Vehicle component manufacturer ElringKlinger, headquartered in Dettingen an der Erms, Germany, includes high-performance, lightweight plastic products such as oil pans and cam covers in its product portfolio for the global automotive industry.

Tobias Gerst, production engineer responsible for capital equipment procurement and process planning says: “Over the past few years we’ve grown steadily and are running out of space for our production equipment, so we’re sometimes faced with very cramped conditions.”

Space is particularly limited where two automated injection moulding machines operate over three shifts. The machines are located in an enclosure and mould exchange is only possible by entering a narrow, low door. These machines, positioned at an angle of about 120° to each other, require a mould change every 8-9 days. As there is no overhead crane in the factory, it is impossible to load the machines from above. Instead, until recently, operators used one of a number of standard transport carts – a challenging and physically exhausting task.

All that changed with the arrival of a compact transport cart supplied by Roemheld. The RWA 1600 is characterised by its small size, an electro-hydraulic lifting platform and a shuttle table equipped with hydraulically actuated ball bars. In addition, Roemheld can customise the carts to meet specific requirements.

With ball bars set into the support surface of the table, it is easy to move the dies manually in any direction. A special safety mechanism ensures that, during mould transportation, the ball inserts lower into the table surface so the die cannot move.
As standard, Roemheld offers three versions of the 1600 kg capacity cart with either four, six or eight ball bars. After detailed consultation, however, Gerst asked ElringKlinger to produce a special version with nine bars.

For further information
www.roemheld.co.uk

A UK engineering specialist has completed its largest-ever rapid tooling project as demand for shorter lead times intensifies. MetLase, which is a joint venture between Rolls-Royce and Unipart, has designed and manufactured a stainless-steel tool measuring 4 m in diameter and capable of holding a component 2 m tall.

The company met the challenge of the major aerospace customer head-on, with manufacturing sign-off and delivery completed in just one month; 150 days quicker than the client would have previously expected. It is just one in a list of notable successes from the Yorkshire-based firm, which harnesses the design skills of a 25-strong engineering team and innovative joining solutions that replace traditional welding process.

“Typical conventional tooling approaches often take a massive block of material and then machine away the unrequired bits to form the tool,” says Richard Gould, business development manager at MetLase. “We take a different stance, basically laser cutting sheet metal, usually stainless steel or titanium, into lots of different elements. These are then joined to form the tool using our own manufacturing technique, removing the need to weld them together and endure the distortion that usually comes with this process.”

He continues: “Everything is controlled ‘in-house’ at MetLase. We’re always adding to our standardised feature library and parametric modelling system that allows us to instantly access formulas for creating tools for specific applications. All of this means we can work with customers to reduce lead times to weeks if not days, ensuring the client has more time for iterating their component design before signing off the tooling. As well as the time saving, our service can also help mitigate massive financial costs associated with last minute changes.”

For further information
www.metlase.com

Kirbi Taylor, an apprentice at Nikken Kosakusho Europe Ltd, is the winner of the Rotherham Apprentice of the Year Award for the ‘Intermediate’ category, beating off competition from over 50 applicants from a variety of industries. In addition, Taylor is also shortlisted as a finalist in the University of Sheffield AMRC Training Centre’s Apprentice of the Year awards and has already won the centre’s ‘Spotlight’ award for the best in cohort last year.

With a lifelong interest in engineering – and inspired by her grandfather’s previous success in the industry – Taylor decided to pursue a career in engineering by undertaking an apprenticeship in mechatronic maintenance with Nikken and the AMRC Training Centre, which is part of the University of Sheffield Advanced Manufacturing Research Centre. The award recognises her exceptional contribution and commitment to Nikken, as judged by a panel of experts from within the Barnsley and Rotherham business sector.

Nikken service manager Mark Timmons says: “Kirbi is a breath of fresh air: friendly, confident and greets everyone with a smile. She is eager to learn and gets involved with as many areas of the business as possible. We have three apprentices in the service department who have all excelled in their careers. They are fundamental to the future of Nikken and engineering. I look forward to watching the progression of Kirbi, and our other apprentices, as they take on more responsibilities and challenges.”

Nikki Jones, director at the AMRC Training Centre, adds: “It comes as no surprise to us that Kirbi has received recognition for her efforts and achievements as an apprentice engineer. Since joining the AMRC Training Centre with Nikken, she has shown true dedication and commitment to the engineering apprenticeship programme, and seized every opportunity with passion and vigour.”

For further information
www.nikken-world.co.uk

A family-owned engineering company in West Yorkshire is aiming to establish itself as an expert in work-holding devices for the production of machined components in electric vehicles.

Craftsman Tools says it is one of only a handful of British companies that specialises in work holding for machining processes, and the only one that designs and manufactures all of its own products. As a result of partnerships built up over several years, Craftsman Tools already produces a work-holding device used by almost all major automotive manufacturers in the machining of camshafts, and is familiar with the unique challenges faced by the industry.

The company’s initial developments are for a friction-welding process to bind two parts of a CV shaft and then machine the joint in situ. Critically, Craftsman Tools will use its expertise to develop work-holding equipment that will last in the harsh manufacturing environment of a fiction welder to ensure conformance with the required geometric tolerances. The company already has supply-chain partnerships with companies targeting major EV manufacturers, such as Tesla.

Electric engines have considerably fewer moving parts than internal combustion engines (20 versus 2000), thus the market for machined components is considerably smaller and there is an even greater emphasis on producing the remaining parts more accurately with tighter tolerances. The initial concept is for a modular design, which can be adaptable to different CV shafts and similar components, increasing its versatility with a host of automotive manufacturers.

Managing director Robert Johnson says: “This is a very exciting project, and one that plays to all of our expertise and knowledge. Sales of electric vehicles increased by 25% last year, and an increase in the uptake of electric vehicles is crucial to the UK achieving its net-zero carbon goal by 2050. The project will be a large step towards Craftsman’s own goal of moving away from carbon-intensive industries and towards the green economy.”

For further information
www.craftsmantools.com

SMW Autoblok has introduced its fully sealed MM e-motion four-jaw chuck, providing contact-free adjustment of the gripping force without unclamping parts during every phase of the production process.

An individual electro-mechanical drive independently controls and monitors each jaw of the MM e-motion. This capability allows for many clamping functions, including self-centring, compensating and individual jaw movement, all within one fully automated chuck.

Suitable for mill-turn applications, horizontal and vertical lathes, the MM e-motion facilitates the heavy-duty precision machining of easily deformed workpieces and provides an automatic centre adjustment for any workpiece shape or configuration, including round, square, rectangular and irregular shapes, as well as workpieces with different wall thicknesses. Also available is a lightweight (LW) version for when mill-turn load-bearing capacity on the spindle is limited. LW versions feature the same functionality as the standard MM e-motion yet allow for higher workpiece weight and more usable Z stroke.

The chuck body and internal parts are case-hardened for increased chuck life, as well as rigidity, precision and durability. This specialty power chuck accepts imperial serrated top jaws and is available in sizes from 500-1250 mm.

Suitable for Industry 4.0, permanent monitoring of the grip force and jaw positions can be stored and recalled for when the process needs repeating. As a result, digital data is easily interchanged between different machines in the same production facility or at other facilities worldwide.

SMW Autoblok’s MM e-motion uses the newly developed F280 wireless inductive radial coupler system that transmits energy and data contact-free through an air gap of approximately 3 mm between rotating and stationary components.

For further information
https://bit.ly/2GcQBEA