Since 2018, Toman in Wolfratshausen, Bavaria, have been manufacturing with two 3-axis machines operating within an automated cell. One year later, in order to expand capacities, take another step towards Industry 4.0 certification and become even more competitive, the automation solution using a robot was to be expanded to include a 5-axis machining center. One of the two 3-axis machines, a Fehlmann PICOMAX 95, in which the company had invested in 2018, had brought excellent results in Wolfratshausen. Therefore, it was quickly decided that the new 5-axis machining center should also be from Fehlmann. The problem with this project, however, was not so much the machine. The difficulties result more from the complexity of parts and workpiece handling with batch sizes between one and 10,000 pieces/year, as well as restrictions in terms of the structural conditions. Managing Director, Josef Toman, was, therefore, looking for suppliers who were able to support this project with individual and compatible products. On the other hand, however, he also expected them to be willing and determined to find solutions with the appropriate flexibility and know-how: "We had a look at Fehlmann’s Versa 825. This is a proven machine that is absolutely stable, reliable and precise in operation. We currently use it for milling 18 to 20 hours a day and I'm sure it will remain stable for years. This is exactly what we were looking for, because any failure within our automation system would be a catastrophe. As far as automation is concerned, our machine cell configuration is an unusual one. The management and software connections via P-Cam, for example, are very intelligent. The companies Fehlmann, P-Cam and Schunk have shown themselves to be very open, flexible and all the while competent.”

These individual requirements begin with the production cell with the robot, which handles both pallets, unmachined parts and tools. When it comes to the workpieces, this solution thus offers two options. It allows the use of pallets or, after a gripper change, a pallet with a Schunk clamping system. The pneumatically controlled clamping system can be used on the one hand to fix unmachined parts in place. And on the other, it is also possible to turn the workpiece and initiate complete machining. One particularly interesting feature is that the clamping pressure can be variably adjusted via an M-function (this control for the clamping system was developed by Fehlmann).

The future has already begun
Toman’s wishes/requirements were indeed very individual. Tools from the production cell, for example, were also to be changed in and out by the robot via the spindle. This was a project which, with the exception of Fehlmann and P-Cam, no other supplier understood. As a parts manufacturer, however, you have to be flexible. At least that's how Production Manager, Herbert Schmidbauer, sees it. For him, flexibility and competence were the basic prerequisites for collaboration: "We don't know today what is going to happen next year. So we also have to plan for the future. In connection with tool changing via the spindle or the handling of unmachined parts and pallets, we have often heard competitors say, "You don’t need that." I don't know whether these companies were unable to do it or did not want to. But these statements were an absolute knockout criterion for us. One example is the variable clamping force, because for roughing I need a different clamping pressure than for finishing or working on filigree components. Only Fehlmann and Schunk addressed this issue and came up with suitable developments. This also applies to tool changing via the spindle or the integration of the somewhat older 3-axis machine.” Storing the tools within the cell has the advantage that the tool changer in the machine does not have to be oversized and that overlong tools can also be stored.

The investment of the Wolfratshausen-based parts manufacturers thus appears to be a well thought out and future-orientated concept. Especially since the Versa 825 reliably and easily achieves tight tolerances of less than 1/100 mm. In Wolfratshausen though, they are already working on new plans for the future. They are planning to integrate a paternoster-rack to load the entire cell with workpieces and tools. It is only hoped that this project will provide the necessary flexibility.

Toman GmbH in focus
The company was founded in 1973 south of Munich and engages in precision mechanics and manufacturing mechanical, pneumatic and electromechanical assemblies in 3-shift operation This mainly involves components and assemblies in simple and complex designs in batch sizes of 1 to 10,000 pieces/year. Here, Toman offers an all-round service from material procurement to complex CNC machining, including complete finishing such as grinding, lapping, honing, eroding, wire cutting, laser cutting and surface treatments. Their customer base includes companies from the areas of automation technology, plant engineering, aerospace technology, drive and medical technology, precision engineering and testing technology.

By the way
Herbert Schmidbauer says: "A major advantage of the Versa 825 is its optimal accessibility and the whole machine set-up in general. We were already familiar with the rotary-swivel bridge from a competitor's machine. Because of the tool change, the tool changer with 80 pockets is sufficient for us".

Interesting side notes
The aging 3-axis machine has been automated by P-Cam, the PLC changed and an automatic door integrated.

back