Automated 6-side complete machining

Process automation Automated 6-side complete machining

2024-05-15 From | Translated by AI 4 min Reading Time

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Brunvoll has been relying on automated processes for years. In a recent investment, the focus was for the first time on the area of complex turned parts. This is where DMG Mori came into play.

Brunnvoll manufactures, among other things, these low-noise crossflow control systems (Low Noise Tunnel Thrusters) with a noise reduction of up to 15 decibels.(Image: DMG Mori/Brunvoll) — Brunnvoll manufactures, among other things, these low-noise crossflow control systems (Low Noise Tunnel Thrusters) with a noise reduction of up to 15 decibels.
(Image: DMG Mori/Brunvoll)

Already at the beginning of the 20th century, the then-founded Brunvoll Motorfabrik produced its first diesel engines and ship propellers for fishing boats. Following an idea from the Gjendemsjø brothers, two local fishermen, the company began developing and manufacturing tunnel thrusters in 1964 - still a common principle of ship drives.

Headquartered in Molde, Norway, the Brunvoll Group today stands for powerful ship drives, reliable transmissions, and innovative control electronics more than ever. Around 520 employees at five production locations ensure smooth processes from development to manufacturing to service. For several years, Brunvoll has been using highly automated processes in manufacturing, including an autonomous manufacturing solution with an NTX 3000 and robot automation that DMG Mori designed for the company in 2022.

Gallery

Magne Gøran Lyngstad (Vice President Process and Production Engineering) and Kjetil Hoem (Supervisor Investment Projects) in front of the Matrix cell with an NTX 3000.(Image: DMG Mori/Brunvoll)

"The Matris system on the NTX 3000 allows us to manufacture different parts in a fully automated and process-secured way. And this is for batch sizes of less than 15 parts including gripper and chuck jaw change." Kjetil Hoem, Supervisor Investment Projects Brunvoll AS(Image: DMG Mori/Brunvoll)

The Brunvoll AS factory in Molde, Norway.(Image: Brunvoll)

Brunvoll manufactures, among other things, such low-noise transverse thruster systems (Low Noise Tunnel Thrusters) with a noise reduction of up to 15 decibels.(Image: DMG Mori/Brunvoll)

Ship drives with over 25 years of operation time.

From fishing boats to cruise ships – Brunvoll's ship propulsion and control systems are used worldwide. "Currently, over 10,000 units are in operation," illustrates Magne Gøran Lyngstad, Vice President Process and Production Engineering, the widespread use of the important ship components. 75 percent of the production is intended for export and the product range is constantly being further developed. "Every year, 70,000 hours go into the development of innovations." The reliability of the propulsion systems is so high that their life span exceeds that of the ships. "Over 25 years are common here," adds Kjetil Hoem, Supervisor Investment Projects. Thus, in addition to development and production – which is almost entirely in-house – service also has a great importance at Brunvoll.

Two unmanned shifts per day thanks to intelligent automation solutions.

"We ensure a high availability of spare parts, because short reaction times are crucial," explains Kjetil Hoem the high level of service readiness. "Our wide product range causes a huge variety of parts from small to large. Usually, batch sizes are less than 15 parts." This therefore requires a high degree of flexibility on the part of production. Magne Gøran Lyngstad mentions a solution: "With intelligent automation solutions, we can operate two unmanned shifts in addition to the conventional daytime shift and significantly increase our capacities." So far, Brunvoll has primarily automated machining centers and turning-milling machines. "For a recent investment, it was the first time we had to handle complex turned parts." This is exactly where DMG Mori came into play.

The automation solution of the machine tool manufacturer is based on the modular Matrix system and includes an NTX 3000, a conveyor system for Euro pallets as well as a FANUC robot with automatic changing of the gripper hands. Seven gripper hands fit in the cell. Using a 3D vision system, the robot picks up workpieces from the Euro pallets and clamps them into the machine. An intermediate storage allows the robot to reposition workpieces. Finished parts are removed, cleaned in a washing station and placed back on the pallets. "Depending on the size of the part, we can load the workpieces on the pallets in several layers using wooden intermediate shelves. In this case, the robot also handles these shelves," says Kjetil Hoem. The entire process is controlled via the user-friendly MAPPS controller. The entire system is also prepared for the use of automated guided vehicles (AGV), which Brunvoll wants to use for the supply and removal of pallets in the future.

Brunvoll has selected the NTX 3000 to machine workpieces with diameters from 45 to 400 millimeters. The maximum length of parts weighing up to 120 kilograms is 400 millimeters. The versatile turning-milling center also ensures a 6-sided complete machining, also of complex components. In addition, thanks to the powerful Compact Master turning-milling spindle with over 130 Newton meters, milling operations are possible like on a machining center. The tools used are equipped with a Balluff chip, so that the correct tool data is always read into the machine.

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The very different workpieces also require very different clamping systems. "In this production solution, it was essential that the robot could also change clamping jaws," describes Magne Gøran Lyngstad one of the challenges. For this purpose, DMG Mori has equipped it with a special gripper and integrated a shelving system with space for 60 sets of clamping jaws, each with three jaws, into the cell. The robot can fetch the clamping jaws into the robot cell via a feed area and either store them or use them immediately. The clamping system developed by the DMQP partner (DMG Mori Qualified Products) Schunk is explicitly designed for such an automatic change. The clamping systems, like the gripper hands and pallets, are identified using an RFID system to ensure absolute process reliability.

The reason why Brunvoll commissioned DMG Mori with the conception and installation of the automation solution was, on the one hand, because everything came from one source - with one contact person who coordinated all trades. On the other hand, the attractive acquisition costs were an important point. A team in Japan was responsible for the conception of the manufacturing solution. "We also carried out the preliminary acceptance there in order to be able to make any improvements more easily," recalls Kjetil Hoem. Since the final installation in Molde, the automated NTX 3000 has been working more than reliably.

The capacity increase through unmanned production at night and on weekends is just one argument for Brunvoll to focus more on automated manufacturing systems. "The fact that we are now also establishing this approach in turning compensates for the shortage of skilled workers and personnel bottlenecks," explains Magne Gøran Lyngstad the use of such solutions. "We are using the potential of our well-trained employees for research and service rather than for comparatively simple machine setup." Although Brunvoll has a good training quota with currently 40 young professionals, they can plan much more independently and flexibly with the help of an increasingly autonomous production. "Automation solutions help us to remain competitive and grow sustainably."