Imagine an industrial developer who really needs a mock-up – a physical plastic model – so that he can “experience” his latest vacuum cleaner design. Or a designer who wants to test how the cast component she has come up with works in practice. In both cases, the ideas look good on the computer, but what will they be like in reality? This is a good time to contact Modellteknik in Eskilstuna. Especially if things are urgent!
Modellteknik started in the 1960’s as a supplier of models for the Swedish foundry industry. Since then, its operations have developed from pure craftsmanship to cutting-edge manufacturing. This is partnered by a total concept in mould manufacture, with streamlined production of one-offs and short series playing a vital role.
Roger Andersson, MD: “Tripled spindle hours! You can imagine the effect on lead times and what our customers think of it.”
Amongst the technologies covered by the concept are: stock removal (metal and plastic); metal casting followed by stock removal; vacuum moulding or vacuum forming of plastic components; rapid prototyping (SLA/SLS/FDM); and, injection moulding of plastic parts.
The majority of assignments are still for short series of castings. Most usually so that the customer can verify design during the development of new products. Working very closely with a number of foundries, Modellteknik selects the casting method, produces the model and carries out any necessary subsequent machining. If the customer wishes, constituent components are fitted and the assembly delivered along with a measurement report.
The simulated throttle control with 24 functions is highly responsive. Large movements must be avoided if the user is to retain fingertip control of the “equipment”.
An ever increasing proportion of assignments now relate purely to stock removal and the one-off or short series production of components in steel, aluminium or plastic.
Clearly enough, production deadlines at Modellteknik are very tight. “We have a high reputation for flexibility,” reveals MD Roger Andersson, “and we seldom have repeat jobs. It’s fair to say that almost every tooling is unique. Thus, setting up has to be done outside the machine so that the jigs with their workpieces can be quickly lifted in. We accomplish this with System 3R’s Dynafix pallet system. All our 5-axis machines now have Dynafix and the results show in our throughput times. Spindle hours have tripled. Looking back, it’s a wonder we could ever have been satisfied with our previously low degree of machine utilisation. It’s almost a little embarrassing.”
The superb and flexible automatic production cell.
Yet nothing is so good that it cannot be better. One year ago, the company installed its first automatic production cell – a five-axis DMU 50 and a WorkMaster robot with Dynafix and Macro pallets in its magazine. Preparation is handled by an operator in the immediate vicinity of the cell.
Roger Andersson: “This really is automated one-off production. We are particularly pleased with the adapter chuck. This enables the cell to switch automatically between smaller workpieces on Macro pallets and larger ones on Dynafix pallets. Superb flexibility! We are also impressed by the stability of the Macro chuck. The workpieces we attach to the Macro pallets are a good size!”
Results have been so impressive that it is now planned to enlarge to a double cell – a WorkMaster serving two machines.
One of Modellteknik’s few recurring jobs is a hand control to simulate the throttle of the JAS 39 Gripen, the pride of the Swedish aircraft industry. Roger explains: “We were not given any final drawings. The assignment was to create something that should be as close as possible to the real throttle control. The idea was that the ‘simulator’ should be used by maintenance technicians. However, our control is so good that it is now also used in the training of pilots.
“Thus, development started from zero. This hand control has 24 built-in functions, all of them extremely sensitive to movement. This places great demands on design precision.”
With a growing number of countries including the JAS 39 Gripen in their defence systems, tiny Modellteknik in Eskilstuna is expanding its deliveries of these hand controls for maintenance and pilot training in simulators.
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Layout drawing:
WorkMaster & Deckel Maho DMU50
Related links:
Automation in general
WorkMaster
Dynafix
Macro