"We think in systems"

Universal energy chain construction kit for modular CNC machining centers

Whether stationary and movable gantry or bridge center: the CNC 5-axis technology of MAKA Systems GmbH demonstrates its capability in many sectors of chip-generating machining whether in wood, aluminum or plastic. And since then, different energy supply systems are installed from the around 80,000 parts of the comprehensive modular kit, significant savings and performance enhancements can be detected at the same time.

"We build and develop CNC machining centers and comprehensive machining solutions at the highest level," says the managing director of MAKA Systems GmbH,
Ulrich Gnädinger. "From decision-making to delivery of machines, we are a reliable partner for our customers, because we also attend to the machining center over its entire lifetime. "Production site is in Nersingen. The number of employees is around 140. With a subsidiary in the UK and worldwide trading partners, the mechanical engineering company is represented around the globe. Founded in 1952, it
is a pioneer in CNC machining. The business operations were realigned in 2010. "As every detail of the customized machine concept has been implemented in the past, today the focus is
on increased standardization," says the managing director. "Our stated goal is to provide largely modular machining centers in the very latest technology at affordable prices. For this reason, we are always open to constructive improvements. “

A series of energy chains are used in this custom CNC machining center for the timber industry.

Intelligent energy chain solutions

"The customers' demands on the stability of the plants have steadily increased. At that time, the name igus® appeared more and more frequently in the specifications," Reinhard Hiller, Head of Production & Logistics, looks back. "And the collaboration has worked well. Over the course of time, we jointly developed a variety of customised solutions for the energy supply of the individual units that clearly stand out from the competition. By creating intelligent energy chain solutions, we saved costs in the double-digit percentage range right from the start, while at the same time increasing the performance data. Our energy chains score particularly well when it comes to unsupported lengths, such as those found on bridge centres. This is where we clearly stand out from our competitors.

All current energy chain series, which have already proven themselves in countless machining centres worldwide, are presently installed in the CNC machining centres. For a machine for machining plastics and composites, the CNC specialist has now also decided to use harnessed energy supply systems. "The issue is currently our number one priority," Reinhard Hiller clarifies. "As we increasingly focus on standardisation, we see a number of technical and economic advantages in pre-assembly.

A suction hose is easily carried in a clamp chain.

From prosthesis to Panamera

The company MAKA Systems is divided into three divisions: wood, aluminum and plastics/composite materials. In the wood sector the CNC machining centers with 5-axis technology are indispensable. "Whether doors, piano body or wooden frames for children's playgrounds – our customers are convinced of our high-quality milling machines," says the MD. The market share in the high-speed machining of light metal, such as the machining of extruded profiles and technical components, is steadily increasing. In the aluminum business segment, versatile features and flexibility lead the applications in industries that provide the highest standards, for example, in the space-frame technology of automotive construction, airplane and rail vehicle construction and in façade construction. Molded plastic, as deep-drawn part, CFRP or GFRP component, is at the center in the plastic/composite material business segment.

"Challenging work on spatial objects are materialized with our 5-axis technology and excel in the aircraft interior design as well as in yacht or large model making," the MD summarizes the product portfolio. This is a complete service package fully for the machine. From a rotary table milling center for a highly-dynamic small parts production of prostheses up to the integration of a CNC machine in a time-dependent assembly line at the Panamera production – the mechanical engineering company offers the right solution for every customer need. The highly complex CNC machining centers are usually in continuous use under difficult conditions. Their stability must therefore be ensured. No company can afford a standstill. The installed components must function reliably. This is also true for energy supply systems.

Changing requirement profiles

The different materials that are machined on the CNC machines place different demands on the energy supply systems. Dust, swarf and abrasive substances promote wear. In addition, there are the topics of agility, speeds and continuous use. 100 m/min and strokes of 40 and 50 m are not uncommon. "Especially the acceleration and deceleration of the masses must not stress the energy supply system in the long run," Reinhard Hiller clarifies. The chains are filled with electrical, pneumatic and sometimes hydraulic cables. The operating pressures, especially with hydraulic cables, reach several hundred bar. During load changes, the cables within the energy chain can develop a life of their own. "We have only good experience. They are so securely installed that we have not been able to detect any problems so far," reports Reinhard Hiller.

Special e-chains® with extender crossbars, which can accommodate suction hoses in diameters from 36 mm to 300 mm, have proven themselves on a number of special CNC machines. If the hose had to be routed within the energy supply system, this would only be possible via larger energy chains, which are of course much more expensive to procure. The relatively light air hose, on the other hand, can be routed separately along the actual energy supply system without any problems and without compromising on mobility.

Preassembling in the future

To get the cost structure under control in the long run, MAKA Systems has decided to concentrate on the prefabrication of basic component assemblies without the end customer determining it. They are then installed from stock. "We put more emphasis on this platform strategy especially in the industry-specific solutions," said Reinhard Hiller. "Here the preassembled energy supply systems play an important role. "
As the travels of the axes have been clearly defined earlier, chain and cable lengths are set to 100% and are quickly installed. In this context, the mechanical engineering company basically singles out the installation-friendly energy chains, which have proven themselves in daily operation. The way to the preassembled energy supply systems is always the same: Project engineers are on site to look at the machine or plant, define interfaces and chain lengths. Under normal circumstances − depending on the requirement profile − all the necessary information are available in a few days, so that the dimensioning can be done appropriately for each model.

From left: Ulrich Gnädinger (MAKA Systems), Michael Offner (igus®), Reinhard Hiller (MAKA Systems).

The advantages for the customer are evident. It is no longer necessary to procure innumerable single parts. The number of suppliers and orders can be reduced enormously. No storage costs are incurred. The harnessed energy supply system is delivered punctually. More than 1,400 cables for all drive and bus technologies are always available from stock. A very large number of plug-in connectors, as well as more than 80,000 plastic parts are also available. They are combined on the basis of the order and, after being checked, are delivered. This means that no compromises have to be made with regard to quality and reliability. "In our case, we only installed the energy supply system and are using the freed capacity elsewhere in the company", confirms Reinhard Hiller. "Due to the good experience in the case of the pilot project, we will choose the harnessing option more often in future. " The advantages of harnessing will be irrelevant only in the case of the CNC special machines in the high-end area. "Such machines are completely tailor-made products that are designed individually from start to finish. “

The machine in monoblock design is impressive in the single-version with best conditions for top machining quality at maximum feed rates. The application is in the trimming and finishing of thermoplastic and plastics. The energy chain with the routed suction hose is clearly visible.

The name says it all

The platform strategy reveals its first successes. Two machines,
which have been pre-fabricated as component assemblies and found in stock,
are sold within a very short time to a supplier in the automotive industry for the processing of aluminum. "We have also saved a lot of installation time through the preassembled energy supply systems and were able to deliver quickly," Reinhard Hiller clarifies. The company sees itself as a system integrator. "We think in systems and want to persist in combining the individual parts of our machines to modules and to mini-systems", says the MD. "We want to take this step together with our suppliers. In this environment, of course, the preassembled energy supply systems also play an important role, because in the long run they pay off. First, procurement costs are reduced and second, we can flexibly react to our specific utilization capacity. " The CNC machining centers are the heart of the production. If they fail, the entire production stands still.

"And we want to avoid outages and related services at all costs," concludes Ulrich Gnädinger. "We have had in recent years the best experience with the energy supply systems and will enter into new projects together in the future. “