MMS Technologie SKF LubriLean - Deutsche Messe AGfiles.messe.de/cmsdb/D/001/23112.pdf · 2010. 4. 28. · 26 April, 2010©SKF Group Slide 6 BERGER VOGEL s.r.l. SKF LubSys FRANCE S.P.A.

MMS TechnologieSKF LubriLean®

Ralf Domrös Dipl. Ing.Product Manager MQL

E-Mail: [email protected].: +49 (0) 30 72002- 398Fax.: +49 (0) 30 72002 – 345Mobil: +49 (0) 160 9729 2551

26 April, 2010 © SKF Group Slide 3

Inhalt

SKF – Lubrication Systems Germany AG1

2

3 Anwendungsbeispiele

MMS Technologie

SKF LubriLean Product Features4


1SKF – Lubrication Systems Germany AG


SKF – Group

World wide Comprehensive industry knowledge


BERGER VOGEL s.r.l.

SKF LubSysFRANCE S.P.A.

SKF LubSysHockenheim

SKF Lubrication Systems Germany AG

Berlin

SKF LubSys USA

SKF LubSys Japan

SKF LubSysNEDERLAND B.V.

Centralized Lubrication for Machine Tools

Coolant Pumps

MQL – Minimal Quantity Lubrication

Truck- und Off-Road-Lubrication

SKF Vert riebsnetz weltweit

Company

SKF Berlin

SKF Hockenheim

Sales+Service Centers

Group, total

Foreign countries

Employees

457

904

150

22

275

Turn over 2008: 170 Mio. €

SKF Lubrication Systems Germany AG, 2008

Lubrication of Windmills

Lubrication of marine engines


Hockenheim

Berlin

MühlheimSKF GmbH

SKF – Lubrication Systems Germany AG

Berlin: Headquarter

- Production of all parts

- assemblyapprox. 450 employees

Hockenheim:- assemblyapprox. 140 employees

Subsidiaries:- Newport News, USA- Osaka, Japan- Saumur, France

2MQL Technology


Trockenbearbeitung mit MMSNassbearbeitung

Stark verringerte UmweltbelastungStark verringerte Umweltbelastung

Geringe Gesundheitsrisiken

(Haut- u. Atemwegerkrank.)

Geringe Gesundheitsrisiken

(Haut- u. Atemwegerkrank.)

Umwelt-Aspekt Kosten - Aspekt Gesundheits-Aspekt

Verringerungder

Hauptzeiten

Einsparung KSS-Anlage und KSS-Aufbereitung

Motivationsfaktoren für die Trockenbearbeitung


interne ZuführungPartiklegröße 0,3 µ up to 1µ

externe ZuführungPartiklegröße 15 µ up to 40 µ

Werkstück

Example

Principle Principle

Example

Interne und Externe Aerosol Zuführung


Internal and External Aerosol Supply

Turret Lathe Machine


SchmierstoffBehälter

KoaxialschlauchIntern Öl, Extern Luft

Düse

Air

Oil

Covering air stream

Particle size

15 - 40 µm

Dosierter Schmierstoff wird in einer Sprühdüse durch Druckluft zerstäubt. Dabei entstehen Mikrotröpfchen, die mit der Trägerluft ohne Nebelbildung zur Reibstelle gelangen.

Prinzip der Externen MMS


Prinzip der Internen MMS

Drehdurchführung

Spindel

Werkzeughalter

Werkzeug

Schmierstoff

Aerosol

Aerosolerzeuger

Zuführung

Kugelhahn

UFZ.U00-009


Vario VarioSuper DigitalSuper1

InterneMMS

ExterneMMS

Info Info 1-2-Kanal

Info Info Info Info MonitoringInfoBsp Bsp Aufb AufbAufb Aufb

VarioPlusSmart Basic

Überblick der VOGEL LubriLean MMS Produkte


Tools

Engineering

Schmierstoff Werkzeugmaschine

MQL-SystemLubriLean®

- Staub- Öl- Späne

Absaugung

Spindel

Dry Cuttingwith MQL

MMS Gesamtsystem

3Application examples


Improvement of Environmental Issus using MQL

Coolant

MQL

*


Berechnungsbeispiel


Improvement of Environmental Issus using MQL

*


1. Long-run test with MQL

2. Convincing results

Retrofitting with MQL at 7 lathe machines

Total cost saving:

Costs for: Coolant MQL

Improved environment

maintenance:oil:compressed air:cost of transportation:

Total costs/year:

Savings/year:

177.305 EUR35.461 EUR

---

1.655 EUR

214.420 EUR

44.326 EUR5.319 EUR11.820 EUR

473 EUR

61.938 EUR

214.420 - 61.938 = 152.482 EUR

- Significant drop of the oil consumption from20 000 Litre to 500 Litre/year- Dry workpieces- Less health hazard- Less interrupt for cleaning offilters, tanks, leakages etc.- Improved environment- No waste disposal costs- Dry chips- Less damage of the environment- Equal production time

Roller bearing steel 100Cr6, roughness of surface Ra < 0,5 µmCutting-off operation with Oil as coolant.

Source:

Cost Savings: MQL vs. Coolant


1) GM Nodular Cast Iron Billets (Crankshaft Iron)2) Machine Tool Builder: Ingersoll CM Systems3) Tool: Sumitomo Carbide MQL drill4) 6.00 Dia Tool5) MQL-System: SKF LubriLean VarioSuper6) Lubricant: Vogel LubriOil7) Air pressure = 7.5 Bar (108 PSI)8) Depth of cut = 100mm [4"] //(17 Times Diameter)9) Tool Life distance = 108.5 Meters

10) Tool life distance for test at Mack Trucks 220 Meters

VarioSuper

Customers with same application:Mack Trucks Inc. (Volvo Group), Toyota

Deep Hole Drilling in Crankshafts


Drilling Balance Holes in crank shafts

1. Machine Adaptation2. Excellent Chip Formation3. No Thermal Effects4. 14mm Tool 5. Up to 2.5 x D6. Tool life increased 150%

VarioPlus

Balance Hole Drilling at Ford USA


VW Engine Plant Salzgitter

• 22 stations with LubriLean® Vario• Fully automatic refilling• Tool life increased by as much as 50%

Engine Block Production with Vogel LubriLean®


Series Production of Connecting Rod‘s


Success Stories – GROB-WERKE GmbH & Co KG

First order of 18 Digital Units (UFD10-021) (for 18 Grob machine Centers) which will be installed at Volkswagen Salzgitter for Cylinder Head works.

70 cent Einsparung pro Zyliderkopf

UFD10-021DigitalSuper 1 MQL System

Quelle: fertigung 08/2009


Tool: � 3,25 mm; straight grooved

Material: AlMgSi1

RPM: 18.000 min-1

Feed: 3.780 mm/min

Length of drill: 150 mm

Depth of hole: 70 mm

Approximately 500 holes without wear

Tool supplier: Gühring

BZ 500 L LubriLean DigitalSuper 1

New engine block transfer line of Grobfor

DaimlerChrysler Mannheimequipped with Vogel LubriLean

Transferline of Grob with SKF LubriLean


Workpiece: - Cylinder-head of row 6 cylinders truck engine

Machine: - 8 “G-Modules” of GROB equipped with 8 DigitalSuper units- 1 Transferline of GROB equipped with 3 DigitalSuper units

Ø-Range: - 8-30mm

Applications: - drilling, deep-hole-drilling, boring, monting, tapping and reaming

Source: GROB

MQL at DaimlerChrysler Plant: Mannheim


MQL Unit: LubriLean DigitalSuper1

Machine Tool Center: DMC 160

Material: Inconel®

Application: Tapping (1/4 inch to 2 inch)

Depth: 20 - 40 mm

Tapping of Threads in Inconel® at Volvo Aero

13 Machine tools equipped with LubriLean MQL-Systems DigitalSuper


MQL Cutting of Airplane Parts


Main results:

Reduction of liquid consumption:

- Previously: 3 liter/day

- Currently: 0,5 liter/day

- 83%

- Increasing of rollers output:

+ 10%

EHS!

New Tool holder

MQL Process at Roller Channel 2, SKF Gothenburg


Main results:

Reduction of liquid costs: 97%

� Cost Payback: 0,67 year

MQL with SKF LubriLean at SKF Cage Factory in Gothenburg

Example for a short Payback of Investment in MQL


previous today

Saving Potential using MQL instead of Coolant

Oil consumption: 1 l/dayCoolant consumption: 80.000 l/day

Coolant loss: 150 l/day

Traditional Milling with coolant Milling with MQL


wet

MQL

Time saving

Turned parts

0 5058%

59%

49%

48%

45%

82%

70%

78%

37%

73%

45%

24%

Mounting flange BK 3.18

Guide rod KFA 1.20

Mounting flange DS-4E.04

Housing SP 9.31

Holding device BK 6.104

Mounting flange AZ7

Valve body 873-780-004

Delivery plunger PFP-90.02

Housing PFP-90.12

Head PFP-90.01

Plate KFE-25.01

Pump spindle MS-40980

Operation time (wet)100%

Time savings at Vogel production by using MQL

4SKF LubriLean Product Features


• Product features• Pressure reservoir with integrated aerosol generators• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter � 0,5 mm• Integrated control system for automatic control of aerosol • quantity and quality• Profibus as standardized interface with machine tool• Startup and diagnosis possible via PC

• Applications- for turning, drilling, milling, tapping, broaching, deep drilling, etc.

- high-speed spindles- machining centers and turning cells- complex production processes in flexible manufacturing

• Integrated topping-up device• Meets HPC standard

Digital1Super - Product Features


MQL Process Monitoring of LubriLean DigitalSuper

Analoge pressure switch

Digital display

Flow-Sensor

Oil level switch

Aerosolsensor


Customer requirements• Inline and online monitoring of aerosol supply• Teaching of operating conditions

Unique position feature• The only MQL-monitor on the market• Integrated into DigitalSuper MQL-system• Can be operated as a stand alone device

Schedule / Status• series start 09/2006

Aerosol Monitoring System for MQL

AM1000 Aerosol Monitor


• Product features• Pressure reservoir with integrated aerosol generators• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter ≥ 0,7 mm• Adjustment of air and oil quantity via machine tool’s SPC• Filling level monitoring with capacitive sensors (2 points)• Automatic topping up possible• Applications: - turning, drilling, milling, tapping, broaching

- multispindle units- high-speed spindles

VarioSuper - Product Features


• Product features• Pressure reservoir with integrated aerosol generator• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter ≥ 1,5mm• Manual adjustment of air and oil quantities• Manual adjustment of supplementary air for dilution of aerosol• Filling level monitoring (4 Points)• Automatic topping up possible• Applications: - turning, drilling, milling, tapping, broaching


VarioPlus - Product Features


• Product features• Pressure reservoir with integrated aerosol generator• Reservoir with 1.8 l oil capacity• Aerosol with droplet size < 1 µm• For tools with coolant duct diameter ≥ 2mm• Manual adjustment of air and oil quantities• Manual adjustment of supplementary air for dilution of aerosol• Filling level monitoring possible• Automatic topping up possible• Applications: - turning, drilling, milling, tapping, broaching


Vario - Product Features


Smart - Product Features

Product featuresOil and air feed via coaxial lines

Aerosol generated at nozzle outlet

Reservoir sizes 0.3, 0.5 and 0.7l2 separately meterable outlet ports (via oil choke)

Extensive range of lines and nozzles available

Can be fastened to machines with magnetic clampsUsed for simple production processes

- sawing techniques

- model construction, training- simple milling, turning and drilling operations

Entry-level unit for external MQL


Smart - Application


• 3 liter reservoir capacity

• Oil and air feed via coaxial lines (up to 20m)

• Aerosol generated at nozzle outlet

• up to 8 outlet ports can be switched, independently or in groups

• Extensive range of lines and nozzles available

• Filling level monitoring possible

• Autom. topping up possible

• Applications - sawing- simple milling, turning and drilling

• operations - broaching- forming- oiling jobs

• Product features

• All outlet ports can be separately regulated by hand (oil choke and atomizing air)

Modular system for external MQL

Basic - Product Features


Basic - Application

Thank you for your

attention!

MMS Technologie SKF LubriLean - Deutsche Messe AGfiles.messe.de/cmsdb/D/001/23112.pdf · 2010. 4. 28. · 26 April, 2010©SKF Group Slide 6 BERGER VOGEL s.r.l. SKF LubSys FRANCE S.P.A.

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