THE DMG MORI MAGAZINE FOR CUSTOMERS AND INTERESTED PARTIES 02 – 2022

TECHNOLOGY

EXCELLENCE

WORLD
PREMIERE
PH Cell Twin

AUTOMATION

Experience the whole world of

DMG MORI automation solutions.

Our special automation website

can be found at:
love-automation.dmgmori.com
 CONTENT

42 54
Sandvik Coromant: Automated manufacturing solution of bodies for drilling Pallet handling PH-AGV 5000: The autonomous, driverless transport system
tools with over a hundred variants in batch sizes from 2 to 80 using the NTX 2000 for pallet sizes up to 1,600 × 1,400 mm and 5,000 kg handling weight.
turn-mill center and MATRIS, the flexible robot system from DMG MORI

08 AUTOMATION 66 DMG MORI

– We love Automation SUSTAINABILITY
– Retrofit – Green and efficient
– Hintersdorf GmbH & Co. KG with our After Sales
– Fr. Aussieker Metallverarbeitung – Körting Hannover GmbH SINCE 2021:
GmbH & Co. KG – DMG MORI Green Economy 100 % CLIMATE-
– PH Cell 2000 – Meindl-Köhle Umform- und NEUTRAL
Systemtechnik GmbH & Co. KG
MANUFACTURING
22 WORLD PREMIERE – NEHER GROUP
OF OUR
– PH Cell Twin
MACHINES
82 ADDITIVE MANUFACTURING
24 AUTOMATION – Wolfgang Doose Werkzeug- &
– SPECK Pumpen Vorrichtungsbau GmbH & Co KG
Walter Speck GmbH & Co. KG
– Robo2Go – The best-selling
standard automation
– STROMBOLI GmbH
– NEW: Pallet handling by MATRIS
GREEN
– Nabeya Co., Ltd.
– Sandvik Coromant MACHINE
– HYDAC Technology (Shanghai) Ltd.
– Interview – AGV / AMR
– Pallet handling – PH-AGV 5000
– KIGUCHI TECHNICS INC.
– CTS – Central Tool Storage für TH-AGV
– Grede Casting Integrity LLC

WORLD
PREMIERE
2022

22 PH Cell Twin
Modular and compact
pallet handling for two machines.

2 TECHNOLOGY E XCELLENCE
 EDITORIAL

Dr. Eng. Masahiko Mori

President
DMG MORI COMPANY LIMITED

Christian Thönes
Chairman of the Executive Board
DMG MORI AKTIENGESELLSCHAFT

WITH AUTOMATION AND

DIGITIZATION TO
GREATER SUSTAINABILITY
In a challenging market environment, LIMITED, and Christian Thönes, Chairman Christian Thönes: Take the utilization rate of a
DMG MORI has proven itself to be a firm of the Executive Board of DMG MORI machine as the key indicator for the overall
and reliable partner in global machine AKTIENGESELLSCHAFT. equipment effectiveness as an example.
tool manufacturing. The world's leading While conventional machine tools achieve a
manufacturer of high-precision, sustain- With the current campaign utilization of around 34 percent according to
able machines and technologies benefits “We love automation” DMG MORI emphati- a study from RWTH Aachen in 2020, flexible
from its consistent implementation of the cally addresses the use of automation. manufacturing systems are demonstrably
strategic triad of automation, digitization Why should users love automation? able to achieve rates of up to 90 percent.
and sustainability. Stability is also ensured Dr. Masahiko Mori: Because automation So instead of around 2,600 hours achieved
by the company's global footprint and a demonstrably creates added value – through conventionally, our machines can be used for
wide-ranging product and service port- increased process productivity and higher up to 6,000 hours or more in an automated
folio that sustainably integrates forward- quality products as well as through reduced system. Our machines are designed for this
looking manufacturing solutions for cus- personnel costs and therefore lower costs and ideally should be used accordingly.
tomers from a single source. Learn more per unit. Moreover, longer machine run times
about the status quo and current innova- ensure more efficiency and sustainability,
tions for the manufacturing industry in the while enhanced transparency and repeat
following interview with Dr. Eng. Masahiko accuracy create the basis for a continuous
Mori, President of DMG MORI COMPANY improvement process. »

TECHNOLOGY E XCELLENCE 3
EDITORIAL

But these arguments are not new … Dr. Masahiko Mori: Another basic topic is the What innovative highlights can visitors
Dr. Masahiko Mori: New is that we have extensive central control computer techno- at the international DMG MORI fall trade
democratized automation so to speak, with logy. The new CELL CONTROLLER LPS 4 fairs expect?
massive investments and innovations over is not only able to integrate all single Dr. Masahiko Mori: We are currently expanding
the last few years. Flexible manufacturing machines, but also manufacturing cells and the successful series of Robo2Go models for
cells and manufacturing systems have now manufacturing systems on the shopfloor to turning and milling to include the Robo2Go
become economically viable for companies a flexible manufacturing network. Moreover, Max as a solution for workpieces up to 115 kg
of all sizes. Today a unique range of modular the intelligent new development can, where and small until medium batch sizes. This
equipment puts DMG MORI in a position necessary, also control the automatic pro- model can also be prepared for its tasks
to perfectly map the entire spectrum of vision of material, tools and operating quickly and simply directly from the CELOS
flexible automated production from a single resources. Integration to ERP, MES or APS control without any programming knowledge.
source – from simple to complex, for work- systems and tool management is also reliably
pieces, pallets and tools as well as from solved by means of adequate interfaces. In addition we are expanding the Matris
large series to single part production. family for modular entry into the world of
Customers thus receive their entire tailor- manufacturing automation with the highly
Christian Thönes: Our innovative automation made system consisting of high-tech flexible and compact MATRIS Light for
portfolio comprises in total 57 automation machines, automation plus control intelli- workpieces up to 5 kg. The handling system
solutions in 13 production lines for machine- gence and central control computer techno- can be connected to the machine in less
specific, universal and scalable solutions – logy from a single source and under a single than 5 minutes, operated intuitively and,
including the entire hardware and software. responsibility. This gains in importance the as a collaborating robot solution, needs no
We thereby can already equip or upgrade higher the degree of automation, a fact safety fence.
more than 150 different machine models reflected in our sales success. In the past
for our customers, often even as a retrofit few months we managed to place dozens of For entry into automatic pallet handling,
option. The levels of our automation offer systems with a Linear Pallet Pool (LPP) and DMG MORI will also present the PH 50,
range from machines with tool and pallet systems from the MATRIS building blocks an entry model that is both compact and
change, through flexible manufacturing cells successfully on the market. In addition, economical. In the medium range, the
to automatic tool provision and from there are several hundred Robo2Go and PH Cell 300 offers space for up to 40 pallets
driverless transport vehicles to different PH Cell solutions – plus the standard auto- of varying sizes of 320 × 320, 400 × 400 and
turnkey expansion stages of flexible manu- mation solutions. 500 × 500 mm for transfer weights up to
facturing systems. 300 kg on a footprint of just 10.7 m2. And
finally, the PH Cell 2000 expands the port-
folio with the flexible handling of work-
pieces up to 2,000 kg on 21 pallets.

The democratization of manufacturing

has been DMG MORI's focus for years,
so today automation is accessible
and economical for companies of all sizes.

Dr. Eng. Masahiko Mori

President
DMG MORI COMPANY LIMITED

4 TECHNOLOGY E XCELLENCE
 EDITORIAL

DMG MORI
GLOBAL FULL-LINER FOR AUTOMATION CELL CONTROLLER
LPS 4

SET-UP TIME NEW

TURNING
WORKPIECE HANDLING

NEW

MILLING

NEW
PALLET HANDLING

NEW

NEW

MACHINE-SPECIFIC UNIVERSAL (1 MACHINE) SCALABLE (≥ 1 MACHINE)

COMPLEXITY

DMG MORI's portfolio consists of 57 automation solutions in 13 product lines for machine-specific, universal and scalable solutions, including the complete hard-
and software: from machines with tool and pallet changer, flexible manufacturing cells, automatic tool supply (CTS), driverless transport vehicles (AGV & AMR) to the
various turnkey expansion stages of flexible manufacturing systems, such as LPP or MATRIS, completed by the DMG MORI CELL CONTROLLER LPS 4.

Christian Thönes: In particular at the AMB in Although automation is booming on a broad today creates the cost-effective, transparent
Stuttgart, DMG MORI will exhibit the RPS 14 front, studies show that especially small and reactive environment in which the
rotary pallet storage system, the Robo2Go and medium sized enterprises in manufac- sustainable effect of industrial digitization
Max for turning and the Robo2Go Milling. turing technology are still reticent where can better evolve. To be more specific: the
There will also be two very compact auto- digitization is concerned. Does this disparity current situation does not indicate disparity,
mation solutions on show – the WH 3 Cell surprise you? but perfectly normal customer behavior.
and the MATRIS Light. Another absolute Christian Thönes: Automation and digitization »
AMB highlight is the new PH Cell Twin, via are the strategic pillars for cost-efficient and
which two DMU 50 machines are linked on sustainable manufacturing technology. Every
the smallest of spaces. You will find reports change always begins where innovation
on many of the highlights mentioned in for customers demonstrably creates value.
this magazine. In this respect the automation of production

TECHNOLOGY E XCELLENCE 5
EDITORIAL

DIGITIZATION

DIGITAL TWIN

1. PLANNING 2. PREPARATION 3. PRODUCTION 4. MONITORING 5. SERVICE

62 Technology Cycles 27 CELOS APPs

DMG MORI's connectivity solutions open up a holistic portfolio of digital tools and applications for the immediate workshop environment. This portfolio of digital
end-to-end solutions supports our customers from planning with ISTOS, through work preparation and production, to the optimization of maintenance and service processes,
for example with my DMG MORI.

… which according to the studies comes at the relevant production and service information. This includes direct and indirect emissions
expense of digitization! In addition we open up a direct digital from our own value creation as well as
Dr. Masahiko Mori: The value of digital communication channel for them in our indirect emissions from upstream processes
products and services is not measured on worldwide service organization, which we along the supply chain. Energy experts refer
the basis of visions but by predictable are currently expanding to include another here to scope 1, 2 and 3 upstream.
customer benefits. Wherever this is the 100 service technicians. All these digital and
case, digitization will take place. This is real measures accelerate the processes Christian Thönes: More specifically, all
proven by the enormous acceptance of our holistically and convincingly enhance the machines delivered since January 2021 have
customer portal my DMG MORI, where al- service quality. been produced completely climate-neutral.
ready today more than 30,000 customers For this, DMG MORI was recently awarded
with over 140,000 machines are connected Meanwhile, the term “triad” referred to the Platinum Medal in the Sustainability
to our service organization. As a result, we at the beginning can also be found in the Rating by the internationally renowned
already receive 67 percent of all service sustainability offensive from DMG MORI. institute EcoVadis. This means that we are
ueries via the customer portal. What elements interact here? among the TOP 1 % of over 35,000 companies
Dr. Masahiko Mori: In this case the triad evaluated worldwide.
To what do you ascribe the success reflects the holistic nature of our climate
of the customer portal? measures. By avoiding, reducing and com-
Christian Thönes: my DMG MORI quite simply pensating, DMG MORI has achieved both a
makes digitization worthwhile. We use it CO2-neutral “Company Carbon Footprint” and
to offer our customers direct access to all a climate-neutral “Product Carbon Footprint”.

6 TECHNOLOGY E XCELLENCE
 EDITORIAL

Automation and digitization are the

strategic pillars for cost-efficient and
sustainable manufacturing technology.

Christian Thönes
Chairman of the Executive Board
DMG MORI AKTIENGESELLSCHAFT

Does the energy-efficiency of the DMG MORI the electrical power requirement in industry pushing the consistent use of consumption-
machines play a role here? worldwide to be around no less than 5 to optimized components (e. g. for lighting),
Christian Thönes: Not directly. The machines 10 percent. the recovery of braking energy as well as
and their utilization by customers have been the energy-efficient control and regulation
a key pillar of our sustainability strategy for Dr. Masahiko Mori: Efficient starting points in of units. For example, customers save up
many years. This topic has again gained this respect can be found especially in the to 20 % of energy in machine usage with
momentum in view of the price develop- optimization of the main and auxiliary units the CELOS app “ENERGYSAVING”, while
ment on the energy market. Various studies of our machines – in particular, within the simultaneously reducing process times.
indicate just how elemental this field of framework of new developments, but also
action is; they estimate the share of wherever possible in the re-engineering of
machine tools and production processes in existing series. At the same time, we are «

GREEN ECONOMY
100 % GREEN MACHINES

CLIMATE-NEUTRAL RESOURCE-EFFICIENT
MACHINE PRODUCTION MACHINE USAGE
GREEN 1. Neutral Product Carbon Footprint (Scope 3 Upstream) GREEN (Scope 3 Downstream)
MACHINE 2. Neutral Company Carbon Footprint (Scope 1 + 2) MODE

TECHNOLOGY EXCELLENCE
FOR GREEN TECHNOLOGIES
GREEN
TECH

TOP 1 % FROM MORE THAN 35,000 COMPANIES!

DMG MORI's sustainability strategy covers the entire life cycle of the machines. From climate-neutral machine manufacturing through resource-efficient machine operation
to a machine recyclability of > 99 %. In addition, we support our customers in the field of green technologies, such as wind & water power, recycling and e-mobility. For this,
DMG MORI recently received the Platinum Medal in the Sustainability Rating from the internationally renowned EcoVadis Institute. This means that DMG MORI is among the
top 1 % of over 35,000 companies rated worldwide.

TECHNOLOGY E XCELLENCE 7
AUTOMATION

GLOBAL LEADER IN
AUTOMATION: 13 PRODUCT LINES
AND 57 PRODUCTS
NEW
SET-UP TIME

TURNING
Robo2Go
Turning /
Vision
WORKPIECE HANDLING

Robo2Go Max

SR (WASINO)

IMTR (NTX 1000) NEW

MILLING Robo2Go
Milling

MATRIS Light

WH Cell 1

NEW
PALLET HANDLING

PH Cell 2000 /
PH Cell 300

PH Wheel 3

NEW

AWC
(NMV / CMX V) RPS 2 PH 150 PH 50

MACHINE-SPECIFIC UNIVERSAL (1 MACHINE)

8 TECHNOLOGY E XCELLENCE
 AUTOMATION

Technology expertise, machine

and automation from a single
source. Future-proof your
production with DMG MORI.
Harry Junger
Managing Director
GILDEMEISTER Drehmaschinen GmbH
DMG MORI
CELL CONTROLLER
LPS 4

GX / GX T

MATRIS

WH Flex WH-AMR (AGV)

NEW

LPP

PH Cell Twin
PH-AGV
TH-AGV
CPP

SCALABLE (≥ 1 MACHINE)
COMPLEXITY
DMP, CMX V, CMX U, DMU, DMU monoBLOCK, DMU eVo, LASERTEC
1

NHX, DMC H linear, monoBLOCK, duoBLOCK, Portal

2

DMC 65 monoBLOCK, DMU 65 H monoBLOCK

3

TECHNOLOGY E XCELLENCE 9
AUTOMATION

WE

love AUTOMATION
Specialists to load machines?
No night shifts due to staff shortages?
WHY YOU SHOULD ALSO
Lack of process integration for LOVE AUTOMATION
quality control?
Our automation solutions make these a thing
+ Simple to operate: unified and
of the past. This will leave you free to deploy
integrated user interfaces
your experts where they are really needed.
+ Proven technology: All solutions are
Your machines will be better utilized and not
optimized and tested in our factories!
only produce large quantities impressively
+ Night shifts and weekends:
quickly but also work flexibly from a batch
Let the machine work!
size of 1.
+ Become more competitive: Reduce the
cost per part with workpiece and process
The biggest benefit: A fully automated
optimization!
machine can replace three stand-alone
+ Flexibility: From large batches
solutions. The advantages are obvious: Lower
to individual pieces!
costs, fewer downtimes, less space require-
+ Sustainability: Optimization of footprints
ments, ensuring the long-term success of
and energy resources including minimization
your company. And don’t forget – you can
of CO2 emissions!
upgrade almost every one of your machines.

DMG MORI supplies automation

and turnkey solutions for every
machine from a single source.
Get in touch with us, we will
take care of your production
requirements.

Ralf Riedemann
Executive Officer Engineering and Application
for the worldwide DMG MORI Sales and Service
DMG MORI Management GmbH

10 TECHNOLOGY E XCELLENCE
 AUTOMATION

PORTFOLIO

Did you know that we offer an automation solution for

almost every one of our machines?

→ Find out more in our web special!

FIND AN
AUTOMATION
SOLUTION!

Our special automation website can be found at:

love-automation.dmgmori.com

TECHNOLOGY E XCELLENCE 11
 AUTOMATION – RETROFIT

RETROFIT

now
AMORTIZATION OF YOUR RETROFITTED AUTOMATION
EXAMPLE: DMU 75 monoBLOCK WITH PH Cell 300
E R AT I O N
OP TION AUT
RA OM
1- S H I F T

PE

AT
FT
8h

ED
3-SHI
24/7

1-shift operation
= 1,560 spindle hours per year* 24/7 operation
AMORTIZATION
< 6 MONTHS = 6,552 spindle hours per year*
(AUTOMATION) + 2 × additional unmanned shifts per day
(< 19 months for machine & automation)
+ 6 × additional unmanned shifts at the weekend
(< 12 months for machine & automation)

AMORTIZATION 3-shift operation

< 9 MONTHS = 4,680 spindle hours per year*
YOUR CONTACT PERSON: (AUTOMATION)
+ 2 × additional unmanned shifts per day
Torsten Zwerenz (< 19 months for machine & automation)
Head of Global Service Systems
[email protected]
Tel. +49 (0)83 63 89 29 17

WE AUTOMATION
Our special interactive website not only offers you
CHECK
information on technical details but also allows you EXISTING
to see how quickly our automation solutions pay MACHINES
for themselves based on calculated examples.
We are not talking about years here but just months!

Do you already have a machine?

We can help you find a suitable automation solution:
love-automation.dmgmori.com

*
 MU 75 monoBLOCK with PH Cell 300 stack magazine, 20 pallets – simplified calculation with
D
75 % spindle hours: 1-shift: 52 weeks × 5 days × 8 h × 0.75 = 1,560 h/a;
12 TECHNOLOGY E XCELLENCE 3-shift: 52 weeks × 5 days × 24 h × 0.75 = 4,680 h/a; 24/7: 52 weeks × 7 days × 24 h × 0.75 = 6,552 h/a
 CUSTOMER STORY – HINTERSDORF GMBH & CO. KG

AUTOMATION THROUGH
RETROFITTING P E R ATION AUTOM
A

O
INSTEAD OF A NEW INVESTMENT

TE
FT

D
3-SHI
24/7

AMORTIZATION
< 1 YEAR
(AUTOMATION)
After moving to a new plant, DMG MORI retrofitted the DMU 60 eVo linear with a PH Cell 300.
As a result, Hintersdorf can now produce unmanned during night and weekend shifts.

The production process runs

autonomously for long periods and
can even be maintained throughout
the weekend. This means that
investment in the PH Cell 300 can
pay for itself in less than one year!

Holger Hintersdorf
Managing Director of
Hintersdorf GmbH & Co. KG »

TECHNOLOGY E XCELLENCE 13
CUSTOMER STORY – HINTERSDORF GMBH & CO. KG

Hintersdorf GmbH & Co. KG was founded training as a mechanical engineering

in 2014 in Rahden as an engineering technician, the experienced designer reco-
company. In just a few years it has gnized that an integral range of services
established itself as a reliable service would be more flexible and would also
provider for manufacturing blow molds, deliver the best quality at all times. “Existing
casting molds and extrusion tools as well colleagues were won over by the idea and put
as for assembly and measuring devices, all their support behind my team.”
prototype construction and small special-
purpose machines. International customers, Skilled specialists as the backbone
RETROFIT particularly from the automotive industry, of success
NOW
chemical industry and heating engineering Holger Hintersdorf still considers skilled
put their trust in the expertise of the almost engineers to be the backbone of the
30-strong team. A high-performance array company: “We have toolmakers that are
of machines is a part of the total range not responsible for machining but instead
of services and includes new machining understand every detail of the complicated
centers and turning machines from design and who also assemble the tools
DMG MORI. The machine tool manufacturer themselves.” The team is thus able to work
had already provided considerable support extremely independently and over and again
during the founding of the company by contribute ideas for optimization. Holger
offering attractive financing solutions from Hintersdorf maintains the high level of
DMG MORI Finance. The latest investment manufacturing with an in-house training
was a DMU 60 eVo linear, which was program, but has also noticed that skilled
retrofitted with a PH Cell 300 to ensure that staff and trainees are getting harder to find:
Hintersdorf can continue to produce even “This is the reason we need to continuously
PH Cell 300 more efficiently – around the clock. optimize our manufacturing strategies to
remain competitive.” This begins with the
RETROFITTABLE Integral range of services development and design of new tools. “Our
PALLET “After founding the engineering company, it customers ask us to get involved very early
quickly became clear to us that an on-site on in the process to ensure we can find the
HANDLING manufacturing facility would be the perfect best possible solutions,” according to Holger
FOR UP TO complement to these services,” says Holger Hintersdorf. Sophisticated jigs are used to
Hintersdorf looking back at his company’s make machining more efficient during the
40 PALLETS first year. As a toolmaker with specialist manufacturing process.

+ Up to 300 kg transfer weight

(workpiece incl. pallet)

+ 10.7 m2 footprint

+ Separate setup station for ergo-

nomic and simultaneous loading
and unloading of pallets

+ Handling of different pallet sizes

in one system

Retrofittable and available

for 9 series, e. g. monoBLOCK,
DMU, eVo etc.

The PH Cell video on

modular pallet handling:
https://youtu.be/_W3KjhMykqo
Hintersdorf has already invested in nine machining centers and turning machines
from DMG MORI with the support of DMG MORI Finance.

14 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – HINTERSDORF GMBH & CO. KG

Company founded with support from individual parts, prototypes or very small
DMG MORI Finance series.” With 20 spaces for pallets up to a
When it comes to CNC technology, Hintersdorf size of 320 × 320 mm, the configuration of the
has relied on DMG MORI since the begin- storage racks is ideal.
ning – as a machine supplier and as a
finance partner. “DMG MORI Finance Automation and digitization for flexible
made our start easier with attractive con- work planning
ditions,” says Holger Hintersdorf looking The next investment is proof that Holger
back. Sven Stolle, an experienced Area Hintersdorf is more than satisfied with the
Sales Manager (ASM), was also a great help automation. Another DMU 60 eVo linear
in choosing the machines. To start with, with a PH Cell 300 will be installed in 2023.
they comprised a DMU 75 monoBLOCK, a Moreover, sustainability and digitization are
DMC 850 V and a used NL 3000. Hintersdorf becoming increasingly important for the
has continued to invest since then and added future. “A solar power system means that
a DMU 60 eVo linear in 2019. “The speed, we will be able to cover the majority of our
acceleration and precision of the machine power requirements ourselves. Deliveries
is ideal for our applications and we are also are made with an electric vehicle and we
able to utilize our work space optimally for use regional suppliers as much as possible.”
our range of components,” is the opinion Digitization has meant that Hintersdorf is
of Holger Hintersdorf regarding the 5-axis well on its way to networked manufacturing.
universal machine. Due to space restric- When machine service is needed, the team
tions, he was initially unable to automate the relies on fast and transparent interaction
DMU 60 eVo linear. through my DMG MORI. Holger Hintersdorf
sees further potential: “Digital solutions for
work planning will enable us to react more
flexibly in the long term.” The setup station of the PH Cell 300 enables the

FLEXIBLE
next job to be prepared while production continues.

«
MANUFACTURING
DURING UNMANNED
SHIFTS

As there was already a new plant in plan-

ning when the DMU 60 eVo linear was being
purchased, Holger Hintersdorf ordered the
HINTERSDORF FACTS
machine prepared for automation: “There
was really no way to avoid this, as we need + Founded in Rahden in 2014 as
to utilize our machines to the maximum an engineering company
while also tackling a shortage of skilled + Reliable service provider for the
labor.” Although it is also possible to ret- manufacture of blow mold tools,
rofit a machine that has not been prepared, prototype construction, extrusion
the approach significantly alleviates the tools, fixtures and mechanical
effort. This was confirmed when moving engineering
into the new plant. DMG MORI retrofitted + International customers,
the DMU 60 eVo linear with an PH Cell 300 particularly from the automotive
within one week. industry, chemical industry
and heating engineering
Double the spindle runtime + 30 employees
The investment in the PH Cell 300 paid off
quickly, explained Holger Hintersdorf: “Pro-
duction continues autonomously for long
periods and can even be maintained over
the weekend. We have someone come in Hintersdorf GmbH & Co. KG
from time to time to exchange the parts.” It Carl-Zeiss-Str. 3
was possible to double the spindle runtime. 32369 Rahden, Germany
www.hintersdorf-inform.de By retrofitting a flexible PH Cell 300,
Another argument in favor of the PH Cell Hintersdorf can now produce unmanned
300 was its flexibility: “We mainly produce during night and weekend shifts.

TECHNOLOGY E XCELLENCE 15
CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG

CAPACITY PLUS
THANKS TO AUTOMATION
The company Aussieker Metallverarbeitung two automated machines: a DMU 50 with Managing Director since 2003. Production
GmbH & Co. KG from Preußisch Oldendorf PH 150 and a DMU 95 monoBLOCK with requires both modern CNC technology and
was founded in 1969 as a classic subcontract PH Cell 300. well-trained engineers. Although Aussieker
manufacturer. Right up to the present day, trains its own future employees in-house, it
customers in the general machine and plant Combating the skills shortage nevertheless recognises how it is becoming
engineering sector and the medical industry with automation ever more difficult to find good staff. “This
place their trust in the competence of the “The challenge we face has always been to makes it difficult to fulfil a healthy order
30-strong team. For producing its high produce complex and high-precision work- book over the long term – in particular
quality workpieces, Aussieker uses modern pieces as economically as possible”, explains when we sometimes have to work three
machine tool among which since 2019 are Frank Aussieker. He has led the company of shifts.” In view of the growing lack of skilled
four models from DMG MORI – including the same name as the second generation staff, the company decided to invest in an

Prototypes and small series are part of our daily

business. Thanks to the PH 150 and PH Cell 300 pallet
handling systems, we can respond flexibly.
Frank Aussieker (left), Managing Director, and
Jan Kleine-Beek, authorized representative
Fr. Aussieker Metallverarbeitung GmbH & Co. KG

16 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG

The ten pallet places of the PH 150 are sufficient

to allow an unmanned night shift.

PH 150

THE UNIVERSAL
PALLET HANDLING
SYSTEM FROM
DMG MORI
Aussieker entered into automated 5-axis machining in 2019 with a DMU 50 and a PH 150 pallet
handling system. The ten pallet places of the PH 150 are sufficient to allow an unmanned night shift.
+ High variability of the available
configurations of 24 round pallets
of ø 148 mm and up to four pallets
measuring 500 × 500 mm
+ Up to 250 kg workpiece weight
(150 kg as standard)
+ Possibility of prioritizing orders
automated manufacturing solution in 2019. “This only takes a few minutes and ensures
+ EROWA clamping system as standard,
A authorized representative Jan Kleine-Beek that we can more or less produce around the
optionally SCHUNK
recalls the purchase of the DMU 50 with clock and so meet tight delivery times”, says
+ Optimal accessibility to machine
PH 150: “Based on the positive experience Frank Aussieker.
and automation
we have had with a DMU 100 P duoBLOCK
since 2004 and a DMF 260 | 7 since 2018, it High capacity utilization and flexible
Retrofittable & available for the
was clear to us that DMG MORI was the production thanks to pallet handling
10 series, e. g. CMX V / U, DMU etc.
right partner for this investment.” The move The good experience with the first automation
ultimately led to the purchase of the DMU
95 monoBLOCK with PH Cell 300 in 2022.
“Compared to the PH 150, the PH Cell
UNMANNED 300 offers us additional capacity”, explains
The video of the
DMU 50 3rd Generation:

SHIFTS AND Jan Kleine-Beek regarding the purchase of

the automation solution, which DMG MORI
https://youtu.be/57vl-BgHKzw

MULTI-MACHINE launched onto the market in 2020. The pallet

OPERATION storage system is modular in design and can

be configured specifically for each customer.
The version at Aussieker is equipped with a
shelf module for 19 pallet storage places – 15 be exploited during automatic production.
towards unmanned production has helped for pallets of up to 300 × 300 mm, and four for Another innovation: Control of the PH Cell 300
enormously. “All our employees have to do pallets of up to 400 × 400 mm. “The storage is directly via the CELOS interface of the DMU
now is set up new orders, load the automation system is designed in such a way that we can 95 monoBLOCK. “And if we wish to increase
and then unload the finished parts.” This load components that protrude a little over our capacity, we can expand the system in
leaves them enough time to operate other the end of a pallet”, Frank Aussieker goes the future with another shelf module.”
machines. If necessary, the PH 150 is loaded on to tell us. This means that the large
at night or at the weekend. work area of the DMU 95 monoBLOCK can »

TECHNOLOGY E XCELLENCE 17
CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG

AUTOMATED
SMALL SERIES
PRODUCTION

With the PH 150 and the PH Cell 300, Aussieker

has confirmed that automatic production is
certainly not limited to large series. Quite
the opposite: ”Prototypes and small series
are part of our daily business”, is how
Jan Kleine-Beek describes typical orders.
“Thanks to pallet handling we can respond
flexibility certainly not.”

The PH Cell 300 is loaded via an The PH Cell 300 is equipped with a shelf
ergonomic setup station. module with 19 pallets positions –
15 for pallets up to 300 × 300 mm and four
for pallets up to 400 × 400 mm.

PH Cell 300

MODULAR PALLET
HANDLING FOR
UP TO 40 PALLETS
IN A FOOTPRINT
OF 10.7 m 2
+ Up to 300 kg transfer weight
(workpiece incl. pallet)

+ Separate setup station for

ergonomic loading of the pallets
during production

+ Handling of different pallet sizes

in one system

Retrofittable & available for 9 series,

e. g. monoBLOCK, DMU, eVo, etc.
Aussieker expanded automated production in 2022 with a DMU 95 monoBLOCK with PH Cell 300.

Workpiece height
ø 500 mm 500 mm* 300 mm
500 mm
PH Cell Pallet size Max. number of pallets
300 kg 500 × 500 mm 18 24
The PH Cell video for modular 400 × 400 mm 24 32
pallet handling: Max. workpiece
320 × 320 mm 30 40
https://youtu.be/_W3KjhMykqo dimensions
No limit to component height on the top shelf
*

18 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – FR. AUSSIEKER METALLVERARBEITUNG GMBH & CO. KG

Reliable production thanks to digital Fast amortization FR. AUSSIEKER FACTS

products from DMG MORI The path to automated production soon paid
+ Founded in Preußisch
Aussieker also works with digital products for itself, sums up Frank Aussieker: “It is
Oldendorf in 1969
from DMG MORI to ensure automatic quite clear that it has allowed us to combat
+ 30 employees
production runs smoothly. “The DMG MORI the skills shortage effectively.” A the same
+ Subcontractor for demanding
Messenger informs us of any unscheduled time, machine utilization has increased
applications
stoppages during the night and weekend significantly. “Against this background, auto-
+ Wide range of customers from
shifts, so someone can drive to the plant and mation solutions will play a key role in future
the general machine and plant
restart the automation”, mentions Jan Kleine- investments”.
engineering sector and the
Beek as just one example. We rarely have any
industry, sectors among others
serious problems thanks to the integrated
tool breakage monitoring. Digitization has
also benefited our service, adds Frank
Aussieker: “my DMG MORI enables technical
problems to be sent to the the DMG MORI Fr. Aussieker
Metallverarbeitung GmbH & Co. KG
service team at the press of a button, so help Am Alten Markt 30
can be provided via the NETservice or hotline, 32361 Preußisch Oldendorf
reducing stoppages to a minimum in many Germany
www.fr-aussieker.de
cases. In view of the good order situation, the
company depends on reliable production. «

PRECISION ENGINEERING MEETS DIGITIZATION

September 13 – 17, 2O22
Come and visit us at
AMB in Stuttgart!
Hall 1, Booth #1F5O

Tooling Technology Shrinking Technology Balancing Technology Measuring- and

Presetting Technology

www.haimer.com

TECHNOLOGY E XCELLENCE 19
PH Cell 2000

PH Cell 2000
MODULAR ROTARY PALLET STORAGE
FOR UP TO 21 PALLETS

TRANSFER
WEIGHT
2,000 kg

Retrofittable!
Connection to existing
machines possible
if automation interface
already integrated

Compact!
up to 21 pallets in a
16.5 m2 footprint

CONSTRUCTION KIT
Modular concept for individual customer requirements with 2 different sizes and 2, 3 or 4 shelf levels

handling device shelf storage setup station

+ Fast pallet change in under 45 seconds + Heavy loads possible with 2,000 kg + Rotatable setup station as standard
due to integrated twinFORK gripper per storage location + High precision FD setup station
+ Handling device for pallets from + Fast commissioning. The shelf optionally available
500 × 500 mm to ø 1,100 mm storage system is transported as a + Setup station optionally available in
whole including the handling device conjunction with clamping hydraulics
+ Maximum 21 pallets on 4 levels
in the overall system

20 TECHNOLOGY E XCELLENCE
 PH Cell 2000

Celos / Joblist en 0

PH Cell MAX Joblist Projects

Number Name Home

Pocket

Available for:
9 10 11 12
1 Aluminium rocker arm 6

– DMU 65 H monoBLOCK NEW: 5 6 7 8

2 Device holder 3

Pallet Master
3 Steel Mold forge 1

– DMU 85 H monoBLOCK 1 2 3 4

– DMU 80 P / FD duoBLOCK Software

– DMU 90 P duoBLOCK L0 Shuttle L1 Machine L2 Setup

– DMU 100 P / FD duoBLOCK Objects per page: 10 1 - 3 from 3

– DMU 125 P / FD duoBLOCK

1 2 1 1

HIGHLIGHTS

WORKPIECE SIZES + Transfer weight up to 2,000 kg

+ 12 to 21 pallets in system,
pallet size 500 × 500 mm to ø 1,100 mm

+ Fast pallet change time < 45 seconds

due to integrated twinFORK gripper
ø 1,100 mm
1,350 mm
+ Can be retrofitted with machine preparation
PH Cell 2000
2,000 kg
+ Short commissioning time within 3 days
due to defined interface and modular principle

25 %
PH Cell 2000 VS. RPS SMALLER
A DIRECT COMPARISON FOOTPRINT

PH Cell 2000 AREA COMPARISON

+ Retrofittable for machines with automation interface + 16.5 m2 footprint of the PH Cell 2000
with up to 21 pallets on 4 levels
+ Also available for DMU machines
+ 25 % reduction in footprint compared
+ Up to 21 pallets can be handled and
to the RPS with 12 pallets
stored in the system
4,700 mm (PH Cell 2000)
+ Modular design with different pallet sizes
5,240 mm (RPS 12)
+ Integrated pallet changer in the handling device
3,490 mm (PH Cell 2000)

RPS
4,060 mm (RPS 12)

+ Machine-integrated solution
for DMC machines with pallet changer

+ Maximum number of workpieces

corresponds to the machine

+ Very fast pallet change times due to the

machine pallet changer

+ Also for DMC 160 U / FD and Portal machines RPS 12

PH Cell 2000 RPS 12

16.5 m2 21.3 m2

TECHNOLOGY E XCELLENCE 21
 PH Cell Twin

WORLD
PREMIERE
2022

PH Cell Twin with DMU 50

and DMU 65 H monoBLOCK

Retrofittable!
Connection to existing machine
with already integrated automation
interface possible

Extendable!
Subsequent connection of
a second machine possible

PH Cell Twin
MODULAR AND COMPACT
PALLET HANDLING
Available for:
FOR TWO MACHINES
– DMU 65 / 75 monoBLOCK
– DMU 65 H monoBLOCK
– DMU 50 3rd Generation HIGHLIGHTS
– DMU 40 / 60 eVo + Proven PH Cell 300 pallet handling as Twin
– CMX 50 / 70 U solution now for two machines
Machine combination possible + One pallet handling device for 2 machines
+ Up to 30 pallets in a 12.9 m2 footprint due to double
row pallet storage on each level
+ Workpieces up to 500 × 500 × 500 mm
+ Up to 300 kg transfer weight (workpiece incl. pallet)
+ Retrofit of a second machine possible
+ Separate station for ergonomic setup
of pallets during production
+ Short installation time due to defined interface
and modular concept
PH Cell Twin with DMU 50 and DMU 65 H monoBLOCK + Attractively priced automation in DMG MORI VERTICO design

22 TECHNOLOGY E XCELLENCE
 PH Cell Twin

PH Cell Twin
OPERATING PRINCIPLE

PALLET HANDLING DEVICE

Up to 300 kg transfer weight
(workpiece incl. pallet)

Machine 1 Machine 2

SEPARATE
SET-UP STATION
+ Ergonomic setup
+ Optionally rotatable

Maximum
workpiece dimensions

30 pallets 24 pallets 18 pallets

PH Cell
500 mm
300 kg

320 × 320 / 345 × 345 mm 400 × 400 mm 500 × 500 mm

500 mm 500 mm

TECHNOLOGY E XCELLENCE 23
CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG

INVESTMENT &
INNOVATION –
AUTOMATION &
COMPLETE MACHINING
The history of SPECK Pumpen Walter Speck used in its Chinese facility. What all models apart. Orders come from a diverse range of
GmbH & Co. KG from Roth goes back to have in common: They are among the most industries and from a multitude of customers.
the year 1909. At that time – still located modern machines that DMG MORI has on “Our specialized products are principally
in Nuremberg, Daniel Speck started man- offer – as are the most recently acquired used in the medical, chemical and pharma-
ufacturing piston pumps. With over 600 DMC 65 H monoBLOCKs – one with an ceutical industries, in cooling and tempering
employees worldwide, the SPECK Group is RPS 12 pallet changer, the other with appliances and in the plastics industry”, says
an internationally successful company that amill-turn table. Dr. Thomas Krüger, Member of the Manage-
produces its extensive and highly individual ment Board, giving us an impression of the
range of pumps for customers in every Solutions and further developments product portfolio. Its customized orientation
conceivable sector. SPECK has been work- tailored to customer needs has resulted in the consistent expansion of
ing with CNC technology from DMG MORI A strong customer focus, high levels of a wide range of variants, which continue to
for decades. There are around 75 machines expertise and the development of cus- gain in importance.
in operation alone in Roth, with twelve more tomized solutions have always set SPECK

1. Machining of gray cast iron and stainless steel components for the Thanks to the RPS 12 with 12 pallets, the DMC 65 H monoBLOCK
vacuum housing of pumps. 2. Evacuation of chips under gravity on the is used optimally for several hours. Setup is carried out in parallel
horizontal machine enables reliable production. to machining.

24 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG

RPS 12
Torsten Hahn (left), Authorized representative
Dr. Thomas Krüger (center), Member of the Management Board
Dieter Meier (right), Head of Mechanical Engineering
MACHINE-
SPECK Pumpen Walter Speck GmbH & Co. KG INTEGRATED
AUTOMATION

“We help our customers move forward with from the machine tool manufacturer as well + Unmanned shifts due to circular storage
new solutions and further developments to multifunction machine models – both turn- system with up to 12 pallets
our existing products.” mill centers and mill-turn machines. + DMU / DMC 65 H monoBLOCK:
Workpieces up to ø 800 × 700 mm,
Reliable processes thanks to horizontal 600 kg max.
mill-turn machining + Reduction of non-productive time
LATEST The latest acquisitions include two DMC 65 due to loading and unloading during

MANUFACTURING H monoBLOCK centers. SPECK uses the

5-axis horizontal machining centers among
production
+ Flexible production of different
TECHNOLOGY other things to machine gray cast iron and workpieces

FROM DMG MORI stainless steel components. Vacuum hous-

ings for pumps are produced on these, which
+ Separate setup station for ergonomic
setup of pallets during production
are used in the sterilization of hospital beds,
for example.
With the high standards it sets on its own »
quality management, SPECK guarantees
perfect products. The many years of experi-
ence of its employees plays a significant role,
as does its use of the latest manufacturing
technologies. Authorized representative
Torsten Hahn adds in this respect: “Invest-
ments in new machine tools are made
primarily with a view to expanding capacity.
We boost our productivity at the same time by
continuously purchasing the most advanced
manufacturing technologies.” DMG MORI
plays a key part in this. For over ten years,
SPECK has been using automation solutions

TECHNOLOGY E XCELLENCE 25
CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG

SPECK Pumpen uses 75 machines for the production of high-precision pump components at its
location in Roth. These include a DMC 65 FD monoBLOCK, the new DMC 65 FD H monoBLOCK and
a DMC 65 H monoBLOCK with an RPS 12 rotary pallet storage system.

DMC 65 FD H monoBLOCK

MILL-TURN “The horizontal machining concept with its the manufacturing process for the vac-
optimum chip evacuation is ideally suited uum housing. “Each housing consists of six
TECHNOLOGY for the production of such precision parts”, components, which we can now machine
FOR COMPLETE explains Dieter Meier, Head of Mechanical completely in sets”, explains Dieter Meier
Engineering. This is especially true of the about the application. The pallet changer
MACHINING DMC 65 H monoBLOCK with mill-turn table. can, of course, be set up during machining.
“We can position the table vertically during “So we can make optimal use of the machine
HIGHLIGHTS turning, so no water collects in the compo- for several hours without any long idle times.”
nent.” The second DMC 65 H monoBLOCK
+ Complete machining thanks was equipped with an RPS 12 pallet changer, Individual machine solutions thanks to
to milling and turning in a which enabled SPECK to further optimize DMG MORI’s wide range of products
single setup on one machine The reason SPECK has maintained such
+ Direct Drive technology close cooperation with DMG MORI for so
for up to 1,200 rpm many years is due in part to the reliable CNC
+ Lower investment costs and
reduced space requirements LOVE OF AUTO- technology, is how Torsten Hahn judges the
quality of the machines. Another aspect is the
thanks to the use of just one MATION – RPS 12 extensive portfolio, as Dieter Meier goes on
machine
FOR THE AUTONO- to tell us: “We always find solutions that are
both individual and innovative, which ensure
MOUS PRODUCTION sustainable optimization of our processes.”
OF COMPLETE «
You can find the video on the
DMC 65 FD H monoBLOCK here:
VACUUM HOUSINGS
https://youtu.be/0twEUGh8eYE

26 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – SPECK PUMPEN WALTER SPECK GMBH & CO. KG

SPECK PUMPEN FACTS

+ 1909 founded in Nuremberg,

headquarters now in Roth
+ Over 600 employees worldwide
+ Development and
production of pumps tailored
to customer needs
+ Competent partner in a multitude
All from a single source. Fortunately, of industries, including medical,

DMG MORI has a full line-up of automation chemical and pharmaceutical

systems in addition to a comprehensive

machine programme. This enables us to
serve our wide range of industries. SPECK Pumpen Walter Speck GmbH & Co. KG
Regensburger Ring 6–8
91154 Roth, Deutschland
www.speck.de
Torsten Hahn, Authorized representative
SPECK Pumpen Walter Speck GmbH & Co. KG

DMG MORI ROUND STORAGE SYSTEMS – MACHINE-INTEGRATED

AUTOMATION WITH MINIMAL SPACE REQUIREMENTS
System RPS PH CELL 2000
Advantages Machine-integrated solution for one machine type Usable for different machine types

For DMU machines without pallet changer thanks to the

For DMC machines with pallet changer
integrated twinFORK gripper

Ex-works in combination with a new machine Ex-works & retrofittable for various machines with automation interface

Maximum workpiece size and pallet dimensions depending on the machine Modular design with different pallet sizes

Short pallet change time thanks to rotary pallet changer in the machine 25 % smaller footprint thanks to the integrated pallet changer

Machine 1 2 3 4
DMC DMC DMC DMU / DMC H NHX DMU duoBLOCK
monoBLOCK duoBLOCK Portal monoBLOCK DMU H monoBLOCK

Number of pallets 3/6 6 / 7 / 12 4/5 5 / 7 / 9 / 12 12 / 14 / 21 12 / 17 / 21

Max.
mm ø 800 × 590 ø 1,600 × 1,350 ø 3,400 × 2,400 ø 630 × 700 ø 800 × 1,000 ø 1,100 × 1,350
workpiece size*
Max. load* kg 800 4,000 10,000 600 700 2,000
*
depending on the machine

2
4

1 3

TECHNOLOGY E XCELLENCE 27
Robo2Go – THE STANDARD AUTOMATION

Robo2Go – RETROFITTABLE
CHECK EXISTING
MACHINE NOW

THE BEST-SELLING
STANDARD AUTOMATION love-automation.dmgmori.com

THE Robo2Go APP: ONE FOR EVERYONE!

Turning, Vision, Milling and Max
1. I ntegrated app for uniform control –
no adaptation of the existing NC programs
2. No robot programming knowledge required
3. Process creation based on
predefined program modules
4. Setting up a new workpiece <5 minutes
5. Multijob function: different jobs on one
workpiece tray, ideal for small and medium
batch sizes.
6. Home function for simple retraction
and system setup

AVAILABLE FOR 38 DMG MORI MACHINES

Z. B.: CLX, CLX TC, CTX, CTX TC, NLX, NZX, NTX, DMU, DMV, CMX

NEW
AVAILABLE FOR
DMU 65 / 75 mB

Robo2Go Milling Robo2Go Turning

+ Handling of workpieces up to 200 × 200 × 200 mm + Handling of shafts ø 20 – 170 mm
as standard. Other dimensions on request and chuck parts ø 20 – 175 mm
+ Now with alignment and turning station + Laser scanner with automatic restart
For automated 6-sided complete machining + Now with alignment and turning station
+ Full accessibility to the machine thanks to loading + Enables the gripping of long shaft workpieces
from the side

28 TECHNOLOGY E XCELLENCE
 Robo2Go – THE STANDARD AUTOMATION

NEW
Robo2Go Jobs AS
STANDARD
+ Paperless job management
+ Easiest processing of orders using checklists
+ Definition of various orders in the job queue
+ Multijob: Different workpieces possible in one order

1. Basic module
Robot, control cabinet, cover

2. Storage module
Basic variant for two EU pallets
NEW! 1 2
with roller shutter:
210 kg – Rotate the module by ± 90 degrees
to change the loading direction
– AGV-compatible
3
Telescopic door 3. Flexible tower and safety system
– Telescopic door for easy access
to the machine and automation
– Left- or right-sided installation
4 possible

ENTIRE 4. Extensions
SYSTEM Space for upcoming options such as:
Alignment station, turning station
Loading with standard pallets
IS
CERTIFIED

NEW
OPTION
1

Robo2Go Max
1. Zero point detection of the workpiece
+ Strongest version with 210 kg payload
and 115 kg workpiece weight
+ Handling of workpieces ø 40 to ø 400 mm as standard LENGTH REFERENCE DETECTION
+ Free accessibility to the control system
and the tool magazine + Increased process reliability during shaft machining
+ Ensuring a defined clamping length
+ Detection of axial position deviations,
e. g. due to slippage of the shafts during transport

TECHNOLOGY E XCELLENCE 29
CUSTOMER STORY – STROMBOLI GMBH

HIGH-TECH
READY FOR E-MOBILITY
FROM THE RUHR DISTRICT

The DMP 70 with the

WH 3 Cell enables
autonomous and
flexible production
in unattended shifts.
Components are fully
machined on all 6
sides thanks to the
turn-over station.

Andreas Köppel
Founder and Managing Director
STROMBOLI GmbH

STROMBOLI produces numerous

workpieces on the 5-axis DMP 70;
shown here is a component for a battery
test bench for electromobility.

30 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – STROMBOLI GMBH

STROMBOLI GmbH in Bochum has been that manufacture innovative products have
manufacturing fine mechanical components moved to the region,” explains Andreas
and complex assemblies for challenging Köppel, founder and managing director of
industries for over 30 years. Customers, STROMBOLI. The subcontractor established
including some from the medical sector, itself on the grounds of the former Robert
semiconductor industry and electromobility, Müser mine and also serves this innovative
continue to put their trust in the manu- new marketplace. “We see ourselves as
facturing expertise of the 18-strong team. a integral partner – from design to quality
The high quality standard also requires assurance and assembly. One of our core
high-performance machines on the shop focuses is complex niche products.” The
floor. Eleven models from DMG MORI are in challenge lies in producing high-quality
use – including an automated DMP 70 since precision tools economically. This challenge
2021, which thanks to the WH 3 Cell during is tackled by a young and experienced team.
unmanned shifts, contributes significantly “We have two engineers and five fully trained
to overall productivity. production supervisors. We also train one
or two apprentices every year to ensure we
From mining to high-tech can fulfil our specialist requirements,” says
A disused mine head tower in Bochum- Andreas Köppel.
Werne is a reminder that the Ruhr region
was dominated by mining until a few decades
ago. Since then, many high-tech companies »

A turn-over station enables workpieces to be Included in the eleven DMG MORI machines are two MILLTAP 700s
machined on all six sides. and the DMP 70 with WH 3 Cell, which was installed in 2021.

TECHNOLOGY E XCELLENCE 31
CUSTOMER STORY – STROMBOLI GMBH

DMP 70 WITH WH 3 CELL

VERTICAL
HIGH-SPEED
MACHINING
CENTER Thanks to the fast chip-to-chip time of 1.5 seconds and the integrated swiveling rotary table,
the DMP 70 is ideal for highly productive production of small workpieces.

HIGHLIGHTS

+ 5-axis simultaneous A flat organization and a modern company standards, STROMBOLI invests in pioneering
machining through direct drive culture provide a great motivation for all manufacturing technologies from DMG MORI.
table up to 100 kg company members. Flexible shifts, company “A sustained trend is complete machining –
+ 24,000 rpm inline spindle bicycles and a car fleet with electric vehicles whether this is on 5-axis milling machines or
with 20 Nm are only three examples of the forward- turning centers with milling functionality. We
+ 5 µm positioning accuracy looking orientation of STROMBOLI. have been producing complex components in
thanks to linear scales from one setup in this way for several years.” The
MAGNESCALE Complete machining for e-mobility and added benefits are obvious: “Both we and our
+ Up to 2 g acceleration for the semiconductor industry customers profit from shorter throughput
1.5 sec. chip-to-chip time The modern orientation is also reflected times and improved component quality.”
+ WH 3 Cell – workpieces up to in the orders, Andreas Köppel says,
300 × 200 × 100 mm and 5.5 kg referring to requests from the futuristic STROMBOLI has taken another step towards
industries supplied. “We work increasingly the future of manufacturing with their
for customers in electromobility or the purchase of a DMG MORI DMP 70. The 5-axis,
semiconductor industry.” The business is compact machining center is fitted with a
becoming ever more international as well. WH 3 Cell. Henrik Kieslich, a master precision
You can find the online
configurator here: “Requests from China confirm our focus on instruments mechanic who was involved in
https://configure.dmgmori.com quality.” To ensure they maintain their quality selecting the machine adds: “The robot

32 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – STROMBOLI GMBH

With automation into the future

Automated production has paid off quickly for
STROMBOLI. For Andreas Köppel, there is no
other way for the future: “We need to increase
our economic efficiency to remain competitive
internationally.” Extending manufacturing
capacity to unmanned shifts is a logical step.
Quality assurance including documentation is an integral part of the range
of services offered by STROMBOLI.

DMP 70 WITH
WH 3 CELL:
UNFAILING,
PROCESS RELI-
ABILITY AND
AUTONOMOUS

This also applies to the area of turning, he adds.

“Since June 2022 we have been successfully
using a Swiss type lathe.”
«

Depending on the workpiece dimensions and weight, the WH 3 Cell offers space for up to
1,000 workpieces, ideal for unattended series production (30 × 30 × 30 mm aluminum / paternoster system
with 15 workpiece carriers measuring 600 × 400 mm).

enables autonomous and flexible production DMG MORI technology cycles for operation
during unattended shifts.” After initial training with high process reliability:
and with a good grasp of programming, he To ensure the DMP 70 operates securely STROMBOLI FACTS
was able to put the automation to work for and with high process reliability, DMG MORI + Founded in 1990 in Bochum
more complex processes. “We are now able equipped it with tool breakage monitoring + 18 employees
to place the blanks randomly in the relatively and the DMG MORI 3D quickSET technology + Manufacturing of precision
large fixture of the magazine trays and the cycle. “A defective tool would have serious components and assemblies
robot adjusts their position them so it can pick consequences in automated operation, but + Customers from future-oriented
them up.” There is also an additional setup the 3D quickSET enables continuous measu- industries such as medical and
station as well as a turn-over station, which rement and correction of the position of rotary electromobility
makes it possible to invert the component and swivel axes. This guarantees consistent
for machining on all 6 sides. STROMBOLI quality. Moreover, STROMBOLI makes
needs this type of flexibility, as the WH 3 Cell use of the machine measurement cycles,
is not used for producing large series of certain which reduce the effort involved with quality
STROMBOLI GmbH
workpieces. “Depending on the order situation, assurance. Von-Waldthausen-Str. 79
we want to be able to machine completely 44894 Bochum, Germany
different parts automatically one after the www.stromboli.de

other on the DMP 70,” adds Henrik Kieslich.

TECHNOLOGY E XCELLENCE 33
 NEW: PALLET HANDLING BY MATRIS

With MATRIS, we offer our customers

easy-to-use automation, including secondary
processes such as measuring and labeling.
What is completely new is that MATRIS can
now also be used for pallet handling.
Mr. Satoru Kashiwagi
General Manager of Technical Sales Department
DMG MORI CO., LTD.

MATRIS
Flexible modular
robot system for ≥ 1 machine
With innovative developments, DMG MORI What are the components of MATRIS? HIGHLIGHTS
has been a pioneer in the automation of The core of MATRIS is a robot, which brings
+ Modular concept with standardized
machine tools for many years. Its products the workpieces into the working area of the
peripheral devices, e. g. washing,
include highly flexible automation solu- machine tool. It is installed on the side of the
measuring or marking
tions such as the modular MATRIS. Satoru machine. Peripheral devices can be placed
Kashiwagi, General Manager of Technical around it to enable further functions – from + 80 % shorter setup time due to
Sales Department at DMG MORI CO., LTD. tool storage and a turnover station to cleaning modular, standardized peripherals
talks about the versatile robot system in an and tactile or visual measurement. Here, we and robot programs
interview. use only carefully selected products certified
+ Flexible adaptation to system
by DMG MORI that work reliably.
changes after installation
Mr. Kashiwagi, what prompted you to
develop MATRIS*? What are the features of the system? + Simple and easy operation
As the demand for simple robotic automa- Each unit of MATRIS is modular and avail- via the MATRIS controller
tion grew stronger, we needed to create an able in a standardized size of 710 × 710 mm
offering that would allow us to meet our per module.
customers' needs quickly and with the high »
quality they have come to expect. That's why
we started standardizing our robot systems
in 2016. This has resulted in MATRIS. It is an
automated handling system consisting of
standardized units and devices.

MATRIS = MODULAR AUTOMATION TRANSFER

*

ROBOT INTELLIGENCE SYSTEM

Up to 2 machines in one system

34 TECHNOLOGY E XCELLENCE
 NEW: PALLET HANDLING BY MATRIS

MODULES AND EXPANSION STAGES

Transfer Measurement
Material table 1-point measurement
Workpiece quality check 2-point measurement
NG chute 3-point measurement
Workpiece turnover 3D measurement
Workpiece phase positioning External checking
IN / OUT conveyor

Stock Other
Workpiece stocker Deburring
Tray changer Washing
Manual changer Air blowing
Buffer Marking

Robot

Transfer weight
(single / double gripper):
10 / 20 kg

FANUC
Kawasaki
NACHI
YASKAWA
ABB

MATRIS controller

+ A system controller that offers

integrated control of the whole automation
system, including robot, each module
and machine

+ Monitoring, schedule management

and operational control of the whole
automation system possible

TECHNOLOGY E XCELLENCE 35
NEW: PALLET ­HANDLING BY MATRIS

The video for the NHX series The system can be easily adapted to each
with MATRIS robot system
can be found at: customer's requirement. The layout is also
https://youtu.be/vtWcMlJR4H8 completely reconfigurable, allowing flexible
response to changes in the range of com-
ponents. In addition, the communication
MATRIS – format of each unit is standardized, sup-
porting Ethernet IP and PROFIBUS. This
WORKPIECE HANDLING allows MATRIS to significantly increase
setup speed.
HIGHLIGHTS
What about the software?
+ Handling of workpieces up to ø 200 × 200 mm, We have developed our own control system
1 × 20 kg or 2 × 10 kg to standardize the operation of each robot.
+ Stacking magazine: The MATRIS controller is connected to the
– 14, 20 and 26 pallets: ø 150 × 120 mm, max. 35 kg per pallet machine tool, the robot and the peripheral
– 10 and 20 pallets: ø 200 × 200 mm, max. 75 kg per pallet devices. In this way, we realize complete
+ Available for 13 series, control of the entire MATRIS system. The
e. g. NLX, NTX, NHX, DMU, NMV, eVo, etc. user interface is adapted to that of CELOS,
→ more at: https://love-automation.dmgmori.com ensuring smooth and efficient operation.

In addition, the robot programs and motion

sequences (teaching) are already predefined.
Whereas previously it was necessary to read
and understand complex robot programs,
the MATRIS controller uses an intuitive and
interactive processing method.

What benefits does MATRIS offer you?

Typical system packages are available in
advance. This means that we can quickly cre-
ate layouts based on these packages. Con-
sequently, we achieve fast implementation in
a short turnaround time. Another advantage
of MATRIS is the reduced installation time.
Modular concept with standardized peripheral devices, Whereas it used to take ten days to install
e. g. deburring, washing, air blowing or marking. a system, today we only need one to two
days. System changes after delivery are also

36 TECHNOLOGY E XCELLENCE
 NEW: PALLET ­HANDLING BY MATRIS

Storage capacity
for up to 40 pallets
with a transfer
weight of 150 kg

NEW

MATRIS –
PALLET HANDLING
HIGHLIGHTS

possible within one day. In the past, this took designed for pallet handling. The use of + Ideal for the flexible production
at least five days. We owe this to the oil pan, pallets and fixtures for workpieces offers of 50 to 200 workpieces / day
which is an integral part of the robot frame, even greater flexibility in terms of compo- + Space-saving pallet handling
so no work is required here either. This also nent variety and batch sizes. It allows our for up to 40 pallets
reduces life cycle costs. customers to react more flexibly to the + 400 × 400 mm pallet size
production of different workpieces. + 150 kg transfer weight (workpiece
The customer can independently modify the « and pallet)
robot program to take account of additions + Integration of secondary processes
and changes to the workpieces. This, of such as deburring or marking possible
course, reduces any travel expenses and + Available for the CMX 50 U, CMX 70 U,
labor costs for system integrators. DMU 50, DMU 65 monoBLOCK,
CMX 600 V, CMX 800 V, CMX 1100 V
What does the future hold?
Further machines on request!
In addition to the already familiar work-
piece handling design, MATRIS is now also

TECHNOLOGY E XCELLENCE 37
CUSTOMER STORY – NABEYA CO., LTD.

HIGHLY PRODUCTIVE 5-AXIS MACHINING

IN 24 HOUR OPERATION
Nabeya Co., Ltd. is headquartered in Gifu permission by the emperor to found the isolators for semiconductor manufacturing
City (Japan, Gifu prefecture) and was family company specializing in casting equipment and surface plates for precision
founded in 1560 in the midst of the Sengoku production. Today, Nabeya continues this testing under the widely distributed ERON
period in Japan, the time of warring states. tradition, employs around 200 people and brand. The design, machining, assembly and
During one of the most notorious battles – dedicates itself to technological innovation. inspection of these industrial components
the Battle of Okehazama – the ancestors of The company uses cutting-edge technology are carried out in-house.
President Tomohiko Okamoto were granted from DMG MORI to manufacture vibration

The combination of Nabeya

fixtures and 5-axis machining
on the DMU 50 3rd Generation
enables different workpieces
to be clamped and machined
on one pallet or clamping
fixture.

38 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – NABEYA CO., LTD.

Thanks to MATRIS, we are able to carry

out our high-mix, low-volume production
of precision components during
unmanned night shifts.

Shoichi Sakai (center), Managing Director

Tomoaki Masuda (left), Plant Manager
Ryoma Sonoda (right), Operator in the machining area

Automation and 5-axis machining to Last year, Nabeya introduced the 5-axis DMU Various clamping elements can be used on
combat the lack of skilled workers 50 3rd Generation machine and the MATRIS the pallets during the process as well as
“The same is probably true for other robot automation system with a rack for 20 different workpieces, depending on the fixture.
manufacturers, but our company is facing the In the past, the operator had to adjust every
growing challenge that qualified engineers fixture for every type of workpiece. Thanks to
are becoming ever scarcer. This has led to
a lack of personnel who are able to manage
DMU 50 WITH MATRIS, only minimal setup is required as it
can handle different workpieces and fixtures
complex processes with conventional vertical MATRIS AS PALLET on each pallet for 5-axis machining on the
and horizontal machining centers,” explains
Managing Director Shoichi Sakai. “My idea
HANDLING SYSTEM DMU 50 3rd Generation.

was to integrate the processes as much

as possible to simplify process design and
to implement automation and unmanned pallets at their main plant in Motosu, Gifu.
production at night at the same time. The system is being used for the production
5-axis machines are the perfect solution for of machine vices – Nabeya’s main product –
this! I wanted to combine 5-axis machines as well as clamping units and other similar
and automation to reduce process steps, products. Only one operator is required to
improve productivity and enable continuous operate the automation system. The MATRIS
24-hour production.” system automatically processes all pallets. »

TECHNOLOGY E XCELLENCE 39
CUSTOMER STORY – NABEYA CO., LTD.

DMU 50

BESTSELLER!
> 10,000
DMU 50 INSTALLED
WORLDWIDE

+ Swivelling Rotary Table for 5-Axis

Simultaneous Machining
– Table load up to 300 kg
– Swivel of the B-axis
–35° / +110° for excellent flexibility
– Cooled table bearings for maximum
precision

+ 5-Axis Machining with up to 20,000 rpm

– speedMASTER 15,000 rpm with 21 kW
and 111 Nm in basic version
– speedMASTER 15,000 rpm with 46 kW
and 200 Nm optionally available Nabeya Co., Ltd. manufactures a wide range of workholding equipment such as machine vices
and clamping units, which contribute to higher machine tool productivity.
– speedMASTER 20,000 rpm with 35 kW
and 130 Nm optionally available

+ High Quality for up to 5 µm Precision

– Comprehensive cooling concept for
excellent long-term precision
– One-piece machine bed Use of their own clamping materials
– Direct ball screw drives What makes this automation system so
– Linear scales in all axes unique is the use of Nabeya's own fixtures,
base elements, pallets and robot grippers.
Their fixtures make it possible to clamp
more than eight workpieces on one base
plate, which can be automatically machined
and measured on all sides in the 5-axis
machine without retooling. The introduction
of this automation solution in combination
with in-house products enabled Nabeya to
automate its varied production of small batch
sizes and achieve highly precise, unmanned
production during the night.

Increased productivity thanks to

unmanned night shifts
“The work that used to take four people can
today be done by just one operator. We only
need to set up the workpieces during the day
and the system automatically takes care of the
rest during the night. All the workpieces are
finished by the time we arrive at the factory in
the morning. This means that our productivity
has been considerably increased and it is
much easier to plan our manufacturing,” says
Factory Director Tomoaki Masuda.

Visit our online configurator:

https://configure.dmgmori.com

40 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – NABEYA CO., LTD.

It is important when using automation like this From ten process steps to one
that the system runs as reliably as possible. Shoichi Sakai reveals Nabeya’s future plans: NABEYA FACTS
Tomoaki Masuda explains the reason for “It was the first time that we introduced a
the successful operation: “Our system runs 5-axis machine into our production and the + Traditional company that has
without any problems at all, thanks to the positive effects could be felt immediately: been manufacturing castings
in-depth advice and troubleshooting provided The eight to ten work steps that used to be for over 460 years.
by DMG MORI. For example, their engineers required can now be reduced to just one or + Precision ERON brand machine
helped us to avoid downtimes caused by two.” In addition, Nabeya is able to use its vices are valued and used by
incorrect timing when exchanging the pallets own fixtures and clamping systems in this manufacturers all over Japan.
or an accumulation of chips.” automation system. This makes it the perfect + “Techno-craft”, the combination
showcase for its customers at the same time. of technology and craftsmanship,
“We would also like to show this automation is the hallmark of the company
solution to other manufacturers that are + Continuous improvement
CUSTOMIZED battling a lack of skilled labor and automating of the process design, NC
programming and production
PROCESS
high-mix, low-volume production – and to
support them in increasing their production management through

OPTIMIZATION efficiency.” automation, in the spirit of

“techno-craft”
«

Nabeya Co., Ltd.

Wakasugicho 25, Gifu City
Gifu 500–8743, Japan
https://eng.nabeya.co.jp

The MATRIS robot automation system with a rack for 20 pallets.

The clamping devices and robot grippers manufactured by Nabeya are in use here.

TECHNOLOGY E XCELLENCE 41
CUSTOMER STORY – SANDVIK COROMANT

HOLISTIC
AUTOMATION
Founded in Sandviken, Sweden, in 1942,
Sandvik Coromant has become a global
industry leader in tool manufacturing with
over 8,000 employees worldwide. Customers
from a wide range of industries – including
1
aerospace, Automotive and oil & gas – rely
on Sandvik Coromant solutions. The tool 2
experts have a long-standing strategic
partnership with DMG MORI, from which
innovative machining solutions continue to
emerge. Sandvik Coromant also benefits
from these in its own production. For exam-
ple, two NTX 2000s were installed at the
Gimo plant in 2021, each of which operates
fully automatically with a MATRIS. The robot
handles both the loading of workpieces and
the exchange of fixtures and tools.

DEVELOPMENT
OF 2,500
NEW PRODUCTS
PER YEAR

“As a market leader, we are required to

meet the extremely high expectations of our
customers in terms of innovation and quality,”
says Philip Eriksson, project manager at At the Gimo plant, DMG MORI 2021 has installed two NTX 2000s,
Sandvik Coromant, explaining the company’s each fully automated with a MATRIS.
dependence on development and production.
“Gimo is part of our Production Technology 1. Automatic tool change for the turret
Center and is responsible for industrializing 2. Six locations for different tool bodies
2,500 new products per year.” He says this 3. + 4. Change of centers and chuck inserts

is done in close cooperation with the R & D

departments in Sandviken and Stockholm.

42 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – SANDVIK COROMANT

The strategic partnership with

DMG MORI is a win-win situation.
Our individual MATRIS automation
is the ideal example of this.

Peter Andersén (left), Global Manufacturing Equipment, and

Philip Eriksson, Project Manager
Sandvik Coromant

TECHNOLOGY E XCELLENCE 43
CUSTOMER STORY – SANDVIK COROMANT

On the two NTX 2000, Sandvik Coromant machines the turned profile of drill bodies.
Being a tool manufacturer, Sandvik Coromant has equipped the turrets entirely with its
own Coromant Capto C4 tool holders.

NTX 2000 / 2500 / 3000

BEST IN CLASS
+ Turn & Mill – 6-sided complete Competitive thanks to automated goal was an automated manufacturing solu-
machining of workpieces up to manufacturing tion that reduces this non-productive time as
ø 670 × 1,538 mm The realization of new products also includes much as possible.” In the NTX 2000 turn &
+ turnMASTER main spindle: their manufacture. “We need highly efficient mill center and the MATRIS, a flexible and
8″ chuck, 5,000 rpm, max. 421 Nm technology in order to be able to offer our modular robot system, they found an optimal
+ compactMASTER Turn & Mill tools competitively,” explains Peter Andersén, solution, he says. “An important point for us
tool spindle with 132 Nm torque responsible for Global Manufacturing Equip- was the fact that we got the two manufactur-
and 350 mm length ment at Sandvik Coromant. For this reason, ing cells from one source.”
+ Multitasking: Direct Drive B-axis he says, the company has been using auto-
for 5-axis simultaneous machining mated manufacturing processes in end-to- Fully automated production of over a
of complex workpieces end digitalized production for decades. “Even hundred variants in a range of batch sizes
+ High flexibility due to X-axis our NC programs for the production of tool “The challenge in this project was to auto-
travel up to −125 mm below bodies are created automatically in Gimo and mate exchange of components and turret
the spindle centreline are new for each order.” The factory received tooling as well as the centers and chuck
+ 12-position BMT turret with 'lighthouse' recognition by the World Eco- inserts,” says Philip Eriksson, describing
12,000 rpm and 80 mm Y-axis nomic Forums in 2019, he said. the scope of the automation. This is nec-
+ CELOS with MAPPS on FANUC and essary due to the large number of different
CELOS with SIEMENS available MATRIS – modular automation for highly bodies produced.
flexible production
Using the example of tool bodies for drillis,
Philip Eriksson refers to a new manufactur-
ing solution that DMG MORI has worked out
The video for the and implemented with Sandvik Coromant.
NTX 3000 2nd Generation
can be found at: “We manufacture over a hundred variants
https://youtu.be/aUrrM9ZOO0Y here, which involves a lot of setup. So our

44 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – SANDVIK COROMANT

Automatic chuck inserts of chucks The robot also handles this change reliably.”
and centers As a tool manufacturer, Sandvik Coromant
A look at the MATRIS installation at Sand- took on this part of the project and equipped
vik Coromant reveals the complexity of this the turrets with its own Coromant Capto C4
automation solution. A total of six carts with tool holders.
bodies can be accommodated in the cell,
enabling autonomous production even dur-
ing unmanned night shifts. Peter Andersén
is pleased with the good capacity utilization: STRATEGIC
“This significantly increases our production
capacity.” The robot takes the raw parts from
PARTNERSHIP WITH
the cart and turns them through 90 degrees DMG MORI IS A
at another station so that it can clamp them
in the NTX 2000. The blanks are mainly sup-
WIN-WIN SITUATION
ported in centers in the main and counter
spindles, but there is also the possibility to
machine them in a collet chuck. “Since the Sandvik Coromant has achieved its goal of
chuck inserts and centers vary depending on realizing more and longer unmanned shifts
the job, they are also housed in the MATRIS,” due to this project, which Philip Eriksson sees
says Peter Andersén. The robot replaces as further proof of the good cooperation with SANDVIK COROMANT
them fully automatically when the compo- DMG MORI: “For us, the strategic partner- FACTS
nents require it, he adds. ship means that we support each other and + Founded in 1942 in
achieve a win-win situation for all parties Sandviken, Sweden
Automatic tool change for the turret involved.” That is why we all want to main- + Over 8,000 employees worldwide
The highlight of the automation solutions tain this cooperation, he said. Peter Andersén + Development and production
of the two NTX 2000s is the automatic turret looks ahead: “Both in Gimo and at our global of innovative tooling solutions
tool exchange by the robot system. “While the locations, we are currently working on fur- + Customers from demanding
tools for the milling spindle, both milling and ther projects with DMG MORI – productive industries such as aerospace,
turning tools (the magazine of the NTX 2000 automation solutions will of course remain automotive and oil & gas
has 114 Coromant Capto C6 tool positions) important in the future.”
are changed automatically, this is normally «
a manual process for turret tools,” explains
Philip Eriksson. “This ties up a lot of labour
because there are only twelve tool stations.”
Sandvik Coromant
For this reason, he says, a separate tool mag- Verktygsgatan 11
azine has been integrated into the MATRIS 747 44 Gimo, Sweden
with space for 32 tools. “This allows us to www.sandvik.coromant.com

put significantly more tools into the system.

Automatic tool change for the turret. The robot in the MATRIS loads and unloads the NTX Six carts with bodies can be accommodated
Separate tool magazine with space for 2000 with workpieces and changes tools in the turret as in the cell, so autonomous production is possible
32 tools integrated in the MATRIS. well as centers and chuck inserts. during unmanned shifts.

TECHNOLOGY E XCELLENCE 45
CUSTOMER STORY – HYDAC CHINA

AUTOMATION MAKES
PRODUCTION EASIER
HYDAC International GmbH was founded in the purchase of several more machines and working closely with DMG MORI for a long
1963 in Saarland and, with 9,500 employees continued to optimize processes. The latest time.” The machining quality as well as the
worldwide, is a leading provider in the areas highlight is automated manufacturing process stability have been excellent right
of hydraulics and systems technology. The comprising six NHX 4000s and a linear from the start.
company established a wholly owned sub- pallet pool.
sidiary in Shanghai in 1996, which initially Growing together – everything from a
focused on the sale of products, particularly An alliance for top performance single source and hand in hand
hydraulic components such as filters HYDAC’s production is based on the principle There is no doubt that the growth of HYDAC
and accumulators. HYDAC China started of guaranteed quality. Consequently, the China has benefited from the support of
local production in 2003 in line with the company has high demands when it comes DMG MORI, Zhu Min, production manager
trend towards localization and to shorten to manufacturing technology. Both the of HYDAC China, says candidly. “HYDAC and
delivery times. Expansion took place step machines and tools have to be first-class. DMG MORI are both leaders in their own
by step. The Chinese subsidiary installed the “We put our trust in leading brands. Machining industry. The two companies have the same
first machine tool from DMG MORI in 2005. accuracy and efficiency are particularly vision when it comes to brand awareness,
Since then, HYDAC and DMG MORI have important,” explains Qiu Feng, production product quality and development strategy.
successively expanded their cooperation with manager of HYDAC China: “We have been This provides a solid basis for cooperation.”

The central tool storage system offers space for up to 4,000 additional tools. The setting of tools is carried out via a tool setting station (TSS) with a maximum of 60 tools.
Here the tools are identified by a DMC reader and loaded and unloaded into the system fully automatically along with the data.

46 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – HYDAC CHINA

Automation solution with 4,000 tools and 48 pallet positions,

including host computer for overall control of machines,
pallets and tool automation.

Against the backdrop of increasing

digitalization and automation, there
are almost no limits to future technical
advances. Exactly like the cooperation
between HYDAC and DMG MORI, the
After starting production with a single development will become even more
machine and later adding semi-automated
material transfer and automated production
long term and intensive.
cells, HYDAC China has now implemented
a fully automated production solution with
Zhu Min (right)
material handling systems. Production Manager
HYDAC China

SIX NHX 4000s

WITH LPP AND
TOOL MAGAZINE Large fully automated, flexible a central tool system (CTS) with 4,000 tool

FOR 4,000 TOOLS production line in Asia

On the basis of this successful cooperation,
stations along one side of the line is certainly
impressive,” adds Manager Qiu Feng. “This is
DMG MORI also installed the same auto- a technically complex production line with a
mated production system in the HYDAC China lot of highlights.” It includes the LPP, the CTS,
In 2020 HYDAC installed in its German plant plant in 2021. This is a fully automated and the LPS control computer, a tool presetter and
an automated production system from flexible manufacturing line into which a pallet six NHX 4000s.
DMG MOR comprising six NHX 4000s, high- magazine is integrated. “After a smooth trial
performance horizontal machining centers, run, the system has performed as expected
a pallet pool system with 48 pallets and a in every respect,” confirms Production
central tool store with up to 4,000 tools – ManageZhu Min. At the moment, it is probably
everything from a single source. The auto- the largest fully automated, flexible production
mated pallet solution completely fulfilled all line in Asia. “While it quite common to have
production requirements. an automated line with six machine tools, »

TECHNOLOGY E XCELLENCE 47
CUSTOMER STORY – HYDAC CHINA

TURNKEY AUTOMATION
Over a width of 33 m, six NHX 4000 are automated with a 48-position pallet storage system.

COMBINED
In addition, a central tool storage with 4,000 places has been integrated into the system.

PALLET AND
TOOL HANDLING
HIGHLIGHTS 5 setup stations and 48 pallet locations The LPS control computer acts as the “brain”
The linear pallet automation system (LPP) of the automation. Although the automation
+ 6 NHX 4000 machines are linked
at HYDAC China has five setup stations and system is huge, it can be managed by just one
via an LPP linear pallet storage
48 pallets. Four setup stations have been operator. The LPS can assign the machine
system with 48 pallet positions
provided for the machine operator to load tool programs, improve productivity and
+ 5 setup stations, including fixtures and another for fully automated at the same time display the work status
two robot setup stations for fully loading and unloading by robot. The LPP of the machine. It offers an overview of the
autonomous loading handles the pallets and delivers them to each work status of every individual machine. In
setup station, storage position and machine. addition, before each machining operation or
+ Integration of a central tool
The complete control and mana-gement
storage system (CTS) for up to
of the system takes place via a DMG MORI
4,000 additional tools
LPS 4 control computer.
+ LPS 4 control computer for LPS 4 CONTROL
overall control of machines,
pallets and tool automation,
One system, many machines
and one operator
COMPUTER FOR
incl. interfaces to ERP and tool The CTS central tool storage system provides OVERALL CONTROL
management systems 4,000 places and is the most impressive
highlight of this automation system. It
OF THE SYSTEM
has the capacity to operate autonomously,
24 hours a day, seven days a week. The
image processing camera on the robot transport to a machine tool, it checks whether
arm monitors whether the positions in the the tools are available and if their service life
tool racks are occupied or free during tool is sufficient. This is a significant advantage
transport. At the same time, the position in combination with the CTS (central tool
→ More about the
of the tool racks is checked via the vision storage), as missing tools and expired service
LPS 4 control computer system to ensure that neither thermal nor lives are automatically reported to the tool
on page 53 any other influences pose a problem for the room so replacements can be prepared.
safe operation of the system.

48 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – HYDAC CHINA

The tool presetter is connected with the LPS Min adds: “In light of increasing labor costs and connection of the existing CTS are in
to enable the tool data to be automatically and difficulty in finding staff, there is no doubt planning or have been ordered for Hydac
written to the database of the cell computer. about the attractiveness of these benefits for Sulzbach. “Against the backdrop of increasing
Should the machine operator need to load our company.” digitization and automation, there are almost
the tool, its QR code is first read by the TSS no limits to future technical advances,” is
(tool setting station) and the tool is loaded into > 97 % good parts and savings in the opinion of Zhu Min. “Exactly like the
the magazine. The robot then automatically raw materials cooperation between HYDAC and DMG MORI,
transports the tool to the correct position in Once again it shows that high efficiency and the development will become even more long
every machine or into the magazine. reliability can be achieved by automated term and intensive.”
machining. “Our yield used to be approximately
Essential automation solutions 85 percent. In a very short time, it is now over «
“Although the range of parts is extremely 97 percent, thanks to the new production line
diverse, this automation system is perfectly and it continues to improve.” says Zhu Min.
suited to fulfil our requirements. The manu- “We also profit from the associated savings in
facturing system currently handles 70 percent raw materials along with a reduction in stock
of HYDAC China orders,” comments Zhu Min. levels and many other advantages.”
HYDAC is very satisfied with the performance
of the installation. “The advantages are Technological advances for the future
obvious, whether in reference to staff deploy- Within the context of increasingly tough
ment, process reliability, technical support, competition, the automation solution from
error rate, stock ratio or the proportion of DMG MORI has enabled HYDAC China
good parts produced.” It has been possible to maintain and build on its advantages.
to reduce the six people that were needed to Recently, cooperation between HYDAC and
operate the manufacturing line per shift to DMG MORI has increased and an additional
just three operators, one for each shift. Zhu LPP automation line with four machines

HYDAC CHINA FACTS

+ Founded in 1996 in Shanghai

as a wholly owned subsidiary of
HYDAC INTERNATIONAL
+ Initially a sales company for
hydraulic components such as
filters and accumulators
+ Local production since 2003

HYDAC Technology (Shanghai) Ltd.

Lvchun Rd 271 Economic & Technological
Development Zone
200245 Minhang, Shanghai, China
www.hydac.com.cn

Shuttle of the 48-position LPP system.

TECHNOLOGY E XCELLENCE 49
INTERVIEW – AGV / AMR

1b

1
PH-AGV

PALLET AUTOMATION 1a PH-AGV 950

+ Pallet sizes:
Pallet automation with maximum flexibility through 500 × 500 mm, 630 × 630 mm, ø 800 × 630 mm
versatile layout design – our PH-AGV solutions transport
pallets from 500 × 500 mm to 1,600 × 1,250 mm weighing 1b PH-AGV 3000
(workpiece and pallet) up to 5,000 kg and ø 1,600 mm.
+ Pallet sizes: 1,000 × 800 mm

PH-AGV 5000
+ Pallet sizes:
The video for the PH-AGV 1,250 × 1,000 mm, 1,600 × 1,400 mm
can be found at:
https://youtu.be/_evyeQ8LFUQ

50 TECHNOLOGY E XCELLENCE
 CTS – Central INTERVIEW – AGV / AMR
Tool Station

1a

AGV / AMR – DRIVERLESS

TRANSPORT SYSTEMS FOR
THREE APPLICATIONS
DMG MORI is driving forward integrated automation on the shop floor
with Autonomous Mobile Robots (AMR) and Automated Guided Vehicles (AGV).

2 3
WH-AMR* TH-AGV

WORKPIECE AUTOMATION TOOL HANDLING

The solution for handling workpieces up to ø 150 × 120 mm Driverless transport system for the autonomous
and 10 kg. The WH-AMR travels autonomously, does not transport of tools between the central tool magazine
need rails and can automatically avoid people and obstacles (CTS = Central Tool Station) and the machine tool.
that it detects using laser sensors. The TH-AGV can transport up to 16 tools with a maximum
total load of 480 kg.

The video for the WH-AMR 5 The video for the TH-AGV
can be found at: can be found at:
https://youtu.be/aR3brPXRMSY https://youtu.be/WqNlOOemktg

AMR = Autonomous Mobile Robots

*

(“WH-AGV” was renamed “WH-AMR” from July 2022) TECHNOLOGY E XCELLENCE 51

INTERVIEW – AGV / AMR

PH-AGV

PALLET HOLISTIC AUTOMATION ON

AUTOMATION THE SHOP FLOOR
→ more on page 54

Within the context of manufacturing pro- DMG MORI started with the PH-AGV.
cesses, which are becoming increasingly When is it advisable to use autonomous
automated, more and more driverless pallet handling systems?
transport systems, so-called Automated Michael Trenkle: The modular concept of the
Guided Vehicles (AGV), are taking over PH-AGV makes it possible to have a flexible
the shop floor. DMG MORI supports its layout design, which is an advantage in
customers in this area with products in situations where there is not enough room
its AGV portfolio. The vehicles collaborate for a system consisting of a machine and a
with people in one working environment to pallet store, for example. The pallet rack of
transport workpieces, pallets or tools from the PH-AGV is also to extend at a later date.
external storage loca-tions to the machines. and additional machines may be integrated.
The layout of this modular concept can The machine also remains completely
be freely designed and quickly adapted accessible to operators. Pallet sizes up to
to changing production environments 1,600 × 1,250 mm and with a total weight of up
if necessary. Michael Trenkle, Head of to 5,000 kg also guarantee that a wide range
WH-AMR
Special Construction at DMG MORI and of components can be handled. Material
WORKPIECE Hideki Nagasue in the AMR Development pallets can also be transported. However,
Office at DMG MORI discuss how WH-AMR, the speed must be taken into consideration.
AUTOMATION PH-AGV and TH-AGV contribute to process Classic linear pallet storage (LPP) has clear
→ more on page 56 automation and digitization of production. advantages in this case. With the LPP, cycle
times should be more than 5 minutes. With
Mr. Trenkle, Mr. Nagasue, DMG MORI is the PH-AGV it is at least 20 minutes.
regarded as a pioneer in automated
production. You have also been Hideki Nagasue: Production is similarly made
concentrating on processes outside the more flexible when the TH-AGV assists in tool
machine tool since last year with the management. The TH-AGV can transport up
introduction of automated guided vehicle to 16 tools, each with a maximum weight of
systems. What was the reason for this? 30 kg. It has an interface to the tool loading
Michael Trenkle: DMG MORI takes a station of the DMG MORI wheel magazine
holistic view of the subject of automation. and is supplied with tools via a central tool
Autonomous production on machines is only store (CTS, see page 60).
a part of the overall picture. The demand
for flexible processes is increasing at the The WH-AMR (Autonomous Mobile Robot)
same time. This means that a wide range differs from these two AGVs in that it has a
of workpieces, pallets and tools have to be robot which clamps workpieces in a machine.
stocked in large quantities. Many machines This process is significantly more complex
TH-AGV do not have the necessary capacity, meaning than simply loading pallets or tools.
that external storage has to be installed. Hideki Nagasue: That is correct. Workpiece
TOOL We provide economical decoupling of the clamping in particular requires technologies
HANDLING machine from the workpiece, pallet or tool which are significantly more precise. For
storage with our automated guided vehicle workpiece handling we have combined the
→ more on page 60 systems. principle of the AGV with a collaborative robot,
which transports the workpieces into and out
Hideki Nagasue: The AGVs from DMG MORI of the machine. The robot of the WH-AMR
drastically reduce the use of manual pallet has an optical system with a positioning
trucks and forklifts. This gives engineers time accuracy of ± 1 mm, which permits loading
to concentrate on demanding tasks such as with sufficient precision into any fixture. We
planning and programming. have standardized the WH-AMR to such an
extent that it can interact with any machine
on the shop floor. AMR is able to travel
autonomously and reroute itself when an
obstacle blocks its path. It is so flexible that
deployment in production environments

52 TECHNOLOGY E XCELLENCE
 INTERVIEW – AGV / AMR

LPS 4
TO O L
MAN
LING
AND
THE MASTER
AG
EH EM
P IEC EN
T
W
O RK
CONTROLLER FOR
ALL AUTOMATION
SOLUTIONS
G
IN

AG
DL

VC
AN

ON
+ Pallet, workpiece & tool handling
TH

T RO
PALLE

+ Tool administration and tool management

L
+ Fixture management
+ AGV control
+ ISTOS PRODUCTION
PLANNING & CONTROL
+ CELOS Job Manager
FOR CPP, LPP, MATRIS,
WH Flex and AGV + Reporting & evaluation functions
(PH, WH & TH) and such as OEE
combinations thereof

>> Modular software modules can be precisely

adapted to any customer requirement

outside of the machine tool industry is also What about flexible layout design
feasible. This means that we are in a position and control of the AGV?
to develop new markets. Michael Trenkle: The basis for the flexible THE BASIS OF THE
How compatible are the AGV's in
layout lies in the modularity of the system.
The storage and the setup stations can be
FLEXIBLE LAYOUT
a production environment? freely positioned, regardless of whether this LIES IN THE
Hideki Nagasue: All AGVs generally have to
drive over uneven floors and cable ducts
is for pallets, workpieces or tools. A buffer is
also available as an option for achieving faster
MODULARITY OF
some of the time and are able to do so. changeover times. The entire system can be THE SYSTEM
Obstacles are bypassed with the aid of a integrated into an existing production envi-
laser scanner, meaning that safety fences ronment and extended at a later date – and
are not required. A laser makes it possible other machine types can be added. Modern Customers who wish to fully automate their
to scan the environment and react to changes lithium-ion batteries make continuous production can obtain everything from a
in the layout in a flexible way. The sensors operation for eight hours possible. The single source at DMG MORI.
and scanners of the AGV make safe opera- vehicles have their own stations for auto-
tion possible at speeds of up to 9 km/h matic charging. «
(WH-AMR: 4 km/h).
Hideki Nagasue: The AGV is controlled using
the DMG MORI LPS 4 central computer, with
which DMG MORI successfully optimizes the
entire production process. In other words:

Michael Trenkle
Head of Special Construction AMR and AGV are the
DECKEL MAHO Pfronten GmbH
ideal solution for auto-
mating existing produc-
tion. And in a completely
collaborative way.
Hideki Nagasue
AMR Development Office
General Manager

TECHNOLOGY E XCELLENCE 53
PALLET HANDLING – PH-AGV 5000

PH-AGV
AUTONOMOUS PALLET
HANDLING UP TO 5,000 kg
DMG MORI has already presented the first expandability, the AGV system can also be DECKEL MAHO in Pfronten. The configura-
AGV (Automated Guided Vehicle) solution for effortlessly integrated into existing produc- tion of the pallet rack and the set-up stations
pallet handling (PH) at EMO in Hanover in tion areas and quickly adapted to a changed is modular. “The number and positioning
2019. The PH-AGV automated guided vehicles production environment if required. NEW can thus be completely adapted to suit the
move autonomously and collaboratively with is the PH-AGV 5000 for pallet sizes up specific requirements of the customers.”
people on the shopfloor and transport pal- to 1,600 × 1,400 mm and 5,000 kg handling The control and the management of the
lets from external storage facilities to the weight. “The automation solution enables system is taken on by the DMG MORI CELL
machines. They ensure even more flexible maximum flexibility through free accessi- CONTROLLER LPS 4, which optimizes all
production processes with unrestricted bility to the machines and freely program- processes in production.
machine accessibility at the same time. mable travel paths for the handling unit”,
Thanks to its free layout design and simple says Cornelius Nöß, Managing Director at «

PH-AGV 5000 for pallet sizes up to 1,600 × 1,400 mm and 5,000 kg handling weight.

54 TECHNOLOGY E XCELLENCE
 PALLET HANDLING – PH-AGV 5000

Large vertical stroke of 2,010 mm for pallet storage in racks up to 3 m high.

PH-AGV

PALLET AUTOMATION

The PH-AGV 5000 connects the + Modular concept with flexible layout design
– Automated guided vehicle systems without
machine and the material into a guide rails or tracks

perfectly coordinated value chain. – Collaborative: Man and machine in one system –
Maximum safety thanks to area scanners
The autonomous, driverless trans- – Laser navigation

port system for up to 5,000 kg + Pallet sizes from 500 × 500 mm to 1,600 × 1,250 mm

enables efficient and collaborative + Workpieces weighing up to 5,000 kg (including

work between the material store pallet) and with a diameter of up to ø 1,600 mm

and the machine with free layout + Used for machine pallets and material pallets

design. Access to the machine

remains unrestricted in the process.
A video of the PH-AGV 5000
Cornelius Nöß can be found at:
Managing Director https://youtu.be/4CGHswmO_EA
DECKEL MAHO PFRONTEN GmbH

TECHNOLOGY E XCELLENCE 55
CUSTOMER STORY – KIGUCHI TECHNICS INC.

24-HOUR PRODUCTION
THANKS TO
WH-AGV 5*

By connecting the NTX 1000

2nd Generation to a pallet warehouse
via the WH-AGV 5*, we were able to
sustainably optimize our processes.

Tatsuya Kanou
Production Department Manager
KIGUCHI TECHNICS INC.

56 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – KIGUCHI TECHNICS INC.

WH-AGV*

WORKPIECE
AUTOMATION
HIGHLIGHTS

+ Modular concept with flexible

layout design
– Autonomous Mobile Robot systems
without guide rails or tracks
– Collaborative: man and machine
in one system
+ The vision sensor enables robot arm
accuracy of less than ± 1 mm
+ Workpieces with a diameter of up to
150 × 120 mm and a weight of 10 kg
+ Compact design (700 × 1,035 mm)
+ Laser sensor
+ High performance and stability,
including on uneven surfaces

The video for the WH-AGV 5*

can be found at:
https://youtu.be/aR3brPXRMSY

The WH-AGV 5* does not need rails and can

automatically avoid people and obstacles

In Shimane Prefecture, known since ancient KIGUCHI TECHNICS to have a fully auto- industrial materials used in production is
times for its iron production, KIGUCHI mated process from the transport of raw therefore essential to ensure human safety.”
TECHNICS INC. has its headquarters in parts to 6-sided complete machining and KIGUCHI TECHNICS came to material
Yasugi. Japanese sword polisher Hisashi return of the finished test specimens. inspection when a steel company asked the
Kiguchi founded the company in 1961 and then Kiguchi Polishing Company to polish
today KIGUCHI TECHNICS' core business Inspection of industrial materials the surface of the high-grade special steel
is quality control of metals and other “Defects in components can lead to serious Yasuki-Hagane to a high gloss. It was then
materials. Since 2021, test specimens have accidents and endanger people’s lives,” to be inspected under a microscope.
been processed on two NTX 1000 2nd Gen- explains Takahiro Kiguchi, Executive Vice
eration machines that are connected to a President KIGUCHI TECHNICS INC. This
pallet warehouse via the WH-AGV 5*, an applies to cars, airplanes and power plants,
autonomous transport system. This allows for example, he said. “Quality control of »

*
“WH-AGV” was renamed “WH-AMR” from July 2022.

TECHNOLOGY E XCELLENCE 57
CUSTOMER STORY – KIGUCHI TECHNICS INC.

Metal inspection specialists – more

demanding tasks through automation
Since then, KIGUCHI TECHNICS has consist-
ently refined its expertise in metal inspection.
Today, the company has an integrated sys-
tem to perform everything from making test
specimens to testing and evaluating them
in-house – primarily in the aerospace, auto-
motive, energy and medical sectors. As part
of its 60th anniversary celebration, KIGUCHI
TECHNICS has been working for two years
to automate test specimen machining. Tat-
suya Kanou, head of the production depart-
ment responsible for this anniversary project,
recalls, “We aimed to eliminate human error
and increase productivity. At the same time,
we wanted to use automation to reform our
work processes so that our employees could
concentrate on more demanding tasks.”

HIGH-MIX, On the two NTX 1000 2nd Generation machines, KIGUCHI TECHNICS processes
around 50 different material types and 200 variants of specimens.
LOW-VOLUME
PRODUCTION

KIGUCHI TECHNICS' testing business is

characterized by high-mix, low-volume pro-
duction. The company cuts the materials
received from customers, machines them
into the optimum shape for testing and
performs strength and fatigue tests. Finally,
KIGUCHI TECHNICS provides the test data.
The iron, stainless steel, aluminum or tita-
nium test specimens each have to be molded
into dozens of shapes. “Sometimes engines
that have broken down due to metal fatigue
are brought to us as they are,” Tatsuya Kanou
said. “Our job then is to process such ‘irre-
placeable specimens’ flawlessly and with the
highest precision.”

DMG MORI excels with autonomous

and collaborative automation concept
After evaluating several suppliers for the plan- KIGUCHI TECHNICS INC. (from left):
ned automation solution, KIGUCHI TECHNICS Hiroyuki Uchida, Division Manager,
opted for the concept from DMG MORI. The Production Division 2, Production Department
Shohei Yamaura, Section Chief, Section 1,
innovation leader combined two NTX 1000 Production Division 2, Production Department
2nd Generation – compact turn & mill centers – Takahiro Kiguchi, Director / Vice President
with an autonomous transport system, the Tatsuya Kanou, Department Manager,
Production Department
WH-AGV 5*, enabling linkage to the pallet Tatsuhiro Okamura, Section Leader, Section 1,
warehouse. The WH-AGV 5* takes the work- Production Division 2, Production Department
piece from the warehouse and trans-ports The city of Yasugi in Shimane Prefecture has
been known in Japan for its iron production
it to the two NTX 1000 2nd Generation. One since ancient times. KIGUCHI TECHNICS has its
takes over the pre-machining, the other headquarters here.

58 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – KIGUCHI TECHNICS INC.

Measurement of thread
dimensions is performed in the
machine with a small diameter
stylus of ø 1 mm.

Connection to the pallet storage

system enables unmanned
production of a large number
of workpieces over 24 hours.
The WH-AGV 5* transports workpieces to the
two NTX 1000 2nd Generation. The workpiece length
is measured automatically on the workpiece tray.

the finishing. The WH-AGV 5* then returns more demanding tasks. “Operators used to
the test specimen to the warehouse. Unlike work two shifts to run the machines, but now KIGUCHI TECHNICS FACTS
its predecessor, the autonomous transport automated production is possible around the
system does not need rails. It can avoid peo- clock.” + Founded in 1961, one of the
ple and obstacles automatically. “Since the largest independent testing labo-
NTX 1000 2nd Generation is equipped with 76 Looking to the future, Tatsuya Kanou adds, ratories for metals and
tools, we can machine a wide range of work- “With the increasing use of hydrogen as an other industrial materials in
pieces without much setup effort,” adds Tat- energy source, the need for metal testing the country
suya Kanou. In addition, he says the system will certainly increase even more.” This is + Evaluating the quality and
also improves machining accuracy. “This is because hydrogen embrittlement could performance of materials used
because manual grinding used to be required reduce the strength of metallic materials. “As in the aerospace, automotive,
after finishing.” the overall labor force in Japan decreases, energy and medical industries
there will still be areas where manual labor + A complete quality control
0.5 operators and 2 NTX 1000s instead is required as in this type of metal testing. system from machining speci-
of 4 operators and 4 machines Based on the automation solution we have mens to performing the tests
The automated system is able to measure now introduced, we intend to further auto- + Nadcap certification: Quality
the length of the workpiece and the thread mate such processes and increase their assurance considered essential
dimensions independently, eliminating the precision.” for the manufacture and testing
need for manual operations. “DMG MORI was « of aerospace products worldwide
the only manufacturer able to implement this
automatic measurement,” Tatsuya Kanou
looks back on the decision-making phase.
In addition, he says, the system adjusts the
machining program based on the meas-
urement results. “The automation solution
has been fully operational since January KIGUCHI TECHNICS INC.
2022. Processes that used to require four 114–15, Enoshima-cho,
machine tools and four operator can now Yasugi-shi, Shimane, Japan
https://kiguchitech.co.jp
be performed by just 0.5 operator.” There-
fore, he said, employees can be assigned to

“WH-AGV” was renamed “WH-AMR” from July 2022.

*

TECHNOLOGY E XCELLENCE 59
CTS – CENTRAL TOOL STORAGE FOR TH-AGV

CTS – CENTRAL
TOOL STORAGE UP TO
1,440 TOOLS
IN 29 m2
MODULAR FLEXIBLE TOOL
MAGAZINE FOR UP TO 1,440 TOOLS

3,300 mm

TLS –
Tool loading station
100 % from the wheel
magazine station

4,450 mm

6,500 mm

HIGHLIGHTS

+ Modular concept with the option of expanding in

stages by 360 / 240 tools (taper 40 / 50)
+ Very small footprint with only
29 m2 for 1,440 / 960 tools (taper 40 / 50)
+ Integrated tool loading solutions for portal tool FLEXIBLE
handling or AGV tool loading PLACEMENT IN
+ High transport capacity with portal tool
PRODUCTION
rack handling
+ Taper cleaning and TDS tool identification optional
+ Proven wheel magazine technology
with over 1,600 installations worldwide

60 TECHNOLOGY E XCELLENCE
 CTS – CENTRAL TOOL STORAGE FOR TH-AGV

Wheel element with

80
360 (ISO 40) or 240 (ISO 50) tools
Storage and drive 100 %
provided by the wheel magazine
TOOLS
PER HOUR

TH-AGV

TOOL PORTAL TOOL

Tool changer HANDLING HANDLING SYSTEM
100 % from wheel
magazine station + Autonomous transport of 16 tools (2× 8 + Portal tool handling for maximum efficiency,
sets) between the CTS (Central Tool transport of up to 80 tools per hour
Station) and the machine + Transport of 16 tools
(2 × 8 sets)
+ Tool Loading Station (TLS)
+ Fast tool exchange by rotatable rack
– Transfer station to the CTS
+ Max. linear speed: 80 m/min
and the machine for handling
+ Tool Loading Station TLS interface
8 tools in sets
at machines and CTS
– Tools weighing up to 50 kg
and 650 mm in length

Shuttle
To transfer the tools, the Tool Loading Station (TLS) moves up
to the shuttle, which is used to change the tools.

TECHNOLOGY E XCELLENCE 61
CUSTOMER STORY – GREDE CASTING INTEGRITY LLC

Thanks to the combination

of machining speed,
stability and accuracy,
the NHX 5500 is the ideal
machine for fully automated
processes. The entire system
of 18 machines manufactures
reliably and safely to
an accuracy of ± 0.01 mm.

Mike Latwesen, Plant Manager (left)

Chris Pegelow , Engineering Manager (middle)
Dan Woyak, Project Manager (right)
at Grede in Menomonee Falls

FULLY AUTOMATIC,
SAFE AND PRECISE
Grede Holdings LLC has its origins in a At its machining and assembly facility in Holistic manufacturing from casting
foundry established in 1920 in Wauwatosa, Menomonee Falls, Wisconsin, the machine to ready-to-install component
Wisconsin. Today, with 3,000 employees at tool manufacturer optimized the production “As a full-service provider, we cover the
ten locations in North America, the company of steering knuckles in 2019. The result is entire process chain from design and cast-
is one of the leading experts in the field of impressive: Over 650,000 steering knuckles ing to final machining and quality control,”
metal casting. As a first-tier supplier to the are produced per year in a fully automated explains Mike Latwesen, General Manager
automotive and commercial vehicle industry, production line comprising 18 NHX 5500s. at Grede in Menomonee Falls. He says the
Grede manufactures safety-critical compo- focus is primarily on safety-critical compo-
nents for the powertrain or chassis, among nents for customers in demanding industries.
others. For this purpose, the team has more “To remain competitive, we have to manufac-
than 40 machining centers and lathes from ture high-quality products and deliver them
DMG MORI at its disposal. on time.” The fact that Grede has been one

62 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – GREDE CASTING INTEGRITY LLC

Production line with 18 NHX 5500s and 10 robots.

One robot feeds 2 NHX 5500s. The tenth robot feeds
the blanks and transfers the finished parts into
a separate washing & measuring cell.
The Grede team has more than 40 machining centers
and lathes from DMG MORI at its disposal

of the leading suppliers in the industry for Turnkey project for complete machining of been planned. The project took six months
decades is a direct result of continuous pro- 650,000 steering knuckles per year to complete. Since then, the plant has been
cess optimization. Particularly in machin- Recent installations at Grede include a pro- producing over 650,000 steering knuckles
ing – which accounts for up to 50 percent of duction line for steering knuckles, which for passenger cars per year in a fully auto-
the value chain – there is a lot of potential was installed in Menomonee Falls in 2019. “In mated and highly flexible process – a
for savings, says Mike Latwesen: “Today's DMG MORI, we found a partner for this turn- complete set for one vehicle per process
machining centers are more versatile, faster key project that, offers leading manufacturing operation.
and more precise.” Grede has been using technologies. Additionally, their engineers
machine tools from DMG MORI since 1980, have the necessary competence to implement
so he knows the technology very well. such an extensive project in the allotted time,”
says Mike Latwesen. In view of the order sit-
uation, the capacity expansion had already »

TECHNOLOGY E XCELLENCE 63
CUSTOMER STORY – GREDE CASTING INTEGRITY LLC

18 NHX 5500s for reliable naturally requires absolute reliability – one The same applies to the powerMASTER spin-
one-hit machining reason for acquisition of horizontal machin- dles, on which DMG MORI offers a 36-month
The production line in Menomonee Falls ing centers: “Efficient chip evacuation makes warranty with no hourly limit, thanks to their
consists of 18 NHX 5500s that perform a the NHX 5500 an ideal machine tool for such robust design.
total of four milling operations. Ten robots
load and unload the machines with heavy According to Mike Latwesen, reliable hori-
knuckle parts. This removes the risk of zontal machining was just one of several
injury to the operators, while ensuring the RELIABLE arguments in favor of the NHX 5500: “The
machines are always supplied with raw parts.
The operator loads the raw parts at one loca-
PRODUCTION IN combination of machining speed, stability and
accuracy made the decision easy.” The sys-
tion and the intelligent parts conveyor trans- THE HUNDREDTHS tem machines to an accuracy of +/- 0.01 mm.
ports them to all 18 machines. The DMG MORI
Messenger monitoring software allows status
RANGE Another advantage was the small footprint
in relation to the large work area. “It offers
monitoring of the machines, which enables sufficient space for the required fixtures.”
the operators to address issues such as tool
change in a timely manner. “After the steering automated processes.” The integrated tool
knuckles have passed through the production breakage sensing and the high-pressure
line, only final quality control follows,” adds coolant system are also crucial for the relia-
Mike Latwesen. The fully automated process ble operation of the production line, he adds.

1. Feeding of the blanks 2. Turnover station 3. Discharge of finished parts

64 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – GREDE CASTING INTEGRITY LLC

Up to 650,000 steering knuckles are automatically processed by the production system, consisting of 18 × NHX 5500s.

In addition, CELOS played a role, adds Mike

Latwesen: “We've been using the intuitive GREDE FACTS
control interface since 2014 on NLX 2500s
installed at the time, so in the case of the + 1920 founded in Wauwatosa,
NHX 5500, our team was already familiar with Wisconsin
its operation.” + Today, one of the top foundries
in North America
Turnkey project perfectly implemented + Design, engineering,
With the turnkey solution, DMG MORI met validation and manufacturing
all Grede's productivity and machining qual- of safety-critical components
ity requirements, and Mike Latwesen looks for passenger, industrial and
back positively at the entire project imple- commercial vehicles
Thanks to the LPS 4 master computer control mentation: “In a project of this size, there + 10 facilities across North
system, the entire manufacturing system are always hurdles to overcome. DMG MORI America with a team of
can be centrally controlled and monitored. 3,000 employees
mastered the installation professionally and
on schedule at all times.”

Grede Casting Integrity LLC

Menomonee Falls, WI
W 139 N 5470 Oak Lane
P. O. Box 300 Menomonee Falls
USA WI 53052–0300
www.grede.com
The finished steering knuckles are then
washed and automatically measured.

TECHNOLOGY E XCELLENCE 65
DMG MORI SUSTAINABILITY

GREEN AND
EFFICIENT
WITH OUR AFTER SALES
Mitigating the effects of global climate to reduce your CO2 footprint to a minimum –
change is the greatest challenge that we and in a way that conserves resources and
can only overcome together. energy while at the same time saving costs
and maintaining competitiveness! Often all
As a global manufacturer of CNC machines, that is needed are small changes to achieve
we take our environmental responsibilities great success: Join us in shaping the future
seriously: DMG MORI offers its customers of a green industry for a more sustainable
sustainable services and products for the world!
complete machine lifecycle, allowing you «

DMG MORI focuses

on sustainable value
creation including in GREEN
MODE
the after-sales area.

Dr. Thomas Froitzheim

Managing Director
[email protected]

RETROFITTING, REFURBISHMENT
AND RECYCLING

We bring your machine back to

its original performance level.
Like a new machine for absolute
competitive ness.

Our solutions for retrofitting,

replacement spindles and repairs are
environmentally friendly and inex-
pensive – coupled with the highest
DMG MORI quality.

66 TECHNOLOGY E XCELLENCE
 DMG MORI SUSTAINABILITY

LIVE DATA
AVAILABLE
ANYWHERE

MAXIMUM MACHINE
EFFICIENCY WITH A MINI- AVOID
MUM CARBON FOOTPRINT TRAVEL EMISSIONS
1 LESS
 TRAVEL 2 ALMOST
 LIKE ON SITE –
WITH DIGITAL SERVICES HoloLens TRAINING

Monitoring solutions: + Innovative remote solution for digital practical training

+ Increase the efficiency of your machines with mixed-reality technology
+ Detect and avoid unplanned downtimes at an early stage + Your employees are always available in the company
+ More sustainability for training
Digital remote solutions:
+ Sustainably reduce work travel and CO2 emissions
with our NETservice

my DMG MORI customer portal: The DMG MORI Academy

+ Free your company from working was awarded E-Learning
AWARD 2022 with its concept,

4
with an ineffective jumble of paper
and save the raw material with “Use of HoloLens for practical
our digital customer portal
training within the scope of
blended learning”.

SUSTAINABLE
SERVICE
INSTEAD OF PRODUCTS
NEW PURCHASES
AND DISPOSAL
3 LIKE
 NEW MACHINES – 4 LIKE
 NEW SPINDLES –
RETROFIT & OVERHAUL OVERHAULED & REPAIRED

+ Retrofit: + 60 % of all spindles are refurbished

Bring your machine up to the state of the art and reused
+ Overhaul:
+ 50 % of our customers decide on an
Restore 100 % of the performance of your machine
overhauled replacement spindle or the
repair of their spindle

+ 50 % of all spindle components

are refurbished and reused

TECHNOLOGY E XCELLENCE 67
CUSTOMER STORY – KÖRTING HANNOVER GMBH DMG MORI USED MACHINES – RETROFIT
AND OVERHAUL INSTEAD OF DISPOSAL
+ Retrofit: Return your machine to

GREEN the state-of-the-art

+ Overhaul: Restore the your machine
MODE to 100 % capacity

The overhaul of a DMU 125 FD duoBLOCK by DMG MORI Used Machines allowed Körting
to add many years to the operation of its mill-turn center.

OVERHAUL –
COST EFFICIENT
AND SUSTAINABLE
In 1871, Ernst Körting invented the steam jet include a DMU 125 FD duoBLOCK installed With this unique selling point, Körting can
injector as a boiler feed pump and founded in 2006, which was made fit for at least guarantee outstanding quality and process
the company Gebrüder Körting in Hannover another ten years thanks to a general over- reliability.
with his brother Berthold. Today Körting haul carried out at the end of 2021 / begin-
Hannover GmbH has subsidiaries in Brjzil, ning of 2022. Jet pumps for economic and
China, India, Malaysia and Poland and ranks energyefficient wastewater treatment
as a leading manufacturer in the develop- Development of integrated products Jet pumps require very little maintenance
ment and production of application-specific through collaboration with partners and are designed to operate for decades.
jet pumps as well as vacuum engineering “As an expert in engineering services, com- “So although we have only a negligible spare
products and environmental technology. The ponents and systems, we develop integral parts business, more and more companies
principle of fluid dynamics applied then is solutions in partnership with our customers”, are replacing old jet pumps and vacuum
still valid today. With around 300 employ- explains Dr. York Fusch, Chairman of the systems with more energy-efficient ones
ees, Körting is an important partner in the Board of Directors at Körting. This leads to in order to increase economic efficiency
processing and chemical industries and the consistent further development of the prod- and improve their environmental footprint”,
vacuum technology and environmental tech- ucts and ever more innovative fields of appli- explains Dr. York Fusch. The wastewater
nology sectors. The company manufactures cation. “Our expertise ranges from develop- treatment business is gaining in importance.
its demanding components on CNC machine ment and construction to manufacturing and Körting develops and produces wastewater
tools from DMG MORI, among others. They on to include measurement of our jet pumps.” systems with ejectors whose design is similar

68 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – KÖRTING HANNOVER GMBH

to that of a jet pump. These, too, are dimen- In 2021 Körting considered investing in a new a new model. Secondly, the overhaul did not
sioned according to requirements, require machining center. “However, the DMU 125 FD require any changes on the shop floor and
virtually no maintenance and offer high oxy- duoBLOCK was technically suited to our we were able to continue using our existing
gen efficiency, which is needed for purifying requirements, so we decided to commission tools and equipment, such a fixtures and NC
the water. programs.”

DMU 125 FD duoBLOCK: efficient Overhaul with original spare parts in

milling-turning operations since 2006 OVERHAUL: THE DMG MORI quality
The ejectors are made of polypropylene
and have been produced on a DMU 125 FD
NEW OLD MACHINE – When carrying out a machine overhaul,
DMG MORI Used Machines first records the
duoBLOCK from DMG MORI since 2006. COST EFFICIENT actual condition of a machine, dismantles
“Milling and turning in one work area was
even then the perfect manufacturing solu-
AND SUSTAINABLE it and transports it to Geretsried. After dis-
assembly and cleaning, all components are
tion”, recalls Jürgen Sack, plant manager overhauled and reassembled.
at Körting. In addition, the work area offers 
sufficient space for long tools. “This means DMG MORI Used Machines to overhaul our
we can carry out many machining steps in a existing model”, says Jürgen Sack. This
single clamping, which has reduced through- brought many benefits: “Firstly, we would
put time significantly.” have had to invest at least twice as much for »

Having the machine overhauled by DMG MORI

Used Machines after 15 years brought decisive
benefits for us. We saved 50 % of the costs of a
new machine and thanks to the manufacturer's
more moder, high quality parts, the accuracy
of the machine is improved.

Jürgen Sack, (left) Plant Manager at Körting Hannover GmbH

Lars Günther, Head of Mechanical Production

TECHNOLOGY E XCELLENCE 69
CUSTOMER STORY – KÖRTING HANNOVER GMBH

The paintwork is also renewed. Then comes

a test run, acceptance and pre-delivery
inspection before the machine is reinstalled
at the customer’s premises. “Having the
machine overhauled by DMG MORI was
important for us, because the manufacturer
knows the machine best and uses only orig-
inal, high quality parts”, Jürgen Sack goes
on to tell us. An overhaul after 15 years
also means that DMG MORI uses far more
modern components. “This again further
boosts the accuracy of the machine.”

Three-month machine overhaul

with timely completion
Punctual completion was also important for
Körting. “We were able to plan the three-
month overhaul and produce a large number
of ejectors in advance, yet the DMU 125 FD
duoBLOCK is essential for our production”,
explains Dr. York Fusch regarding the urgency.
The mill-turn center has a multitude of appli-
cations – it can also be used for the demanding
machining of components made of chrome-
nickel alloys. “DMG MORI documented

The Körting ejectors are completed in assembly.

OVERHAUL OVERHAUL OF A
DMU 125 FD AT KÖRTING
IN HANNOVER – FACTS We take care of your
+ 6-month warranty on the
entire scope of the service
+ 1,150 working hours machine, from the last
+ Attractive pricing with
+ 3-month lead time machining operation
exclusive manufacturer
+ approx. 9,100 before it is dismantled
replacement parts
expertise through to the first
+ Short lead times machining operation
for the refurbishment
+ At least 10-year availability
after the overhaul and
of spare parts and service recommissioning.
Lothar Sommer
Managing Director of
DMG MORI Used Machines GmbH
[email protected]

You will find a demo

video of the DMX 200 U at:
https://youtu.be/Z65wssdGx4w

70 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – KÖRTING HANNOVER GMBH

JET PUMPS – Thanks to milling-turning operations, it was possible to reduce throughput times drastically.
CONSISTENT APPLICATION
OF FLUID DYNAMICS

The jet pump is a device in which

the pumping action is achieved by everything with interim reports and put the
a decrease in the pressure of the machine back into operation punctually as
fluid, steam or gaseous medium agreed”, say Dr. York Fusch and Jürgen Sack,
together with a high nozzle exit obviously more than satisfied and impressed.
velocity and delivery of the suction
medium by the jet pump. Reliability with 10-year availability of spare
The application and condition of the parts and service
KÖRTING HANNOVER
medium determine the individual The DMU 125 FD duoBLOCK was predestined
FACTS
shape and cross-section of the for a machine overall, concludes Jürgen Sack:
flow channels in order to ensure “Large, complex, new machines always involve + 1871 founded in Hannover
pumping is energy efficient. It large investments, which are only feasible if + Approximately 300 employees
requires no mechanical drive and you can optimize your processes sustainably + Subsidiaries in Brazil, China,
thus has no moving parts. with a leap in technology.” As this had already India, Malaysia and Poland
been achieved in 2006, the benefits of the + Development and manufacture
overhaul far outweighed the optio of buying of application-specific
new. Dr. York Fusch goes on to add: “What jet pumps as well as vacuum
is more, our engineers were able to carry- engineering products and
ing on working seamlessly on their familiar environmental technology
machines – plus we benefit from a six-month
warranty and 10-year availability of spare
parts and service.”

Körting Hannover GmbH

Badenstedter Straße 56
30453 Hannover, Germany
www.koerting.de

TECHNOLOGY E XCELLENCE 71
DMG MORI GREEN ECONOMY

GREEN ECONOMY
100 % GREEN MACHINES

CLIMATE-NEUTRAL
MACHINE PRODUCTION
GREEN 1. Neutral Product Carbon Footprint (Scope 3 Upstream)
MACHINE 2. Neutral Company Carbon Footprint (Scope 1 + 2)

Through avoidance, reduction and compensation, DMG MORI has both a CO2-neutral “Company Carbon Footprint” and a climate-neutral
“Product Carbon Footprint”. This includes direct and indirect emissions from our own value creation as well as indirect emissions from
upstream processes along the supply chain. Specifically, all machines delivered since January 2021 have been produced completely
climate-neutral.

+ Neutral product carbon footprint

+ Neutral company carbon footprint
+ Machines > 99 % recyclable

Sustainability initiatives
award DMG MORI
TOP 1 % RATING
In 2022, DMG MORI was rated among the top 1 % of
over 35,000 participating companies worldwide as part
of the EcoVadis Sustainability Rating.

72 TECHNOLOGY E XCELLENCE
 DMG MORI GREEN ECONOMY

RESOURCE-EFFICIENT
MACHINE USAGE (Scope 3 Downstream)
GREEN All DMG MORI energy efficiency measures, such as the CELOS Energy Saving App,

MODE are of course standard on DMG MORI machines.

ENERGY SAVING
Up to 30 % energy savings compared
to the predecessor machine, e. g.
+ Regenerative braking
+ Demand-oriented control of process
parameters and components
+ Energy Saving App

TECHNOLOGY EXCELLENCE
FOR GREEN TECHNOLOGIES
GREEN DMG MORI supports its customers in the area of the GREEN ECONOMY

TECH using e. g. recycling, wind & hydropower or electromobility as important levers

against climate change.

Renewable energy

Hydropower

E-Mobility

TECHNOLOGY E XCELLENCE 73
CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG

RA UP TO 0.4 μm
CIRCULARITY
UP TO 5 μm
IT4 AT ø > 300 mm

Exclusive technology cycle

360° TECHNOLOGY COMPETENCE

MILLING,
TURNING AND
GRINDING
+ Milling, turning and grinding
in a single setup
FIT FOR THE
FUTURE
+ Grinding cycles for internal,
external and face grinding, and
dressing cycles
+ Stationary or rotating dressing
unit for dressing a wide
range of tool materials using WITH TECHNOLOGY
INTEGRATION
structure-borne sound sensors
+ AKZ nozzle unit for best possi-
ble flushing of the grinding gap
optionally available

Available for: CTX TC (4A) // DMU / C Meindl-Köhle Umform- und Systemtechnik The 5-axis mill-turn center by DMG MORI
monoBLOCK // DMU / C duoBLOCK //
DMU / C Portal GmbH & Co. KG from Landsberg am Lech features a grinding function that allows the
developed out of a precision toolmaking manufacturing process to be optimized.
company, which was founded by Georg
Meindl in 1928 in Munich. With core expertise A combination of aspiration
in the areas of engineering, toolmaking, CNC and enthusiasm
technology and sheet metal working and “Joy in perfection” is a guiding principle
punching, the 70-strong team is a reliable practiced by Meindl-Köhle and is also
partner for customers in a wide range of an incentive for producing the best
industries – from automotive and aerospace possible products. “We maintain very close
to mechanical engineering and the con- partnerships with our customers and are
struction sector. The company recently involved early on in complex projects,”
A video of DMG MORI –
Milling, Turning & Grinding entered the field of charging technology for explains Matthias Müller, the authorized
can be found at: electric vehicles with their own products. company representative. With many years
https://youtu.be/83DTxnlVxSc Meindl-Köhle has been using a DMC 80 FDS of experience and specialist expertise, the
duoBLOCK for their production since 2022. team implements reliable processes and a

74 TECHNOLOGY E XCELLENCE
TECHNOLOGY EXCELLENCE FOR CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG
GREEN TECHNOLOGIES
+ Integrated manufacturing processes
save time and conserve resources
+ Development and production of
components to optimize the charging
infrastructure of electric vehicles
+ E-mobility: Manufacture of mold
for conduits in cable ducts

zero-error strategy. While partners placing company produces molds for the production
orders profit from this customer-oriented of plastic conduits, for example. “Amongst
philosophy, Meindl-Köhle has long since other things, these are used as cable ducts in
used its know-how and the possibilities cars – and naturally increasingly in electric
offered by DMG MORI to implement its vehicles too,” says Matthias Müller. The
own ideas. conduits are extremely individual in design
and different for almost every vehicle. “A
Innovative solutions for complete set of these molds comprises
charging technology 200 pairs.” For months, Meindl-Köhle
“We would like to contribute by expanding has been producing these components
the charging infrastructure in the strongly almost 24/7.
growing market of electromobility,” Matthias
Müller makes reference to their MEVOLT
electric charging system, which was deve-
loped in-house. The special feature of the
IMPRESSIVE
premium charging stations is a patented THROUGHPUT TIMES
motorized cable extension and retraction
system. “This means it is protected from
THANKS TO COM-
the weather and remains clean. Nobody PLETE MACHINING
has to dirty their hands these days. The
latest development is the MEVOLT MK4
INCL. GRINDING
ROOF CHARGER, a roof charging system
with a 13-meter-long cable, which is ideal MEVOLT MK4 “ROOF CHARGER” is a ceiling-mounted
for car-ports or underground car parks, for “The challenge associated with these molds charging solution for garages, carports, multi-storey
car parks and similar types of parking spaces.
example. is that they need to be ground on all sides
after being milled,” Matthias Müller describes
Toolmaking for electromobility the process that he would like to make more
The order situation at Meindl-Köhle is proof of efficient.
the major importance of electromobility. The »

Joy in perfection is a guiding

principle. We need reliable
machines and partners like
DMG MORI to achieve this.

Matthias Müller
Authorized company representative
Meindl-Köhle Umform- und Systemtechnik GmbH & Co. KG

TECHNOLOGY E XCELLENCE 75
CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG

“In DMG MORI, we have found a partner that

can offer all the machining technologies we
need in one working area.” The machine tool
manufacturer offers grinding integrated
into its duoBLOCK series. “The DMC 80
FDS duoBLOCK with its integral grinding
function was the perfect solution for us as it
allows the throughput time per component
to be reduced significantly compared with
production on several machines.”

Joint process optimization

for 3-shift operation
The development of the machining concept
took place in close cooperation right from
the beginning says Matthias Müller looking
back: “For example, we built the devices for
the two process steps ourselves in such a way
that the grinding wheel was able to rotate
all around twelve clamped workpieces.” For
their part, DMG MORI selected special tools
such as a gear cutter. “The success of this
cooperation is demons-trated by the fact
that the machines were able to be put into
operation after just nine months and have
been working without any problems since
then – and this in 3-shift operation.

RELIABLE
GRINDING THANKS
TO INTEGRATED
MEASUREMENTS

The internal measurements are the reason

why the grinding process is so reliable. “The
machine analyses the measurement data and
calibrates the tools automatically,” Matthias
Müller explains. In addition, there is always a
sister tool in the tool magazine, which has 123
positions. Another feature is setup in parallel
with production by means of a pallet changer.
To all intents and purposes, idle times are a
thing of the past.”

Special tools such as a

gear cutter, for example,
are used for machining
the mold.

76 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – MEINDL-KÖHLE UMFORM- UND SYSTEMTECHNIK GMBH & CO. KG

DMC 80 FDS duoBLOCK

Meindl-Köhle has been using a DMG 80 FDS duoBLOCK with grinding function since 2022.

COMPLETE
MACHINING:
MILLING, TURN-
Flexibly and securely into the future
with DMG MORI technology cycles
ING AND GRIND-
MEINDL-KÖHLE FACTS
Meindl-Köhle purchased the DMC 80 FDS ING ON ONE
+ Founded in Munich in 1928,
duoBLOCK fully equipped to enable them
to react flexibly for future orders. “We will now with headquarters MACHINE
soon be machining larger mold and will be in Landsberg am Lech
able to make use of the turning function,” + 70-strong team HIGHLIGHTS
says Matthias Müller looking to the future. + Comprehensive skills in engi-
neering and tool making + 800 rpm Direct Drive table for
The same applies to the more complicated
+ Their own product range in the 5-axis milling and turning in
grinding operation. “We will be able to rely
charging technology sector one setup
on DMG MORI technology cycles for this.”
+ Workpieces up to ø 900 × 1,450 mm
and 1,200 kg
Countering the lack of skilled staff
+ powerMASTER motor spindle
with technology integration
with 1,000 rpm and 77 kW
The decision to invest in process integration
+ 5X torqueMASTER Spindle
for the DMC 80 FDS duoBLOCK quickly
with 1,300 Nm and 37 kW
proved to be the right path for Meindl-Köhle –
+ High surface quality thanks to
for capacity reasons, but also when it came
grinding technology integration
to the lack of skilled staff, as Matthias
Müller explains: “We are able to deploy our
personnel more flexibly, as the machines Meindl-Köhle Umform- und
can work autonomously for long periods. Systemtechnik GmbH & Co. KG
Justus-von-Liebig-Straße 14 You can find the video on the
86899 Landsberg am Lech duoBLOCK series here:
Germany https://youtu.be/Ql0LzkJXUAY
www.meindl-koehle.de

TECHNOLOGY E XCELLENCE 77
CUSTOMER STORY – NEHER GROUP

PCD TOOLS FOR

E-MOBILITY
APPLICATIONS
At the NEHER GROUP in Ostrach, which Customized PCD and CVD says Tobias Niess, who is responsible for
was established in 1990, 110 experienced tools for e-mobility developing the tools, describing the challenge.
engineers develop and manufacture high- “Our core competence lies in the complete The weight can be reduced in two ways: “By
quality special tools for metalworking and development of sophisticated PCD or CVD using lighter materials such as titanium
woodworking, as well as molds, gages and special tools,” explains Gerd Neher, who and new production methods, but above
other devices. The company's customers is the second generation to manage the all with the aid of innovative manufacturing
come mainly from the automotive industry, the NEHER GROUP. Polycrystalline diamond technologies from DMG MORI.”
aerospace industry and general mechanical is a very hard cutting material which gives
and plant engineering. A special focus is tools a long service life. “If a customer wants
currently on electromobility applications, to manufacture a specific component, we
which repeatedly present the team with new implement the optimum tool for precisely E-MOBILITY: GREEN
challenges. The NEHER GROUP has been
implementing its production for many years
that application.” A sector which is rapidly
expanding is special tools for electromobility
TECHNOLOGY WITH
using innovative manufacturing technolo- applications. NEW CHALLENGES
gies from DMG MORI – from demanding
machining and additive manufacturing on The precision machining of a stator housing,
FOR TOOL DESIGN
LASERTEC SLM machines to cutting blanks i. e. the housing in which the rotor of the
on a LASERTEC 20 FineCutting machine to electric motor rotates, requires comparatively
automated processing on machines from the long and therefore heavy tools. “The weight is LASERTEC SLM: bionic structures
LASERTEC PrecisionTool series. too much to ensure low-vibration and precise using powder bed AM
machining for numerous existing machines One such technology is additive manufac-
in the way that the cutters are normally used,” turing. The NEHER GROUP uses powder bed

The NEHER GROUP develops and

produces top-quality PCD and
CVD precision tools for innovative
applications in a wide variety of
industries, including electromobility
in an increasing number of cases.

78 TECHNOLOGY E XCELLENCE
TECHNOLOGY EXCELLENCE CUSTOMER STORY – NEHER GROUP
FOR GREEN TECHNOLOGIES
+ Machining the stator housings
of electric motors requires tools
that are both long and light
+ Additive manufacturing makes innovative
methods possible in tool development
+ Bionic structures with a weight saving
of up to 70 percent can be realized by
powder bed additive manufacturing

Changeover between different powders on the

LASERTEC SLM models is quick and easy with the
aid of rePLUG exchangeable modules.

Additive manufacturing on the technology from DMG MORI to manufacture

tool bodies – a LASERTEC 30 SLM and a
LASERTEC 30 SLM gives you absolute LASERTEC 30 DUAL SLM. “The layer-by-layer

design freedom – be it cooling build-up takes place directly on a previously

milled interface,” says Tobias Niess. Additive
channels close to a contour for manufacturing gives you complete design

durability or bionic structures that freedom. “On one hand we can integrate
cooling channels close to the contour, which
provide outstanding rigidity and improves the durability of the tool. On the

optimum vibration behavior. And other hand, we can use the Finite Element
method to create bionic structures inside the
what's more, the weight saving tools which provide maximum stability and

compared to conventional tools is optimum vibration behavior.” You also get a

weight saving of between 30 and 70 percent
between 30 and 70 percent. compared to conventional tools.

»
Gerd Neher, owner and managing director (right)
and Tobias Niess, development
NEHER GROUP

TECHNOLOGY E XCELLENCE 79
CUSTOMER STORY – NEHER GROUP

The two 5-axis LASERTEC PrecisionTool machines

can economically produce 1 µm sharp cutting
edges, defined cutting edge radii of
3, 6, 9, 12 or 15 µm and negative chamfers.

LASERTEC Precision Tool:

Precision cutting edge machining
The cutting segments of the tools are first
cut out of PCD or CVD blanks and are then
brazed on. The NEHER GROUP uses a
LASERTEC 20 FineCutting from DMG MORI
for cutting. “The laser penetrates through
blanks up to 3.8 mm thick,” says Tobias Niess.
The diamond tools get their final “finishing
touch” in the form of laser finish-ing. A
LASERTEC 20 PrecisionTool and a LASERTEC
The video for the 50 PrecisionTool from DMG MORI are used in
LASERTEC 50 PrecisionTool
can be found at: this case. The two 5-axis pre-cision laser
https://youtu.be/1dzmrlNjcJ4 machines can economically produce 1 µm
sharp cutting edges, defined cutting edge

LASERTEC 50 PrecisionTool

210 % FASTER AND 1 µm SHARP

56 % LOWER UNIT COSTS IN CUTTING EDGES
COMPARISON TO EDM!
radii of 3, 6, 9, 12 or 15 µm and also negative
+ Diamond tool laser finishing at up to 3.0 mm/min
chamfers. Thanks to High Speed Mode 3.0,
+ Individual cutting edge processing:
the laser can operate at speeds of up to
– < 1 μm sharp cutting edges
3.0 mm/min. The technology is therefore up
– 3, 6, 9, 12, 15 μm defined cutting edge radii
to 210 percent faster in comparison to spark
– negative chamfering
erosion (EDM) and unit costs are reduced by
+ The service life of the tools is increased by a factor of up to 2.5 using
56 percent. The service life of the tools is
laser processing
increased by a factor of 2.5 thanks to laser
processing.
PH 50 – PALLET HANDLING
+ Small footprint of just 2.7 m2
+ Modular system with different tool pallet configurations such as:
– 6 × tools ø 355 × 370 mm
– 22 × tools ø 90 × 440 mm

80 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – NEHER GROUP

The LASERTEC PrecisionTool machines operate automatically in The PCD and CVD cutting edges get their final “finishing touch” in the form
unmanned night shifts, e. g. with a PH 10 handling system for 54 HSK of laser finishing on a LASERTEC 20 PrecisionTool and a LASERTEC 50
tools on the LASERTEC 20 PrecisionTool. PrecisionTool from DMG MORI.

User-friendly software for ample, the LASERTEC 20 PrecisionTool has a DMG MORI across the entire process chain.”
programming cutting edges PH 10 handling system with space for up to 54 With a new DMU 200 Gantry for mold pro-
DMG MORI has implemented the industry HSK tools. The LASERTEC 50 PrecisionTool duction and a DMU 50 3rd Generation and
standard GTR as a programming solution is equipped with automation that can change a CLX 350 for the training workshop, it
for cutting edge machining, which allows the tools weighing up to 30 kg. “In this way, we emphasizes the good collaboration. He goes
importing of EDM projects and requires little can utilize both machines unmanned at night a step further: “We would like to organize our
training when you switch to laser processing. and at the weekend,” adds Tobias Niess. production so that it is paperless in future
Special software features also make it easier – with PLANNING & CONTROL from ISTOS.”
to program rotary and fixed tools, chip breaker Optimum solutions across
geometries and negative chamfers. the entire process chain
As far as Gerd Neher is concerned, the
Unmanned shifts thanks to integrated product portfolio of DMG MORI
automated laser processing is an important argument for long-term
The cutting edges are processed even more cooperation: “Tool manufacturing is an
economically thanks to the automation excellent example of how we have installed
solutions installed by DMG MORI. For ex- innovative manufacturing solutions from «

NEHER GROUP FACTS

+ Founded in Ostrach in 1990

+ 110 skilled workers
+ Development and manufacture
of PCD and CVD special tools for
applications in the automotive,
aerospace and mechanical engi-
neering sectors, among others

NEHER GROUP
Am Sägebach 6, 88356 Ostrach
Germany
The NEHER GROUP manufactures tool The PCD and CVD elements www.neher-group.com
bodies on machining centers and lathes of the tools are cut from blanks on
from DMG MORI. a LASERTEC 20 FineCutting.

TECHNOLOGY E XCELLENCE 81
CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG

LASERTEC –
ADDITIVE MANUFACTURING:
NOTHING IS
IMPOSSIBLE

82 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG

Image left: Laser deposition welding

and 5-axis machining in one clamping.
The LASERTEC 125 DED hybrid is
ideally suited to the repair of large
components.

An important pillar of success is LASERTEC 125 DED hybrid

innovative technologies such as COMBINED LASER

additive manufacturing. We rely DEPOSITION
on machines from DMG MORI to WELDING AND
ensure we can continue to write the 5-AXIS MILLING IN A
successful history of the company. SINGLE CLAMPING
Dr. Ing. Hartmut Frerichs
Managing Director HIGHLIGHTS
Wolfgang Doose Werkzeug- & Vorrichtungsbau GmbH & Co KG
+ Workpieces up to ø 1,250 × 745 mm
and 2,000 kg
+ Automatic changeover between
additive and milling operations in
a single setup
The history of Wolfgang Doose Werkzeug- & LASERTEC 125 DED hybrid, W. Doose makes
+ Complete hybrid CAD / CAM
Vorrichtungsbau GmbH & Co KG began in a full use of the possibilities offered by metal
process chain
garage in Henstedt-Ulzburg in 1999. With the 3D printing.
+ AM assistant: Adaptive process
goal of realizing solutions that are as precise
control, powder feed-rate sensor,
and customized as possible, the current According to Dr. Hartmut Frerichs, managing
AM Evaluator, AM Guard for the
30-strong team supplies customers in the director of W. Doose, the quote below left
highest quality and process safety
automotive, medical and other demanding by Hermann Hesse perfectly describes
industries. The dynamic development of the inspiration behind his team and the
W. Doose is illustrated by the modern, company. Dr. Frerichs took over from the
A video on the
fully air-conditioned production plant company founder, Wolfgang Doose, in 2016. LASERTEC 125 DED hybrid
comprising an area of 2,300 m2. It houses The company has a very customer-focused can be found at:
working style. “We take sufficient time to https://youtu.be/ruTo9hIYQGw

understand the customer’s problem as

best we can at the beginning of every job.”
TO ACHIEVE This understanding, combined with the
specialist’s many years of experience forms
THE POSSIBLE, the basis for a holistic and quality-conscious
WE MUST ATTEMPT approach. The range of services offered by
W. Doose includes traditional tool making as
THE IMPOSSIBLE well as prototype and small series production.
AGAIN AND What all orders have in common: “They are MAINTENANCE
Punching tool – up to
REPAIR
Die-cast core – 3 times
demanding projects that require both a high
AGAIN level of expertise and high-performance,
HRC 63 without heat
treatment
longer tool life by using
multi-material
innovative manufacturing technologies.”

18 CNC machines, including two turning cen- Acquisition of additive manufacturing

ters from DMG MORI. W. Doose carries out technologies
precision machining to an accuracy of up W. Doose retains its competitive edge
to 2 µm across the entire production chain. with regular investment in manufacturing
Its range of services was expanded in 2021 technologies. The best example is metal SPARE PARTS NEW PRODUCTION

to include additive manufacturing – again 3D printing. “We very often received orders Valve – minimal system Closed impeller – 10 %
downtime thanks to a higher performance
with technology from DMG MORI. With two where we had to rely on suppliers of additive 90 % reduction in thanks to new design
LASERTEC 30 DUAL SLM machines and a » lead time

TECHNOLOGY E XCELLENCE 83
CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG

LASERTEC 30 DUAL SLM Material changeover within two hours thanks to

the innovative rePLUG powder module, resulting
GENERATIVE in optimal flexibility.

MANUFACTURING
IN A POWDER
BED WITH A
300 × 300 × 350 mm W. Doose manufactures

BUILD VOLUME
light components such as
this robot gripper in the
LASERTEC 30 DUAL SLM
powder bed.
+ Highly complex components
with function integration
+ Internal conformal cooling
channels
+ Weight reduction due to topology
optimization, lattice and
manufacturing,” says Dr. Hartmut Frerichs, our processes perfectly,” says Dr. Hartmut
honeycomb structures
looking back. Over time, an in-house facility Frerichs. W. Doose now uses both a
+ Powerful DUAL-laser system
became increasingly interesting for W. Doose. LASERTEC 125 DED hybrid as well as two
(2 × 600 W)
LASERTEC 30 DUAL SLMs Thanks to its
+ rePLUG – the powder module for
“After market research in 2021, we made a hybrid functionality, the former really shows
automated powder management
decision to work together with DMG MORI.” its strengths especially when it comes to the
and fast material changeover
The good experience with the existing repair of tool components, says Jens Retzlaff,
< 2 hours
machine tools was just as decisive as the plant manager at W. Doose: “Worn areas can
+ Material-independent filtration
supplier's extensive portfolio in the area of be built up with the powder nozzle, which can
system with filter subscription
additive manufacturing. be combined with 5-axis milling in the same
for 3,000 h
setup, so that the original condition can be
High-quality repairs using laser restored.” This process is considerably less
deposition welding and 5-axis machining expensive and more precise than manual
in one clamping welding with subsequent machining. The
The video on the With products for the powder bed process service life of the repaired mold is also
LASERTEC 30 DUAL SLM and laser deposition welding, DMG MORI is increased 3-fold by the new process.
can be found at:
https://youtu.be/Ne9myMGpj9I considered to be a comprehensive provider
of additive manufacturing machines. “We
were able to integrate both technologies into

84 TECHNOLOGY E XCELLENCE
 CUSTOMER STORY – WOLFGANG DOOSE WERKZEUG- & VORRICHTUNGSBAU GMBH & CO KG

Less space requirements: LASERTEC 125 DED hybrid, 3D printing in a

two machines in one powder bed normally requires post-pro-
An additional advantage of the hybrid machine – cessing of the components. “This means
which is based on the monoBLOCK concept – that our CNC machines are a fixed part of the
is its versatility: “We also use the LASERTEC additive process chain. Nevertheless, we can
125 DED hybrid for machining large base often reduce post-processing to a minimum,
plates, for example.” This has a positive effect such as for drill holes and fits,” says Jens
on the production space required. Retzlaff explaining the process. Complex tool components, small series and individual
parts are produced in the LASERTEC 30 DUAL SLM
powder bed.
LASERTEC 30 DUAL SLM: Spare parts on demand by means of
productive small series manufacturing additive manufacturing
in a powder bed One other area where additive manufacturing
W. Doose uses the two LASERTEC 30 DUAL makes an important contribution at W. Doose
SLMs to achieve functionalities that would be is for manufacturing replacement parts. “We
impossible or difficult to implement using are able to faithfully reproduce the respec-
conventional machining. “This includes con- tive parts based on the component data – the
formal cooling channels in tools or light LASERTEC 30 DUAL SLM is ideal for small
component structures,” says Jens Retzlaff workpieces, while the larger ones fit on the WOLFGANG DOOSE FACTS
with reference to a delicate but nevertheless LASERTEC 125 DED hybrid,” Jens Retzlaff
+ Founded in Henstedt-Ulzburg
stable robot gripper. “Conventionally pro- describes the possibilities. If no data is avail-
in 1999
duced grippers are entire assemblies made able, the team uses a scan box that optically
+ 30 experienced engineers
up of many individual parts. These come measures the old part with high precision.
+ Production of tools, jigs,
out of the powder bed almost complete.” W.
prototypes and small series
Doose mainly processes tool steel powders, Investment in expertise and technology
+ Customized solutions for
but materials such as aluminum and titanium Innovative technologies such as additive
customers, including from
are also possible. “In this case we need to manufacturing as well as training and further
the automotive industry and
introduce argon instead of nitrogen as the education of skilled workers are important
medical sector
shielding gas.” The material changeover itself pillars of success at W. Doose. “We invest
takes less than two hours thanks to the inno- equally in both areas to ensure we can con-
vative rePLUG powder module and thus offers tinue the successful history of the company,”
optimal flexibility to enable the company to emphasizes Dr. Hartmut Frerichs. “After all,
react to different customer requests. we would like to continue in the future to
optimize quality, costs and productivity for
Complete process from the powder our customers.” Wolfgang Doose Werkzeug- &
Vorrichtungsbau GmbH & Co KG
bed to finish machining Tiedenkamp 19
Equipped with two 600-watt lasers, the 24558 Henstedt-Ulzburg
LASERTEC 30 DUAL SLM is extremely pro- Germany
www.wdoose.de
ductive when it comes to the deposition of
individual parts or small series. Unlike the «

The manufacture of conformal cooling channels

in moulds requires advanced technologies such as
additive manufacturing.

TECHNOLOGY E XCELLENCE 85
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