通过 INOFlex® 实现动力和灵活性
通过 INOFlex® 实现动力和灵活性
可可榨油机、印刷机和风力发电厂有什么共同点？几乎没有，只是这三个地方都有 Kersten Maschinenbau 使用 HWR INOFlex® 卡盘加工的零件。
Kersten Maschinenbau GmbH 位于德国尼德劳市，其竞争优势在于拥有制造各种零件所需的能力。为实现这一目标，公司依靠员工的专业知识和可靠性、超现代化的机床系列以及 HWR 的 INOFlex® 补偿、中心夹紧四爪卡盘。
1965 年，Kersten 作为一家工艺品公司成立，德国统一后，公司重新定位为机械制造供应商。1990 年，公司只有 15 名员工，并决定投资第一台数控加工中心。如今，Kersten 拥有 130 名员工和 30 多台超现代化机床。
对于 Kersten 来说，灵活性和效率是其关注的主要问题，而其技术设备在实现这些目标方面发挥着重要作用。例如，这家机械制造供应商意识到，它需要一种更先进的夹紧系统来制造各种高精度部件。在评估各种选择时，Kersten 指出，夹具必须便于工具的使用，并确保灵活性和操作安全性。Kersten 的生产计划和设备采购主管 Dipl.-Ing. Mathias Scheel 认为他可能已经在 HWR INOFlex® VL 卡盘中找到了解决方案。
灵活、通用的解决方案
INOFlex® 是一种通用、补偿、中心夹紧四爪卡盘。它能牢固夹持直径从 160 毫米到 1200 毫米的圆形、矩形和几何形状不规则的零件，是生产各种类型零件的车间的理想解决方案。
Scheel 先生回忆说："我一眼就看中了INOFlex®四爪卡盘的功能，它们只需操作一个主轴就能以补偿方式靠在工件上，而且工件的中心在中间。"当然，我们对用单个卡盘夹持圆形、立方体和几何形状不规则的工件的可能性非常感兴趣"。
发现 INOFlex 后不久，Kersten 就开始购买使用三个这种柔性卡盘：400 手动卡盘、700 VL 卡盘和 420 VL 卡盘。
Scheel 先生说："我们对 INOFlex® 卡盘非常满意。"产品质量很好，补偿四爪卡盘的专利功能完美无缺"。
提高同心度、速度和安全性
Kersten 的许多零件以前都必须使用复杂的夹紧铁或磁铁夹紧板配件进行夹紧。将这些传统夹持改用 INOFlex 后，安装时间大大缩短。如今，只要传统夹具接近极限，公司就会使用 INOFlex。该公司发现，这种卡盘尤其有助于提高薄壁零件的同心度。
Kersten 还能利用 INOFlex 提高加工安全性。公司的 Alzmetall GS1400 车削/铣削中心的应用就是一个很好的例子。
"Scheel 先生说："出于安全考虑，在进行多次夹紧操作时不可能使用车削功能。"现在有了 INOFlex 夹具，这就变得非常简单了。
INOFlex 还可以对零件进行五面加工，从而提高了灵活性。安装时间缩短了，公司对坯料装载的简便性表示赞赏。这种装载只需要操作员清洁支撑部件，然后插入下一个工件。
进一步提高灵活性
除了两台 Alzmetall GS1400 车削/铣削中心外，Kersten 还在车削车间的几乎每台机床上使用 INOFlex® VD400 手动卡盘。
公司自行生产的特殊用途支架可将 INOFlex VL070 和 VL042 四爪定心补偿夹具直接安装到加工台上，或通过安装在几乎适应于所有加工中心上的零点夹紧系统进行安装。
"因此，VL070 可以安装在我们的两台 Alzmetall GS1400、Reiden RX18、Hermle C50U、Hermle C42U、Ibarmia ZVH58 和所有三轴加工中心上，"Scheel 先生说。"除上述设备外，最近购买的 VL042 还可以安装在我们的两台Hermle C800U 上，以取代老式的三爪卡盘。
满足客户需求的灵活性
Kersten 公司总经理Udo Kersten 说："我们自己建造底板非常重要。最重要的是，HWR 在任何时候都非常灵活"。
"Mathias Scheel 补充说："我们认为所提供的三维数据资料非常好。"我们需要精确的三维模型，以便在生产规划阶段制定装夹计划和数控程序。这为我们提前精确、逼真地模拟每种加工情况以及与机床和刀具模型的交互提供了基础"。
带有一个或两个固定卡爪的集成钳夹功能，除了补偿四爪卡盘外，还允许客户将产品用作钳夹、固定卡钳或双爪卡钳。
INOFlex 系统令人难以置信的质量和丰富的灵活性为 Kersten 提供了它所需要的：快速响应客户订单的能力，客户需要的零件尺寸、几何形状和要求各不相同。
Achieving Power and Flexibility with INOFlex®
What do a cocoa press, printing machine and wind power plant have in common? Very little, except that all three contain parts machined by Kersten Maschinenbau using HWR INOFlex® clamps.
Located in Niederau, Germany, Kersten Maschinenbau GmbH has built a competitive advantage out of maintaining the capabilities needed to manufacture an incredibly diverse range of parts. To accomplish this, the company relies on the expertise and reliability of its staff, an ultra-modern range of machines and the INOFlex® compensating, centrically clamping four-jaw chuck from HWR.
Established as a craft company in 1965, Kersten reorientated itself as a machine construction supplier after German reunification. In 1990, the company was staffed by 15 employees and made the choice to invest in its first CNC machining center. Today, Kersten employs 130 and houses more than 30 ultra-modern machines.
For Kersten, flexibility and efficiency are major concerns, and its technical equipment plays an important role in achieving these. For example, the machine construction supplier realized that it needed a more advanced clamping system to manufacture diverse high-precision components. When evaluating its options, Kersten noted that the clamp needed to be easily accessible for tools and also ensure flexibility and operator safely. Dipl.-Ing. Mathias Scheel, head of production planning and tool preparation at Kersten, believed he might have found a solution in the HWR INOFlex® VL chuck.
A FLEXIBLE, UNIVERSAL SOLUTION.
INOFlex® is a universal, compensating, centrically clamping four-jaw chuck. It securely clamps round, rectangular and geometrically irregular parts from 160 to 1,200 mm in diameter, making it an ideal solution for shops producing a wide range of part types.
“What I immediately liked was all clamping jaws of the four-jaw chuck resting in a compensating manner against the workpiece, from the operation of only one spindle, and that this workpiece centres to the middle”, recalls Mr. Scheel. “And we were, of course, extremely interested in the possibility of clamping round, cubic and geometrically misshaped workpieces with a single clamp.”
Soon after discovering INOFlex, Kersten was operating three of these flexible chucks: a 400 manual chuck, 700 VL chuck and 420 VL.
“We are very satisfied with the INOFlex® chucks”, says Mr. Scheel. “The quality of the products is fine and the patent of the compensating four-jaw chuck functions flawlessly.”
IMPROVING CONCENTRICITY, SPEED AND SECURITY.
Many of Kersten’s parts previously had to be clamped using intricate clamping iron or magnet clamping plate fittings. Switching these applications to INOFlex has provided significant setup time reductions. Today, the company deploys INOFlex wherever traditional clamping devices are nearing their limits. It has found the chucks to be especially helpful in improving the concentricity of thin-walled parts.
Kersten also was able to increase process security and safety with INOFlex. Applications on the company’s Alzmetall GS1400 turning/milling centers provide an excellent example of this.
“For safety reasons, it was not possible to use the turning function given several clamping operations,” says Mr. Scheel. “This is now quite easy thanks to the INOFlex clamp.”
INOFlex also improves flexibility by allowing parts to be machined on five sides. Setup times have been shortened and the company appreciates how easy it is to load blanks. Such loading only requires the operators to clean the supporting parts and then insert the next workpiece.
TAKING FLEXIBILITY EVEN FURTHER.
In addition to the two Alzmetall GS1400 turning/milling centers, Kersten applies the INOFlex® VD400 manual chuck on practically every machine in the turning shop.
The company’s own production of special purpose brackets allows the compensating INOFlex VL070 and VL042 four-jaw centering clamps to be mounted directly onto the maching table or via the zero-point clamping system installed on almost all machining centers.
“As a result, the VL070 can be fitted on our two Alzmetall GS1400s, the Reiden RX18, Hermle C50U, Hermle C42U, Ibarmia ZVH58 and all three-axis machining centers,” says Mr. Scheel. “And in addition to the above, the most recently bought VL042 can be fitted on our two Hermle C800Us, where it replaces the somewhat older three-jaw chuck that has had its day.”
THE AGILITY TO MEET CUSTOMER DEMANDS.
“The fact that we constructed the base plates ourselves was important”, says Udo Kersten, CEO of Kersten. “The best thing is that HWR has been absolutely flexible at all times.”
“The the quality of the 3D-data provided is something we find very good,” adds Mathias Scheel. “We need precision 3D models to draw up the clamping plans and CNC programs in the production planning phase. This provides us with the basis to precisely and realistically simulate each machining situation and the interaction with machine and tool models in advance.”
The integrated vice functions with one or two fixed stop jaws allows the customer – apart from the compensating four-jaw chuck – to use the product as a vice, fixed stop clamp or two-jaw clamp.
The incredible quality and abundant flexibility of the INOFlex system have provided Kersten with precisely what it needs: the ability to quickly respond to orders from customers that require parts diverse in their size, geometry and requirements.
