Machines
The essential part of our production is forging hammers. Because hammers need auxiliary machines they are connected into a forging line and comprise: forging hammers, punching presses, induction heating devices and manipulation of hot pieces.We have: 12 forging lines.
FORGING LINES:
– 4 lines equipped with drop hammers- 8 lines equipped with hydraulic hammersIn addition to these basic machines in the forge, we also use in the manufacture of forged parts:- 4 lines for cutting the basic material- 4 lines for sandblasting forged parts
TOOL-MAKING FACTORY
The tools used in our company are manufactured in our tool-making factory, where the following machines are essential:
- 2 CNC milling machines Makino
- 3 CNC milling machines Hurco
- 7 CNC milling machines Haas
- 2 wire erosions
- 3 submersible erosions
MACHINING OF FORGED PARTS
Machining of forged parts is performed on batch production machines equipped with pallet changers. The unit for the machining of forged parts is equipped with the following machinery:- 14 Chiron twin 4 axis machining centers;- 3 Kitamura 4 axis machining centers;- 4 3 axis machining centers;- 6 CNC lathes
MACHINING OF TURNING PARTS
The turning parts are machined on the following machinery:
- 7 CNC machines Citizen for machining long pieces
- 4 CNC milling machines Myano
- 2 CNC milling machines Emag
Dedicated machines
Our own knowledge and development have been oriented into the production of dedicated machines
The increase of the competition, high demands of the market regarding the quality as well as the rationalisation and bigger flexibility of the production dictate the need for the production rationalisation.After many market researches we found too complex solutions or we found out that no standard solution exists for the specific problem, therefore, we decided to make usage of our own knowledge and development. We launched the planning and production of different types of dedicated machines.We have noticed the largest need in the process of raw parts manipulation on the way to the induction furnace and further to the workplace of forging, which we successfully solve by using the feeding device at all forging lines.Furthermore, we recognized the problems, developed solutions and carried out testing in other operations in our company and consequently developed many dedicated machines. Today we use the following dedicated machines:
- automatic feeding device
- automatic band grinding machine
- different automatic dosages of pieces
- pre bending machine for pieces
- automatic measuring and sorting system
Robotics
26 active robots are the fruit of our knowledge and development
Processes where power, precision, speed and continuous operation is required are suitable to be modernised with robots. Therefore, we recognised our production as very appropriate and started with very intensive automatization ten years ago. 26 active robots in our production processes are the result of our work. All robotised processes are the fruit of our knowledge and development; therefore, we are more flexible and adjustable within the process itself. All our systems are equipped with IT control solutions.In our production, we use robots for various operations. In cases of using CNC machines robots from dedicated stores take pieces and insert them into the clamping devices of the machines. In the opposite direction, they discharge the machines; blow out the residues of the treatment, emulsions.
For manipulating hot pieces, we have developed special grips, which enable a good grip even in extremely difficult operating conditions. These robots insert pieces into the presses for cutting and punching operations, and in the opposite direction empty the machine tools.We also have robotic lines for cold calibration of the pieces, abrasion on the pieces, inserting the pieces on the measuring systems between the phases.According to the guidelines for the development of the world economy, we remain focused on the further introduction of automated processes in production.
Marovt IoT (lean production)
The introduction of artificial intelligence in the production processes
IoT is one the major pillars of industry 4.0. This segment remains besides the automatization one of the two main development fields in our company. We work accelerated together with our development partners on the introduction of artificial intelligence in the production processes as well as the communication machine <-> machine.With the development of RRI Project (Machine Intelligence for Effective Production through Prediction of Maintenance and Optimization of Production Processes) resulting in the system which will comprise IoT and applications for data collection from this device as well as the efficient saving, and analysing of this “big data” with the help of Machine Learning we will contribute to the key objective – to increase the level of production robotization and automatization.
Measuring devices
Our own dedicated measuring systems contribute to better work efficiency
Appropriate measuring equipment is essential for the control of our products, processes and purchased material. Variability of processes is a cause for scrap and inefficiency, high costs for assuring the quality and labour costs, moreover, it causes undesired delays.The market research gave us too complex measuring systems. There is not enough adaptability, solutions are rigid. That was the reason why we started with the development of dedicated measuring systems to find nonconformities.We have focused on the transitions between phases, as an early detection of process variation contributes to lower scrap and greater efficiency. Robotic production of the line is of an additional importance, since there are no delays and inefficiencies between the different phases of such a line.
Today, the company has about 1000 scales and measuring instruments. Some are very simple, while others are more complicated, such as for an example optical measuring machines and acoustic test. Most of them are used in batch production and are handled by our workers in the production process.Our measurement systems can be partially or fully automated. The core of the systems is represented by various measuring systems, optical cameras and highly accurate measuring probes. The system to be chosen depends on the complexity of the measurement, the width of the tolerance and the type of process in which the system will operate.
Test lab
Our quality and technology departments have a measuring equipment available to control our own processes / products as well as the control of purchased material and services.The most important equipment includes:
- Coordinate measuring machine DEA Global Performance (500 x 500 x500)
- Coordinate measuring machine Global S Green (700 x 1000 x 700)
- Optical measuring machine Demeet
- Scener ATOS CORE 3D
- Optical measuring machine SmarVision
- Hardness measuring machine Vickers (HV1, 2, 5, 10, 20, 30)
- Hardness measuring machine Rockwell (HRC, HRB)
- Microscope and machines for sample preparation (saw, polishing machine)
- Salt spray test chamber
- spectrometer for steel chemical analysis
- Roughness measuring machine
