MEASURABLE PROCESS IMPROVEMENT THROUGH DIGITAL COOLANT MANAGEMENT
Metzler Fertigungstechnik in Feldkirch, Austria, is recognised as a genuine high-tech forge in the supplier industry. State-of-the-art machines are used to machine workpieces made of aluminium, steel and plastic, which few others can match in terms of technology or price. The company always utilises the latest technologies. With the first installation of the FLUIDLYNX CONTROL system from Swiss coolant expert MOTOREX, the company has taken a further step towards paperless, fully automated production.
As a family business with eight highly specialised employees, Metzler manufactures for demanding customers in the aerospace, automotive, electronics, laser and measurement technology, machine and fixture construction and wind power plant sectors. Metzler offers its customers complete solutions, from product development consulting, pre-assembly or partial assembly to surface treatment or finishing. The company specialises in machining complex geometries, which are produced as prototypes or in small batches. To ensure the highest quality with short throughput times and reasonable costs, Metzler has invested in state-of-the-art machinery from the outset and is constantly on the lookout for process improvements. After programming, machine loading and unloading processes and tool measurement and management had all been largely automated, Florian Metzler and production manager Lukas Kessler saw huge potential in coolant management.
Coolants are crucial in metalworking but are often underestimated as a cost factor. They consist of water and a special concentrate and reduce friction, lower the temperature at the cutting edge and remove chips. The right coolant improves surface quality, extends tool life, ensures higher quality and process stability and reduces costs. However, it must always be balanced and have a constant, defined pH value. If the concentration is too high, coolant consumption increases, foam is formed, and there is a risk of skin problems. If the concentration is too low, odours, bacteria and fungi develop and wear on the machine and tools increases. Corrosion problems can also lead to machine damage.
WORKLOAD DRASTICALLY REDUCED
A production island at Metzler is equipped with two interlinked Georg Fischer 5-axis milling centres, a 5-axis milling centre with a 7-part pallet changer and a 3-axis milling centre from Georg Fischer. These high-performance machines operate almost around the clock and produce huge quantities of chips. This meant that the machine operators had to conduct tests at short intervals to ensure that the concentration and pH values of the coolant in the machines were within the defined limits. They then had to refill water or concentrate as required. This took around an hour on average, making it very time-consuming and, like any human activity, a potential source of error. If too much concentrate was added, the coolant consumption increased, and more wastewater had to be disposed of. If too much water was added, the machine lost its thermal equilibrium, which led to a loss of quality. Manual documentation was at least as tedious. Every measure had to be recorded and filed in lists and Excel spreadsheets. This was unacceptable for a company that had committed itself to automated production, so Florian Metzler started looking for a sustainable alternative. Thanks to decades of excellent cooperation with Motorex, the Swiss technology leader in coolant management, he was confident enough to be the first to test the new FLUIDLYNX CONTROL system in Austria.
AN IMPORTANT BUILDING BLOCK FOR DIGITAL MANUFACTURING
FLUIDLYNX CONTROL from MOTOREX is the first smart, fully automatic measuring, mixing and dosing system for coolants. Up to 16 machines with a total volume of 100,000 litres can be connected. As a first step, four machines were connected at the Metzler site. This was done quite simply during ongoing operations. The system only requires a standard power connection and a water supply line. The machining centres were connected via hoses.
FLUIDLYNX CONTROL measures the concentration, water temperature, conductivity, pH value and fill level and independently controls compliance with the defined values. A redundant measuring system with three sensors ensures optimum dosing with a plus/minus 0.3 per cent tolerance. The automatic adjustment increases process security, efficiency, availability, productivity and quality. The uniform concentration and constant fill level can save up to 15 per cent of coolant concentrate. The system also features the best mixing process on the market, with an average droplet distribution of less than 80 nm. The finely dispersed emulsion positively influences the foaming behaviour, runs off the chips more easily and has a lower bio-susceptibility and a longer service life.
SEAMLESS SURVEILLANCE AND TOTAL TRANSPARENCY
FLUIDLYNX CONTROL monitors all processes and machines in real time, synchronises and analyses the data, regulates and controls itself on this basis and documents every step in a log. A central dashboard in the hall displays the current concentrations and pH values of the coolant for each machine in the factory. In addition, each machine has its own controller that clearly visualises its efficiency. The consumption of water and concentrate is recorded and displayed for each machine.
What is interesting in this context is that the concentration can be set individually for each machine, and two different concentrates are possible. The system and all machines are fully networked. Florian Metzler and Lukas Kessler can see the status of each machine on the central dashboard but can also display the data on their computer or mobile phone. Lists and tables on paper are now a thing of the past. This intelligent process monitoring avoids rejects and, therefore, wasted resources. At the same time, predictive maintenance solutions can boost the longevity of their machines. Another plus point in favour of using FLUIDLYNX CONTROL: The system has noticeably improved the working conditions for Metzler’s employees. They no longer have to worry about the quality of the coolant and can focus on the essentials. FLUIDLYNX CONTROL from MOTOREX is absolutely low-maintenance and works extremely reliably. The system passed the practical test in rugged everyday use with flying colours, once again convincing Metzler of MOTOREX’s expertise and commitment.
More about MOTOREX FLUID MANAGEMENT.