Metzner Maschinenbau GmbH
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Produktbeschreibung:

A global manufacturer of commercial vehicles and buses launched a new truck model in which a wide variety of PA lines for brake fluid and coolant are used. As the existing production facilities for processing and machining the PA lines for the existing truck and bus models were already reaching their capacity limits, a new production facility was needed. Metzner Maschinenbau GmbH provided the solution with fully automatic machinery, which offers the customer a multitude of advantages. The line was dimensioned in such a way that it still has sufficient capacity reserves for an increase in production if sales of the new truck model increase.

One of the challenges for the Metzner development team was to achieve the required output quantity for all PA brake tubes installed in the new truck model in different lengths, diameters and quantities with only one production line. In addition, the machinery should always produce complete tube sets which can be clearly assigned to the subsequent assembly stations. The Metzner development team mastered this difficulty by, among other things, a combination of seven unwinders, two production lanes and a suitable storage system, as well as the elaborate allocation of the two processing lanes. This required, among other things, a network connection of the production line to a central database for material requirements. The Metzner production line is now fully integrated into the customer's MES system with automatic order transfer and feedback function.

The production line consists of seven unwinders with associated feeders, of which three or four each load one of the two tracks. If more quantities of one product are required than of another, several winders can be loaded with the same product and, for example, both production tracks can be used simultaneously. The optimal loading of the winders in combination with the appropriate division of the tracks in order to produce the PA brake tubes required for a truck model was determined by the Metzner developers and now enables piece number capacities of 4000 to 5000 tubes per shift.

After unwinding and feeding into the so-called lane changer, which consists of the two production tracks and automatically selects the correct track and guide for the tube diameter to be processed, the material is transported to the cutter unit by means of contact-free loop control and belt feed, where it is cut to length and printed. The high-quality printing is carried out by two or three inkjet printers at up to 1.3 m/second, alternatively by a laser printer. This way, for instance, both tube ends can be provided with insertion markings for tube couplings with an accuracy of +/- 1 mm.

A gripper handling system then loads the finished tubes into the tube magazines arranged on a conveyor belt. After further transport of the material to the removal station, the operator removes the tube sets as loose bundles which are marked accordingly and are ready for further processing in the assembly department.

The machinery can be operated in three ways: in automatic mode, so that several tube sets are produced in succession, in a mode for the production of individual tubes, and in manual mode, where all processing steps can be carried out individually. The main benefit for the customer is that the machinery automatically feeds the material from the feeder to the main machine after the tube bundle has been inserted into the dereeler. Gating and production start are also performed automatically. Production is carried out just-in-time without intermediate buffer at speeds of up to 1.5 m/second.

Kategorieslider-ID: liste_gummi_kundenspez
Produkt Video Titel: Optimum capacity utilisation and process automation
Produkt Video Beschreibung:

The special Metzner development automatically performs all processing steps from unwinding and tension-free feeding of the various PA tubing to cutting to length, right through to printing and depositing, with optimum utilisation of the two production tracks. Our product video will give you an insight into the machining process.

Produkt Feature 1 Titel: Fast manufacturing
Produkt Feature 1 Beschreibung:

The machinery achieves production speeds of up to 1.5 m/sec and can produce up to 18,000 tube metres with an average tube length of 2.5 m distributed over several tube sizes in an eight-hour shift.

Produkt Feature 1 Icon:
Produkt Feature 1 Bild:
Produkt Feature 2 Titel: Different types of printing
Produkt Feature 2 Beschreibung:

The material can be labeled either by two or three inkjet printers or by laser.

Produkt Feature 2 Icon:
Produkt Feature 2 Bild :
produkt Subfeature 1 Titel: Application of insert markings
Produkt Subfeature 1 Beschreibung:

At both tube ends, insertion markings for tube couplings are applied with an accuracy of +/- 1 mm.

Produkt Subfeature 1 Icon:
Produkt Subfeature 2 Titel: Automatic assembly in bundles
Produkt Subfeature 2 Beschreibung:

The machinery automatically preassembles the orders into bundles according to the corresponding work stations on the assembly line.

Produkt Subfeature 2 Icon:
Produkt Subfeature 3 Titel: Complete integration into MES system
Produkt Subfeature3 Beschreibung:

The machinery is fully integrated into the customer's MES system with automatic order transfer and feedback.

Produkt Subfeature 3 Icon:
Produkt Download 1 Titel: Metzner Product Catalogue
Produkt Download 1:

Program-controlled, Fully Automatic Cutting to Length and Labelling/Marking of PA Cable Wires with Different Diamters/Lengths

A global manufacturer of commercial vehicles and buses launched a new truck model in which a wide variety of PA lines for brake fluid and coolant are used. As the existing production facilities for processing and machining the PA lines for the existing truck and bus models were already reaching their capacity limits, a new production facility was needed. Metzner Maschinenbau GmbH provided the solution with fully automatic machinery, which offers the customer a multitude of advantages. The line was dimensioned in such a way that it still has sufficient capacity reserves for an increase in production if sales of the new truck model increase.

One of the challenges for the Metzner development team was to achieve the required output quantity for all PA brake tubes installed in the new truck model in different lengths, diameters and quantities with only one production line. In addition, the machinery should always produce complete tube sets which can be clearly assigned to the subsequent assembly stations. The Metzner development team mastered this difficulty by, among other things, a combination of seven unwinders, two production lanes and a suitable storage system, as well as the elaborate allocation of the two processing lanes. This required, among other things, a network connection of the production line to a central database for material requirements. The Metzner production line is now fully integrated into the customer's MES system with automatic order transfer and feedback function.

The production line consists of seven unwinders with associated feeders, of which three or four each load one of the two tracks. If more quantities of one product are required than of another, several winders can be loaded with the same product and, for example, both production tracks can be used simultaneously. The optimal loading of the winders in combination with the appropriate division of the tracks in order to produce the PA brake tubes required for a truck model was determined by the Metzner developers and now enables piece number capacities of 4000 to 5000 tubes per shift.

After unwinding and feeding into the so-called lane changer, which consists of the two production tracks and automatically selects the correct track and guide for the tube diameter to be processed, the material is transported to the cutter unit by means of contact-free loop control and belt feed, where it is cut to length and printed. The high-quality printing is carried out by two or three inkjet printers at up to 1.3 m/second, alternatively by a laser printer. This way, for instance, both tube ends can be provided with insertion markings for tube couplings with an accuracy of +/- 1 mm.

A gripper handling system then loads the finished tubes into the tube magazines arranged on a conveyor belt. After further transport of the material to the removal station, the operator removes the tube sets as loose bundles which are marked accordingly and are ready for further processing in the assembly department.

The machinery can be operated in three ways: in automatic mode, so that several tube sets are produced in succession, in a mode for the production of individual tubes, and in manual mode, where all processing steps can be carried out individually. The main benefit for the customer is that the machinery automatically feeds the material from the feeder to the main machine after the tube bundle has been inserted into the dereeler. Gating and production start are also performed automatically. Production is carried out just-in-time without intermediate buffer at speeds of up to 1.5 m/second.

Optimum capacity utilisation and process automation

The special Metzner development automatically performs all processing steps from unwinding and tension-free feeding of the various PA tubing to cutting to length, right through to printing and depositing, with optimum utilisation of the two production tracks. Our product video will give you an insight into the machining process.

Special features

Fast manufacturing

The machinery achieves production speeds of up to 1.5 m/sec and can produce up to 18,000 tube metres with an average tube length of 2.5 m distributed over several tube sizes in an eight-hour shift.

Different types of printing

The material can be labeled either by two or three inkjet printers or by laser.

Application of insert markings

At both tube ends, insertion markings for tube couplings are applied with an accuracy of +/- 1 mm.

Automatic assembly in bundles

The machinery automatically preassembles the orders into bundles according to the corresponding work stations on the assembly line.

Complete integration into MES system

The machinery is fully integrated into the customer's MES system with automatic order transfer and feedback.

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Metzner Product Catalogue

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