LaserControl at Playmobil.
As the firm approaches its 40th wedding anniversary, some 2.6 billion Playmobil numbers presently populate the planet. Many brand-new numbers are launched yearly, placing high needs on the in-house mould shop. To achieve optimal efficiency in unmanned, computerized operation, Playmobil’s many machining centres have been making use of LaserControl determining systems of Blum-Novotest currently for 15 years.
” For Playmobil figures, hundredths of a millimetre count,” states Attila Britting, head of Playmobil’s internal mould shop in Zirndorf near Nuremberg. “The goal in building the shot moulds is to produce completed plastic products that need basically no rework– which is important in view of an everyday manufacturing of about 10 million specific parts and over 100 million numbers a year. Consequently, the mould splitting up must additionally be a high-precision operation, so that there are none burrs on the specific components or the finished figure.”
And also not least, the moulds are defined for exceptionally high volumes, manufacturing runs of 200,000 to 300,000 items from one mould are no rarity. The called for productivity can only be attained by partially automated production along with the normal two-shift operation. So an array of equipments works over night on ready jobs. To implement these tasks, several of the machining centres are outfitted with pallet changers and also device magazines with the capacity to hold as numerous as 120 tools. The machines even keep 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 shop
BLUM laser gauging systems aid geobra Brandstätter to create injection-moulding devices efficiently and in top-notch
After every device modification, the laser immediately determines the size and distance of the device prior to machining, as well as after machining checks for damage and wear. Thus, our skilled workers no longer have to pre-set the device in the pre-setting gadget. A brand-new tool is simply shrink-fitted right into the owner as well as gauged at machining rate after suitable. This makes sure that the tool data in the machine is correct, mathematical errors or information reading blunders can no more take place. Additional functions include high-speed automatic payment for the thermal development of the entire device and for spindle variation. Incorrect tool data can have pricey repercussions such as defective devices, denies, or machine standstill. A spindle harmed by an accident will cost at the very least 18,000 Euros to change.
Without a tracking system to detect worn or damaged tools, automated manufacturing is hardly possible. The LaserControl system’s breakage screen makes sure that broken device detection runs promptly after every machining action. Depending upon the shows, the machining centre can then either exchange the tool for a double or alert the on-call service staff, that can log in to the device over the Internet as well as monitor the workshop through a cam. At Playmobil, as lots of as four of the trick tools are held in the tool changer, which suggests that the automated overnight jobs run extremely reliably.
We mostly use steel with a high chromium material because it shows the least wear throughout the large volume production large. It does create significant tool wear during reducing, nonetheless. That is why it is very important to keep an eye on the running times of the individual devices. The BLUM laser determining systems do this very well.
Blum-Novotest allows the multiple shot mould to be generated in superior top quality.
In the manufacture of extremely complicated injection-moulded tools, hundredths of a millimetre count: All single parts are specifically matched to each various other.
High-precision measurement in an unclean environment presents a major difficulty, as well as cooling is essential to the manufacturing procedure. To protect 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 rotating device is also cleansed with compressed air prior to measuring in order to make sure that the measurement is not harmed by swarf, dirt or cooling lubricating substances. During dimension, a stream of barrier air gives security against staining.
The LaserControl systems have actually genuinely been their cash’s well worth at Playmobil. The systems are practically maintenance free; as well as, after greater than one decade in continual operation, the seals resemble new. Most importantly, nevertheless, the specialists have never ever been pulled down by the laser systems as well as have experienced only advantages in regards to service, too. “We have actually had only excellent experience with BLUM lasers– as well as we save working time due to the fact that there is no need for pre-setting”, Marco Mendl, group leader CAD/CAM/NC, summarises. “The precision of the LaserControl systems is impressive, too. Based upon our experience, its repeatability is within less than two thousandths of a millimetre. As well as for us, one point is for certain: Without the BLUM laser systems, this level of automation would certainly not be feasible.”
Based in Zirndorf near Nuremberg in the Franconia region of southerly Germany, geobra Brandstätter GmbH & Co. KG is the maker of Playmobil, and also therefore Germany’s largest toy maker. The Brandstätter Team runs production centers in Germany, Malta, Spain and the Czech Republic. It uses more than 3,700 people worldwide, and also in 2012 created complete sales of 591 million Euro. At the heart of the multi-award-winning toy idea are the 7.5 centimetre tall Playmobil figures, which are marketed in over 30 historical and modern themed collection to more than 80 nations around the globe. Approaching their 40th anniversary, there are currently some 2.6 billion Playmobil figures inhabiting the earth. Alongside costs plaything quality ‘Made in Europe’, considering that the year 2000 the cutting-edge business has also been making LECHUZA top-quality plastic planters.