Three Points for Increased Productivity
The trend in engine technology is clearly moving towards greater power and performance from the same displacement. This means that the demands and requirements on materials and production accuracy are continuously increasing. To meet these requirements, the engineers at MAG Powertrain are developing high-precision machining equipment and innovative technologies for the future.
1. Process Control through Parts Tracking
The BMW NG-V production system for cylinder heads comprises 41 linear motor machining centers of the XHC 241 series as well as two transfer machines. The production unit is loaded by a surface portal, which is positioned by an optical parts recognition system. A parts tracking system is deployed to monitor the production system. Prior to bolting the cylinder head to the adaptor plate, a multi-digit number is etched on the cylinder head. This number is also written on a chip in the adaptor plate. Information about the machining status and the condition of the parts is also saved on the chip to ensure consistent parts tracking and quality assurance. With this system, machining errors and faults can be tracked to a specific machine so that, if necessary, parts that have been machined on that specific machine can be rejected in the system. For type checking purposes (i.e. to ensure that the correct type is being used), the number is read by cameras at various points within the system.
2. Adaptor Plate Technology
Use of the adaptor plate technology results in a large number of benefits for the flexible production of cylinder heads on machining centers. A wide range of workpiece variants can be clamped, and even if the workpiece is changed, the conveyor belts and grabs on the loading portal do not have to be adjusted. A parts mix for producing a quantity of one is possible, i.e. even exotic parts can be machined on the system in small quantities. The error rate caused by clamping errors is also substantially reduced, since the cylinder head can remain clamped on the adaptor plate throughout the entire production process. These technologies significantly contribute to the high level of production accuracy achieved by the system. The loading concept of the cells has a flexible design as well. At the end of the machining cycle, the XHC machining center orders the portal to return for the next loading and unloading operation. This reduces the downtimes of the machining centers to a minimum.
3. Quality Through Experience
As a result of our many years of experience in linear motor technology and the continuous development of this technology, MAG Powertrain machining centers offer both maximum dynamic performance and sophisticated machine technology for the cost-effective machining of cylinder heads. The axis design and state-of-the-art drive technology in all feed axes, including the B axis and main spindle, guarantee extremely high machining precision and flexibility.
Already back in 1993, MAG Powertrain became the first European manufacturer to produce a high speed machining center with linear motors. This XHC machine is now enjoying success in its third generation and is used throughout the world by the automotive industry and its suppliers. Its high precision and dynamism makes this machine ideal for machining cylinder heads and other engine components. Maximum availability and process reliability were also key criteria when designing the production system. Each production cell contains substituting machines. That means that a tool change can be carried out on individual machines without having to switch off the production cell or system. After the cylinder heads have run through the machining unit, they are removed from the adaptor plate. Subsequent to the various assembly operations, which are required before the components can be further machined, final machining is performed on MAG Powertrain transfer machines.
