Projekt_MAN Crank Case

7/30/2019 Projekt_MAN Crank Case

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M AN N uremberg , Germany

6 -cylinder crankcasemanufacturing system.

Customer Report


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Customer Report M AN N uremberg , Germany

The D20 project.The new heart of the TGA.

Nuremberg,

Summer 2000

After four years of development,

MAN engineers have completed the

prototype of a new generation of

6 -cylinder diesel engines. The inno-

vative project is called D20.


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6 -Cylinder Crankcase Pr oduction Line

Increasing demands on performance and fuel con-

sumption and stricter emission controls require manu-

facturers of commercial vehicles to draw on innovative

technologies. The R&D division at MAN broke new

ground with the development of the latest generation

of TGA engines. Expectations of the D20 project are

high: more power and longer intervals between

maintenance, at the same time reduction of weight,

fuel consumption, pollutant and noise emissions. For

the first time a vermicular graphite casting (GJV 450)

was used as material for the crankcase. In addition to

product and process development the project required

a state-of-the-art production system.

Phase 1:Specificat ions


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Innovat ion through co-operat ion:

engineering par t nership providesaddit ional t ime and cost advant ages.

Nrtingen,

October 2000

HELLER received the assignment

to develop a detailed process layout

for the D20 crankcase. Close co-

operation had a positive influence

on the development process.


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It is necessary to ever excel in product and process

technology to remain the innovative leader in a field. To

keep the innovative edge, MAN and HELLER project

teams started to work together early in the prototype

phase. HELLER design engineers contributed extensive

product and process know-how and the MAN team

added in-depth knowledge of the product. Because of

the close collaborat ion and simultaneous engineering

the time until start of serial production was reduced by

several months and a number of innovative ideas could

be incorporated in the development process. A system

partnership was forged that opened up innovation

potential and assured MAN a competitive lead.

Phase 2:Engineering


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HELLER system solutions ensure a maximum level of

dependability and planning reliability. Experienced pro-

ject engineers will answer any of your quest ions through-

out all phases of a new project, from the preparation

of the performance specification to the development of

an optimum process chain, including system layout,

successful commissioning of the system and achieving

production t argets.

However, HELLERs co-operation is not restricted to

the layout of the production technology. HELLER also

supports the customer in questions of production-

friendly workpiece design, material flow, design of

clamping fixtures or material handling between the

operations. Today, simultaneous engineering involves

computer-based modeling of the complete process

from raw to finished part. This has the advantage that

modifications can be quickly and easily integrated into

the ongoing development process. As a result, the

development period to the actual start of production

can be significantly shortened an important factor

when time is money.

HELLER makes sure customers are kept up-to-date

with the latest trends in production technology so they

can concentrate on their production. Partnership with

HELLER guarantees customers innovation ability for a

lasting competitive edge on the world market.

Process technology made to measure:syst em part nership wit h HELLER unlocks

innovat ion pot ent ial.


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Nrtingen,

January 2001

On the computer 20 different layout

versions are modeled, based on avail-

able space and planned production.

A short way from model to reality:computer -aided layout design speeds up

decision-making process.17 16 15 14 13 12 11 10 9


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Integrating a system into an existing structure is

subject to different requirements than building a new

facility. The MAN plant in Nuremberg had several areas

within the facility available for the production of the

D20 crankcase. In a shor t time, HELLER's layout

experts were able to submit alternative layouts to MAN

by using efficient CAD systems. Special software tools

determined the required machine capacity based on

planned production volume. In this process, various

combinations and automation options of special and

serial machines are considered as well as alternative

manufacturing concepts using various machine types.

The ideal solution for MAN was a combination of 18

machining centers of the model range MCH 400 and

4 FST (Flexible System Transfer Lines) and single

machines from other suppliers.

Phase 3:Layout planning

8 7 6 5 4 3 2 1


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Nuremberg,

September 2002

Modular building blocks for the D20

project are beginning to take shapein HELLERs final assembly shop. All

system components of the manu-

facturing line successfully pass the

required acceptance tests a pre-

requisite to meet the high expectations.


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Detailed planning of each process step during the deve-

lopment phase resulted in time savings that benefited

machine configurations and process trial runs. In case

of the D20 crankcase, installation of three machining

centers with three clamping positions was sufficient to

test run the NC programs and to verify the required

process capability. The remaining fifteen MCH 400

machining centers were shipped to MAN after geome-

trical acceptance. Because of this positive experience,

MAN released the transfer systems for shipment after

they had passed the function tests and trial machining.

Fine adjustment for maximum process capability, a very

time consuming process, was completed at the MAN

facility.

The extensive machining competence of the project

engineers contributed to saving time on the project.

At the Nuertingen plant, HELLER is able to machine

prototypes required by MAN for t rial tests before

commissioning of the manufacturing system. For this

purpose, the machining content of the special-purpose

machines (FST) was transferred to a machining center.

Phase 4:M achine configurat ion


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Nuremberg,

January 2003

HELLER installs the first machines

in the former turbine building. Five

months later pilot production star ted.

One hundred and fifty units will be

manufactured by the end of the year.


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The hybrid production system applied to the MAN

project assures efficient installation of each machine

and fast commissioning of the complete system. It is

based on HELLER's highly modular system components,

characterized by standard basic machines and flexible

assemblies. This is the reason that HELLER manufactur-

ing systems can easily be extended without major invest-

ments. If an increase in production volume creates a

bottleneck in a production area, HELLER can easily solve

the problem with alternatives from its modular range.

In addition to twin-spindle machines and turret head

solutions, dynamic packages are available for enhancing

the performance of existing machines.

Phase 5:Commissioning


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Two steps to full performance:integrated process measuringguarant ees highest qualit y.

Nuremberg,

April 2004

The new MAN manufacturing

system goes into production. It is

planned to increase production from

14,0 00 cases in 2004 to 55,000

units in 2007.


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It was planned to ramp up production at MAN in two

steps. In the first step, the system had been laid out

for a production of 30,000 units. In the second step,

production was gradually raised to the required

55,000 units.

To achieve this goal, only the capacity of the machining

centers for the intermediate operations had to be

increased. Due to their high flexibility, the transfer

systems are scalable according to requirement. To

ensure maximum reliability of the system in high-

volume production, finish-machining is performed using

in-process gauging. Integration of the measuring tech-

nology into the final step of the process chain allows

to compensate for any wear effects that may occur

during pre-machining and to ensure consistent part

quality in batch manufacturing.

Phase 6:Start of production


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Nuremberg,

June 2005

The D20 project moves full speed

ahead, all sales forecasts have been

exceeded. MAN decides to implement

step 2 earlier than planned.

The product

The outcome of the par tner ship between HELLER and

MAN was remarkable. The new D20 engine generation

surpassed all expectations and the projected sales

volume was already exceeded in the first year. This

comes as no surprise considering the improvements

made on the engine: a 25 % reduction in engine

components and a weight reduction of 100 kg are a

quantum leap in heavy engine design. Significantly

reduced pollutant emissions ensure that all existing and

future exhaust emission standards are met. To ensure

this, the engine is equipped with common-rail techno-

logy, exhaust gas recirculation and a special mainten-

ance-free filter. As a result, maintenance intervals were

extended to 120,000 km and fuel consumption was

cut by more than 5 percent.


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HELLER a r eliable par t ner forbest results.

The manufacturing system

4 Flexible System-Transfer lines (FST) with

4 6 single and double machining stations each

18 machining centers MCH 400 with direct loading

1 stand-alone FST

Washers, Alfing cracking system

Lift-and-carry-system for automation of FST

GSA overhead gantry loaders for automationof the MCH 400 machining centers

The process chain

Step 1 (1 st and 2 nd FST): pre-machining of

cylinder head and oil pan face, pre-machining of

cylinder bore, deep hole drilling and pre-machining

of crankshaft bore

Step 2 (MCH): milling (using angular milling head),

deep hole drilling, multispindle machining

Step 3 : intermediate washer

Step 4 : cracking of crankshaft bearings, machining

of oil holes in 3 rd FST with integrated head changerand TBT gun drilling unit.

Step 5 (4 th FST): finish m achining of crankshaft

bore and thrust bearing, machining of front faces,

machining of cylinder bore (2 spindles), milling of

cylinder head joint faces

Step 6 : deburr ing/ assembly

Step 7 : washing

Step 8 : final inspection


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Development and implementation of the manufacturing

line for the machining of the D20 crankcase was only

one aspect of the successful system partnership

between Gebr. HELLER Maschinenfabr ik GmbH and

MAN Nutzfahrzeuge AG in Nuremberg. HELLER also

took on overall responsibility for the planning and

commissioning of manufacturing lines for further key

components of the 6-cylinder engine generation.

Meanwhile, the complete machining of the cylinder

head is performed on HELLER machines. The manu-

facturing line comprises ten machining centers model

MCP-H 400, four HCS 400 head changers and a

flexible transfer system. The latest generation of

HELLERs internal milling machines is employed for

crankshaft machining. The machines of the RFK 400

(300) range provide excellent quality in the machining

of mains and pins.

MAN was more than satisfied with the outcome of the

partnership with HELLER. On 12 May 2005, CEO

Berndt Heller and HELLERs director of sales and

engineering, Manfred Maier, received the prestigious

Trucknology Supplier 2004 award in Munich. The

prize is subject to a strict selection procedure and is

awarded to the ten best of the 1000 MAN suppliers.

The success of the D20 project once more underlines

HELLERs outstanding position as supplier for the truck

powertrain production.

HELLER syst em solut ions:a long line of success.


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www.heller -machinetools.com

We are here for you.

Investments in manufacturing need results that are guaranteed.

HELLER as your partner offers these guarantees with arange of innovative, product oriented machines and machining

centers, with project and process competence, and with fast

responding, qualified service teams. More detailed information

on products and services is available at the following locations

or on the internet.

The Power of Progress

Subjecttoalteration.

MAN

Nuremberg/GB-08/05

FranceHELLER M achines Outils5, rue Saarinen Silic 128

94523 Rungis CedexTl. +33 1.46 .87.34 .52 Fax +33 1.45.6 0.54.8 4E-Mail: [email protected]

ItaliaHELLER It alia M acchine Utensili S.r.l.Via Leonardo Da Vinci, 537029 San Pietro in Cariano (Verona)

Tel. +39 45 6 83 8-231 Fax +39 45 68 38 -23 4E-Mail: [email protected]

UKHELLER M achine Tools Lt d.Acanthus Road Ravensbank Business ParkRedditch, Worcs. B98 9EXTel. +44 1 21 275 -330 0 Fax +44 12 1 2 75-3380

E-Mail: [email protected]

USAHELLER M achine Tools L.P.12 25 Equity Drive Troy, M ichigan 48 08 4Tel. +1 248 2 88 -50 00 Fax +1 24 8 28 8-9560E-Mail: [email protected]

M exicoHELLER M achine Tools de M exicoS. de R.L. de C.V.Cortazar No. 102 Col. HidalgoC.P. 37 32 9 Leon, Gto.Tel. +1 248 2 88 -50 00 Fax +1 248 28 8-9560E-Mail: [email protected]

BrasilHELLER M quinas Operat rizesIndstria e Comrcio Ltda.Rua Joaquim Machado, 250Bairro AparecidinhaCaixa Postal 12618 08 7-280 Sorocaba So PauloTel. +55 15 3 23 5-1360 Fax +55 15 32 35 -13 04E-Mail: [email protected]

ChinaHELLER M achinery & Trading(Shanghai) Co., Ltd.Rm. 4402-4403, Shanghai Maxdo CentreNo. 8 Xing Yi Road, HongQiao Development ZoneShanghai 200336Tel. +86 21 5 208 048 5 Fax +86 21 5 208 049 5E-Mail: [email protected]. cn

DeutschlandGebr. HELLER M aschinenfabrik GmbHNeuffener Strasse 54 72622 Nrtingen

Postfach 14 28 72 60 4 NrtingenTel. +49 70 22 77 -0 Fax +49 70 22 77 -61 0E-Mail: [email protected]

HELLER WerkzeugmaschinenHattingen GmbHHttenstrasse 45 4 55 27 HattingenTel. +49 23 24 9 24 5-0 Fax +49 23 24 9 24 5-99

E-Mail: [email protected]

HELLER Wer kzeugmaschinen GmbHChemnit zSandstrasse 116 09114 ChemnitzTel. +49 3 71 330 0-790 Fax +49 37 1 3 300 -791E-Mail: [email protected]

HELLER Wer kzeugmaschinen GmbHNeufrachAm Riedweg 16 88682 Salem-NeufrachTel. +49 7 553 827 28-0 Fax +49 755 3 8 272 8-61E-Mail: [email protected]

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Projekt_MAN Crank Case