Processes During the fabrication of our products, several processes and machines are utilized. You can gain an overview over our fabrication processes on this page. Mechanical Processing We execute the mechanical processing of rolling profiles and forgings out of steel, as well as extruded sections and forgings out of aluminum. Those are produced in small batch series, middle-scale series and large-scale series. They are processed on one-, two- and four-mandrel CNC machines for smaller and medium quantities and on flexible rotary transfer machines in modular design for high-volume processing. Machines of mechanical processing are partially integrated into our production lines. Automated loading and unloading allow for a more efficient usage. The processing machines with partially automated feeding of parts are fitted with optical and tactile inspection systems to check for the presence and type of parts. All machines have integrated control systems for tool breakage and tool life quantities. Broaching Broaching with inner-diameter tolerances up to IT7 is used as an economic procedure for the creation of complex internal geometries. Hydraulic broaching machines are used for the economic fabrication of inner contours for locking hinges. Those machines integrated in rotary transfer machines for the mechanical processing of hinge parts allow the efficient creation of inner contours for interlocking connections in greater volumes. High cutting velocities enable cycle times of less than or equal to six seconds per part. Arc Welding Arc welding of unalloyed and low-alloyed steel and aluminum is one of the standard bonding techniques at the site in Hainichen. Assembly groups for hinge systems for trucks – as well as roll-over-protection for convertibles – are welded serially. MIG and MAG robotic welding cells in rotary table design or as alternating gate systems are used for those processes. Stable Processes with a high reproducibility are achieved mainly by the application of modern welding procedures like CMT welding (Cold Metal Transfer). According to existing test sequence schedules, welded assemblies aren’t just checked visually acc. to DIN EN ISO 17637 and dimensionally by CNC coordinate measuring systems, but as well by the preparation and examination of macrosections of security-relevant weld seams. Laser Welding Optimal welding results at maximal velocities are achieved by the usage of the most modern laser welding systems at the site in Hainichen. Aluminum assemblies are welded permanently in large-scale series with the use of high performance solid-state lasers by Trumpf. The fully automated laser welding machines in rotary table design are fully integrated in final-assembly lines with cycle times of six seconds per part. Loading and unloading, part inspection, part positioning and the selection of the different laser contour programs is executed by a SIEMENS 840DSL control unit. The inspection of quality of every weld seam is performed straightaway by a fully automated differential pressure testing. Resistance Welding (Projection Welding) In recent years, resistance welding of assemblies for door hinges out of steel and aluminum became one of the standard welding procedures. Assemblies out of steel and aluminum are manufactured and welded in individual and serial production. In fully automated production lines, several components are welded permanently by accurately dosed resistance heating. By positive and frictional locking, high stability and resistance can be achieved in those connections with a low heat input. The five station round table systems contain powerful welding inverters next to the modular welding control unit. Those inverters reach a top rated output of up to 500 kVA. Welding parameters, process sequences, assembly inspections and final measures are controlled permanently and fully automated with the help of envelopes. The Windows based control surface is prepared accordingly with sufficient transparency for use by the systems operator. In addition to normal resistance welding units, flexible water-cooled resistance welding systems are used for small-batch series and middle-scale series. Those are loaded and unloaded manually. Induction Hardening (Surface Hardening) Another process is the induction hardening of parts for door hinges with integrated door checks in medium frequency hardening. This increases the wear resistance of moving and touching parts. Induction hardening raises the hardness in surfaces with tough core and minor distortion. Like that the life time of parts can be increased significantly. An accurate and controllable process of surface hardening makes it possible to achieve demanded hardness and hardening depth in partial surfaces. We use induction hardening systems in round table design with automated loading and unloading and cycle times of equal to or less than 6 seconds as well as hardening systems with manual loading and unloading for small-batch series and middle-scale series. It is possible to achieve a hardening depth of 1.5mm with an accuracy of 0.1mm. Assembly For the production of our products, we use fully automated assembly systems as well as hybrid assembly systems for small-batch series, middle-scale series and large-scale series with cycle times of 3 seconds and more. assembly systems in round table design or as linear transfer systems, partially with integrated manual work stations according to product and quantities chaining of assembly cells for the optimization of overall availability automated part loading with self-sufficient runtime of up to five hours flexibility of processing of large product families slim and modular solution concepts for manifold assembly and control processes self-sufficient usage of individual assembly cells if required integration processes like spring force inspection, calibration, flanging, force/stroke monitoring of press-fitting processes, riveting, laser welding, leak testing, precise grease filling, torque and cogging torque testing, end-of-line testing of mountings, ink jet, stamp, laser or needle signing automated handling of the reworking of parts vast production data acquisition among other things for the analysis of system availability evaluation of production results directly at the master computer of the system and via remote access