Reliability for automated mould making.LaserControl at Playmobil Learn more on this.

LaserControl at Playmobil.
As the business approaches its 40th anniversary, some 2.6 billion Playmobil numbers presently occupy the earth. Lots of brand-new numbers are released each year, placing high needs on the in-house mould shop. To attain maximum efficiency in unmanned, computerized operation, Playmobil’s numerous machining centres have been utilizing LaserControl gauging systems of Blum-Novotest already for 15 years.

” For Playmobil figures, hundredths of a millimetre count,” says Attila Britting, head of Playmobil’s internal mould shop in Zirndorf near Nuremberg. “The purpose in building the injection moulds is to produce finished plastic products that require basically no rework– which is vital because a daily production of roughly 10 million specific parts and over 100 million numbers a year. As a result, the mould separation must additionally be a high-precision procedure, to make sure that there are none burrs on the specific parts or the finished figure.”

As well as not the very least, the moulds are defined for incredibly high quantities, manufacturing runs of 200,000 to 300,000 pieces from one mould are no rarity. The needed performance can just be attained by partially automated manufacturing along with the regular two-shift procedure. So a selection of makers functions overnight on ready jobs. To perform these jobs, several of the machining centres are furnished with pallet changers as well as tool magazines with the ability to hold as lots of as 120 devices. The equipments also keep running unmanned over the weekend break. The Blum-Novotest systems are set up in the machining area of the automated DMG five-axis machining centres.

BLUM laser determining system in the Playmobil mould-making store
BLUM laser determining systems help geobra Brandstätter to create injection-moulding devices successfully and also in top quality
After every device adjustment, the laser instantly gauges the size and also radius of the tool before machining, as well as after machining checks for breakage and also wear. Thus, our skilled workers no longer have to pre-set the device in the pre-setting gadget. A brand-new device is just shrink-fitted into the owner and also gauged at machining rate after suitable. This makes certain that the tool data in the device is appropriate, numerical mistakes or data reading errors can no more occur. More functions consist of high-speed automatic settlement for the thermal development of the entire device and also for spindle variation. Inaccurate tool information can have pricey repercussions such as malfunctioning tools, turns down, or machine deduction. A pin harmed by an accident will cost at the very least 18,000 Euros to change.

Without a surveillance system to discover used or damaged devices, automated production is hardly possible. The LaserControl system’s damage monitor makes certain that broken tool discovery runs right away after every machining action. Relying on the programs, the machining centre can after that either trade the device for a twin or notify the on-call solution team, that can log in to the equipment over the Internet and also monitor the workshop through a cam. At Playmobil, as many as 4 of the key tools are held in the device changer, which suggests that the automated overnight tasks run extremely reliably.

We mostly utilize steel with a high chromium material since it shows the least wear during the big volume manufacturing huge. It does cause significant tool wear throughout reducing, however. That is why it is very crucial to keep an eye on the running times of the specific devices. The BLUM laser gauging systems do this effectively.

Blum-Novotest allows the several shot mould to be created in superior quality.
In the manufacture of extremely complex injection-moulded tools, hundredths of a millimetre count: All solitary parts are exactly matched to every various other.
High-precision dimension in a dirty environment poses a major challenge, and also air conditioning is necessary to the manufacturing procedure. To safeguard the optical system from being stained, the gauging system is mechanically sealed from the coolant by a pneumatically run shutter piston during machining. The turning tool is likewise cleansed with compressed air before gauging in order to guarantee that the dimension is not impaired by swarf, dirt or cooling down lubricating substances. Throughout dimension, a stream of obstacle air gives protection against staining.

The LaserControl systems have truly been their cash’s worth at Playmobil. The systems are practically maintenance complimentary; and, after more than ten years in continuous operation, the seals resemble brand-new. Most importantly, however, the experts have never been let down by the laser systems and have experienced only advantages in regards to service, as well. “We have actually had just good experience with BLUM lasers– as well as we save functioning time since there is no demand for pre-setting”, Marco Mendl, group leader CAD/CAM/NC, sums up. “The precision of the LaserControl systems is astounding, as well. Based on our experience, its repeatability is within less than 2 thousandths of a millimetre. As well as for us, one thing is for sure: Without the BLUM laser systems, this degree of automation would not be feasible.”

Based in Zirndorf near Nuremberg in the Franconia region of southerly Germany, geobra Brandstätter GmbH & Co. KG is the supplier of Playmobil, and also as such Germany’s biggest plaything producer. The Brandstätter Team operates manufacturing facilities in Germany, Malta, Spain as well as the Czech Republic. It utilizes more than 3,700 individuals worldwide, as well as in 2012 created overall sales of 591 million Euro. At the heart of the multi-award-winning toy idea are the 7.5 centimetre tall Playmobil numbers, which are marketed in over 30 historical and also modern-day themed collection to more than 80 nations all over the world. Approaching their 40th anniversary, there are currently some 2.6 billion Playmobil numbers inhabiting the planet. Alongside premium toy high quality ‘Made in Europe’, since the year 2000 the innovative organization has actually likewise been manufacturing LECHUZA high-grade plastic planters.