Redefining Flexibility and Productivity
MAG Powertrain supplied its customer MDC with a complete production system for the highly productive and flexible machining of cylinder blocks and cylinder heads.
Systematic Realization
The MDC project presented MAG Powertrain with a set of special, but by no means insoluble challenges. The task: to provide and deliver it all, from the call for tenders up to production. In plain English, that meant that MAG Powertrain was entrusted with creating the complete system planning work, designing the process and system technology and implementing the system on site. The project involved a complete system consisting of 49 machining centers (19 for the cylinder block and 30 for the cylinder head) and five transfer machines (three for the cylinder block and two for the cylinder head). As testament to the competence of MAG Powertrain the project was completed in just two years and three months.
From Alpha to Omega
Our complete service spectrum at a glance:
- Delivery of all machining equipment (machining centers and transfer machines)
- Simultaneous engineering
- System simulation
- Risk and FMEA analyses
- Complete engineering
- Creation of inquiry documents and evaluation of quotations for all peripheral machines and the complete conveyor system (with the exception of honing machines)
- Creation of schedules and deadline monitoring for MAG Powertrain equipment and associated peripherals
- Change management (commercial and technical)
- Implementation of a ”cost-saving workshop” with external moderation
Design and Adjustment with Consistent Flexibility
The cylinder block and cylinder head systems were designed as hybrid production systems intended to combine flexibility with high productivity. Accordingly, the qualifying and general machining processes were undertaken on type XHC 241 machining centers with linear motors. Geometric or technological changes can be implemented by virtue of the flexible cell design without causing lengthy system downtimes. Measures for model extensions and model variations were also provided for in the coolant discharge system. Depending on the configuration level and design standard, operations utilizing production cells can be expanded with additional machines.
Maximum Precision
The final machining of quality-sensitive operations, such as cylinder bores, is executed using transfer lines. After machining, the cylinder bores are measured in a measuring station, the results are evaluated statistically and adjustments are then made directly on the machining station controller. The finish tool in the machining station is adjusted using a patented compensation spindle, achieving perfect machining results. In addition, the finishing tool is retracted into the toolbody by the compensation spindle when it is withdrawn from the cylinder bore at the end of the process. This results in bores without any retraction marks whatsoever.
