HELLER solutions at Power-Hydraulik
50% energy saving for more productivity alongside a higher degree of process reliability
The use of energy filters and modified control technology as well as process-specific modifications to the HELLER machining centres model H 2000 and H 4000 helped Power-Hydraulik GmbH to achieve measurable energy savings. At the same time, the machines provide absolute stability and precision. Moreover, pressure monitoring helps to prevent tool breakages and to increase feed rates.
Task
- energy saving when producing control blocks, particularly in the case of coolant-intense boring operations
- energy saving with the high-pressure coolant pump, pressure increase to over 85 bar
- pressure-monitored tool break monitoring
- increased feed speed
Project scope & solution
- HELLER H 2000 4-axis machining centre
- pressure increase to over 85 bar
- leak monitoring by sensors
- control system modification for predictive tool break monitoring: starting loop for deep hole drilling, pressure monitoring via frequency inverter
Result
- 50% energy saving alongside a higher degree of process reliability
- less heat input into the coolant, longer coolant pump service life
- leakage reduced by < 5 l/min
- higher degree of process reliability with pressure-based tool break monitoring, applies to any machining operation
- feed speed can be increased thanks to reliable tool break monitoring function
More references
Peter Arnold
Head of Mechanical Manufacturing at Komax
"If you have to deal with 30 pallets containing, at times, up to 50 different clamping points per clamping cube, you need the right tools in the magazine to avoid having to constantly change the tool sets. Our tool count currently stands at 409. Comparable or smaller machines simply do not achieve capacities such as these."
Günter Muhr
Managing Director at Franz Haas Waffelmaschinen
"HELLER has exceeded our expectations. Everything went well, the machines run extremely reliably and our throughput times have also measurably reduced."
Thomas Kaysser
Managing Director at H.P. Kaysser
"Our experience with HELLER, including Service, has been nothing but positive. We speak the same language, so there was simply no reason to change supplier. The entire team has now identified with the HELLER machining centres – because they deliver what HELLER promises!"
Frank Brunner
Head of Manufacturing and Production Engineering at Bitzer
"For batch sizes of up to 3 components, the machining centres have to perform reliably as soon as they are switched on, even after scheduled shutdowns. But neither availability nor the required precision presented a major challenge to the H 6000."
Gerhard Aigner
Head of Production at Engel Austria
"We consider quality to be fundamental. The tolerances for our core components are between two and three hundredths of a millimetre. That's why we made the conscious decision to go for HELLER machines, which are renowned for their stability."
Nicholas Warnken
Project Manager at Fette Compacting
"Key contributors to these massive savings are fewer setups thanks to the 5th axis and higher achievable cutting parameters. On the other hand, however, it was the overall package, including the automation system and new tool technologies, that was able to optimise the processes in this way".
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