LaserControl at Playmobil.
As the company approaches its 40th wedding anniversary, some 2.6 billion Playmobil numbers currently inhabit the earth. Numerous brand-new numbers are launched each year, positioning high needs on the internal mould shop. To attain optimal efficiency in unmanned, computerized procedure, Playmobil’s many machining centres have actually been using 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 goal in constructing the shot moulds is to produce completed plastic things that require virtually no rework– which is important in view of an everyday production of about 10 million individual components as well as over 100 million numbers a year. Subsequently, the mould separation have to additionally be a high-precision procedure, to make sure that there are none burrs on the specific parts or the completed figure.”
As well as not least, the moulds are specified for very high quantities, manufacturing runs of 200,000 to 300,000 items from one mould are no rarity. The required performance can only be attained by partially automated production alongside the typical two-shift operation. So a selection of devices works overnight on ready tasks. To implement these jobs, several of the machining centres are geared up with pallet changers and also device publications with the ability to hold as several as 120 devices. The makers even keep running unmanned over the weekend break. The Blum-Novotest systems are set up in the machining area of the automated DMG five-axis machining centres.
BLUM laser measuring system in the Playmobil mould-making shop
BLUM laser determining systems help geobra Brandstätter to generate injection-moulding devices successfully and also in top quality
After every tool adjustment, the laser instantly measures the size as well as span of the device prior to machining, and also after machining look for damage and wear. Therefore, our skilled workers no longer have to pre-set the device in the pre-setting gadget. A brand-new device is merely shrink-fitted into the owner and gauged at machining speed after fitting. This guarantees that the device information in the maker is proper, mathematical errors or data analysis errors can no longer take place. Additional features include high-speed automated compensation for the thermal expansion of the whole maker and also for pin displacement. Wrong tool information can have pricey consequences such as defective tools, denies, or equipment stoppage. A spindle harmed by a crash will cost a minimum of 18,000 Euros to change.
Without a surveillance system to identify used or damaged tools, automated production is hardly possible. The LaserControl system’s damage screen ensures that broken device discovery runs promptly after every machining step. Relying on the programming, the machining centre can after that either exchange the tool for a twin or alert the on-call service staff, who can log in to the equipment online as well as check the workshop with a webcam. At Playmobil, as many as 4 of the key devices are held in the tool changer, which implies that the automated over night work run very reliably.
We primarily make use of steel with a high chromium material since it shows the least wear throughout the large volume production huge. It does cause considerable tool wear during cutting, however. That is why it is really essential to watch on the running times of the specific tools. The BLUM laser gauging systems do this very well.
Blum-Novotest enables the multiple injection mould to be produced in superior high quality.
In the manufacture of highly complicated injection-moulded devices, hundredths of a millimetre matter: All solitary parts are precisely matched per other.
High-precision measurement in a filthy setting poses a major difficulty, and also cooling is necessary to the manufacturing procedure. To safeguard the optical system from being stained, the determining system is mechanically sealed off from the coolant by a pneumatically operated shutter piston throughout machining. The revolving tool is additionally cleansed with compressed air before gauging in order to ensure that the dimension is not impaired by swarf, dirt or cooling lubricating substances. Throughout dimension, a stream of barrier air provides defense versus soiling.
The LaserControl systems have genuinely been their money’s worth at Playmobil. The systems are practically upkeep cost-free; and, after more than one decade in constant procedure, the seals look like new. Above all, nevertheless, the specialists have actually never ever been pulled down by the laser systems and also have actually experienced nothing but good things in regards to service, too. “We have had only good experience with BLUM lasers– as well as we conserve working time since there is no need for pre-setting”, Marco Mendl, group leader CAD/CAM/NC, sums up. “The accuracy of the LaserControl systems is astonishing, also. Based upon our experience, its repeatability is within less than 2 thousandths of a millimetre. And for us, one thing is for certain: Without the BLUM laser systems, this level of automation would not be feasible.”
Based in Zirndorf near Nuremberg in the Franconia region of southerly Germany, geobra Brandstätter GmbH & Co. KG is the producer of Playmobil, and therefore Germany’s biggest plaything supplier. The Brandstätter Group operates production centers in Germany, Malta, Spain as well as the Czech Republic. It utilizes greater than 3,700 individuals worldwide, as well as in 2012 produced overall sales of 591 million Euro. At the heart of the multi-award-winning plaything concept are the 7.5 centimetre tall Playmobil figures, which are marketed in over 30 historic and modern-day themed collection to more than 80 nations around the globe. Approaching their 40th anniversary, there are currently some 2.6 billion Playmobil figures populating the earth. Along with costs toy top quality ‘Made in Europe’, given that the year 2000 the ingenious service has additionally been making LECHUZA high-grade plastic planters.