On the new Emco Mecof Mecmill at Schlüsselbauer, the Stark.classic.NG.2 zero point clamping system ensures flexible clamping solutions with maximum process reliability for large workpieces
The Schlüsselbauer Technology GmbH & Co KG is an internationally established manufacturer of special-purpose machinery for the precast concrete industry. The company develops and manufactures machines and systems enabling customers worldwide to produce precast concrete elements for stormwater and wastewater drainage. The size of components and systems has increased continuously in recent years. As a result, the demands on in-house manufacturing have also grown.
The Stark.classic.NG.2 zero point clamping system from STARK supports stable machining processes and outstanding process reliability for large workpieces.
Markus Schick
Head of Mechanical Manufacturing, Schlüsselbauer Technology GmbH & Co KG
High Level of Vertical Integration as a Strategy
“The components are becoming increasingly extensive and, as a result, our machines are growing as well,” explains Managing Director Ulrich Schlüsselbauer. “Therefore, there was a need for manufacturing machines with a corresponding working area.”
The high level of vertical integration plays a central role. For many years, Schlüsselbauer has pursued the strategy of handling numerous core processes in-house. “We follow the principle: Everything we sell, we must also be able to produce ourselves,” emphasizes Schlüsselbauer.
Accordingly, the new production facility was designed consistently with this strategy. With the Mecmill from Emco, the company invested in a travelling-column milling machine with a generous working area in order to machine large components economically and with maximum process reliability. “We already have several machines from Emco in-house and are very satisfied with both the reliability of the machines and the customer service,” explains the Managing Director.
Double and triple rails from STARK were integrated on the fixed machine table to accommodate a wide variety of fixtures.
Reducing Set-up Times, Increasing Machine Running Times
Alongside machine selection, clamping technology became a key focus at an early stage of project planning. For heavy workpieces and frequently changing machining tasks, short set-up times and repeatable clamping processes are essential.
“With the Mecmill, a completely new machining range has opened up for us in mechanical manufacturing,” explains Markus Schick, responsible for mechanical manufacturing at Schlüsselbauer. “Reliable workpiece clamping naturally plays a central role.”
The workpieces are prepared outside the machine and subsequently loaded into the Mecmill completely clamped. The objective was to increase machine running times and remove set-up operations from the machining process.
“The components are loaded via the zero point clamping system, plug-and-play as they say,” Schick describes the process.
For implementation, Schlüsselbauer and STARK selected the Stark.classic.NG.2 zero point clamping system. The collaboration between the two companies has already existed for several years.
“A few years ago, Schlüsselbauer approached us with the intention of integrating a zero point clamping system into production,” recalls Erich Mühlgrabner, Key Account Manager at STARK. “Together, we analysed which system was the best fit for the existing machinery and applications.”
The workpieces are prepared outside the machine and then loaded into the Mecmill quickly and precisely via the zero point clamping system
Erich Mühlgrabner
Key Account Manager, STARK Spannsysteme GmbH
Flexible Clamping Concept for Large Workpieces
The requirements were clearly defined: high clamping forces, a broad application range and continued use of existing fixtures from the previous machine.
“That was a very important point,” emphasises Schick. “To work economically and conserve resources, we wanted to continue using many existing fixtures while making no compromises at the same time.”
According to Mühlgrabner, the Stark.classic.NG.2 was particularly suitable for this task. The system operates with active retraction and additionally features an additional lift function, allowing workpieces to be slightly lifted during release.
“This offers enormous advantages when loading with cranes and handling heavy components,” explains Mühlgrabner. “Schlüsselbauer machines large workpieces and performs frequent set-up operations. The system is ideally suited for this.”
A total of 43 Stark.classic.NG.2 zero point clamping system modules were installed on the Mecmill with multiple clamping circuits to ensure maximum flexibility in large-part machining.
Maximum Flexibility Guaranteed
The clamping technology was installed on both the fixed machine table and the rotary table of the Mecmill. Ten double support rails and triple support rails were integrated on the fixed table, while a 13-position fast closing plate was integrated on the rotary table. A total of 43 zero point clamping system modules were installed.
Actuation is provided via a Römheld power unit. In order to cover different machining situations flexibly, the installation was divided into five separate clamping circuits.
“This broad application range was extremely important for Schlüsselbauer,” explains Mühlgrabner. “The machine must be capable of accommodating all existing and future components reliably.”
In addition, all positions of the zero point clamping system modules were aligned directly on the machine using a probe and subsequently bolted in place. This ensured the required precision across the entire working area.
Focus on Process Reliability
Besides versatility, process reliability was also a major focus. Particularly when machining massive components, high forces and vibrations occur.
“The Stark.classic.NG.2 clamps with disc springs. As a result, vibrations generated during the machining of heavy components can be absorbed very effectively,” explains Mühlgrabner.
For Schlüsselbauer, the concept is paying off primarily in daily practice. Set-up times have been significantly reduced and machine availability has increased.
“We manufacture our products just in time,” says Schick. “That is why it is extremely important for us that the machine runs productively in daily operation.”
The solution has also proven easy to maintain during operation. Cleaning and maintenance can be carried out directly in-house.
“That was another important point for us,” emphasises Schick. “Maintenance needed to be simple and possible without sending components away. STARK fulfilled this requirement perfectly.”
Partnership-Based Cooperation
Both parties draw a very positive conclusion.
“We received extremely positive feedback from Schlüsselbauer,” summarises Mühlgrabner. “Most importantly, the system operates reliably and without failures. In the end, that is what counts in production.”
In addition to the technical solution, Schlüsselbauer particularly highlights the cooperative partnership.
“STARK Spannsysteme GmbH has been and continues to be a very good partner for us,” concludes Markus Schick. “From the design phase through ongoing support, the cooperation has functioned excellently.”
User: Schlüsselbauer
Schlüsselbauer Technology GmbH & Co KG, headquartered in Gaspoltshofen, is an internationally active special-purpose machine manufacturer for the precast concrete industry. The family-owned company develops and produces systems for the manufacture of concrete pipes, manhole systems and other infrastructure components for water and wastewater engineering. Its portfolio ranges from individual production machines to fully automated systems.
Founded: 1964
Employees: 300 worldwide
Focus: Plant engineering and system solutions for the precast concrete and infrastructure industries
High level of vertical integration: From cutting, machining, and welding through to surface treatment and assembly.
In-house development, manufacturing and commissioning.
Schlüsselbauer Technology GmbH & Co KG
Hörbach 4
A-4673 Gaspoltshofen
www.sbm.at
SCHLÜSSELBAUER Technology
Stark Spannsysteme Stark.classic.NG.2
The fast closing clamps of the STARK.classic product family are zero point clamping systems with versatile application possibilities. STARK.classic systems are used for installation in machine pallets, plates, angles, cubes, towers and swivel bridges. They can be used for all common machining operations such as milling, turning, grinding and EDM, as well as on test benches and assembly fixtures. The fast closing clamps made from high-quality tool steel are mechanically clamped and hydraulically released.
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