELLER machines. The manu-
facturing line comprises ten machining centers model
MCP-H 400, four HCS 400 head changers and a
flexible transfer system. The latest generation of
HELLERs internal milling machines is employed for
crankshaft machining. The machines of the RFK 400
(300) range provide excellent quality in the machining
of mains and pins.
MAN was more than satisfied with the outcome of the
partnership with HELLER. On 12 May 2005, CEO
Berndt Heller and HELLERs director of sales and
engineering, Manfred Maier, received the prestigious
Trucknology Supplier 2004 award in Munich. The
prize is subject to a strict selection procedure and is
awarded to the ten best of the 1000 MAN suppliers.
The success of the D20 project once more underlines
HELLERs outstanding position as supplier for the truck
powertrain production.
HELLER syst em solut ions:a long line of success.
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www.heller -machinetools.com
We are here for you.
Investments in manufacturing need results that are guaranteed.
HELLER as your partner offers these guarantees with arange of innovative, product oriented machines and machining
centers, with project and process competence, and with fast
responding, qualified service teams. More detailed information
on products and services is available at the following locations
or on the internet.
The Power of Progress
Subjecttoalteration.
MAN
Nuremberg/GB-08/05
FranceHELLER M achines Outils5, rue Saarinen Silic 128
94523 Rungis CedexTl. +33 1.46 .87.34 .52 Fax +33 1.45.6 0.54.8 4E-Mail: [email protected]
ItaliaHELLER It alia M acchine Utensili S.r.l.Via Leonardo Da Vinci, 537029 San Pietro in Cariano (Verona)
Tel. +39 45 6 83 8-231 Fax +39 45 68 38 -23 4E-Mail: [email protected]
UKHELLER M achine Tools Lt d.Acanthus Road Ravensbank Business ParkRedditch, Worcs. B98 9EXTel. +44 1 21 275 -330 0 Fax +44 12 1 2 75-3380
E-Mail: [email protected]
USAHELLER M achine Tools L.P.12 25 Equity Drive Troy, M ichigan 48 08 4Tel. +1 248 2 88 -50 00 Fax +1 24 8 28 8-9560E-Mail: [email protected]
M exicoHELLER M achine Tools de M exicoS. de R.L. de C.V.Cortazar No. 102 Col. HidalgoC.P. 37 32 9 Leon, Gto.Tel. +1 248 2 88 -50 00 Fax +1 248 28 8-9560E-Mail: [email protected]
BrasilHELLER M quinas Operat rizesIndstria e Comrcio Ltda.Rua Joaquim Machado, 250Bairro AparecidinhaCaixa Postal 12618 08 7-280 Sorocaba So PauloTel. +55 15 3 23 5-1360 Fax +55 15 32 35 -13 04E-Mail: [email protected]
ChinaHELLER M achinery & Trading(Shanghai) Co., Ltd.Rm. 4402-4403, Shanghai Maxdo CentreNo. 8 Xing Yi Road, HongQiao Development ZoneShanghai 200336Tel. +86 21 5 208 048 5 Fax +86 21 5 208 049 5E-Mail: [email protected]. cn
DeutschlandGebr. HELLER M aschinenfabrik GmbHNeuffener Strasse 54 72622 Nrtingen
Postfach 14 28 72 60 4 NrtingenTel. +49 70 22 77 -0 Fax +49 70 22 77 -61 0E-Mail: [email protected]
HELLER WerkzeugmaschinenHattingen GmbHHttenstrasse 45 4 55 27 HattingenTel. +49 23 24 9 24 5-0 Fax +49 23 24 9 24 5-99
E-Mail: [email protected]
HELLER Wer kzeugmaschinen GmbHChemnit zSandstrasse 116 09114 ChemnitzTel. +49 3 71 330 0-790 Fax +49 37 1 3 300 -791E-Mail: [email protected]
HELLER Wer kzeugmaschinen GmbHNeufrachAm Riedweg 16 88682 Salem-NeufrachTel. +49 7 553 827 28-0 Fax +49 755 3 8 272 8-61E-Mail: [email protected]