Integrity for automated mould making.LaserControl at Playmobil Find out more on this.

LaserControl at Playmobil.
As the firm approaches its 40th anniversary, some 2.6 billion Playmobil numbers currently inhabit the earth. Lots of new figures are released yearly, putting high needs on the in-house mould shop. To accomplish optimal effectiveness in unmanned, automated procedure, Playmobil’s countless machining centres have actually been making use of LaserControl determining systems of Blum-Novotest currently for 15 years.

” For Playmobil numbers, hundredths of a millimetre matter,” claims Attila Britting, head of Playmobil’s in-house mould store in Zirndorf near Nuremberg. “The aim in building the shot moulds is to generate finished plastic products that need basically no rework– which is essential because an everyday manufacturing of approximately 10 million private parts as well as over 100 million figures a year. Consequently, the mould separation should additionally be a high-precision procedure, so that there are none burrs on the private components or the finished number.”

And not the very least, the moulds are defined for exceptionally high volumes, production runs of 200,000 to 300,000 pieces from one mould are no rarity. The called for productivity can just be attained by partially automated production together with the typical two-shift operation. So an array of devices works overnight on ready tasks. To perform these work, several of the machining centres are outfitted with pallet changers and also device publications with the capability to hold as lots of as 120 tools. The makers even keep running unmanned over the weekend. 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 shop
BLUM laser gauging systems assist geobra Brandstätter to generate injection-moulding tools successfully and in top quality
After every tool modification, the laser automatically measures the size and span of the device before machining, as well as after machining look for breakage and also wear. Thus, our skilled workers no more need to pre-set the device in the pre-setting device. A new tool is merely shrink-fitted right into the holder as well as gauged at machining rate after fitting. This makes certain that the tool data in the machine is proper, mathematical mistakes or information analysis blunders can no more take place. Further attributes include high-speed automated settlement for the thermal growth of the entire device and also for pin variation. Wrong device information can have pricey effects such as faulty tools, rejects, or device deduction. A spindle harmed by an accident will set you back at the very least 18,000 Euros to replace.

Without a tracking system to identify worn or damaged tools, automated manufacturing is hardly possible. The LaserControl system’s breakage screen makes certain that busted tool discovery runs immediately after every machining step. Depending upon the programs, the machining centre can after that either trade the tool for a twin or alert the on-call solution staff, who can log in to the machine over the Internet and keep an eye on the workshop via a webcam. At Playmobil, as several as 4 of the trick devices are kept in the tool changer, which means that the automated over night work run extremely accurately.

We primarily utilize steel with a high chromium web content because it reveals the least wear during the huge volume production large. It does trigger significant tool wear during cutting, however. That is why it is extremely crucial to keep an eye on the running times of the private tools. The BLUM laser measuring systems do this extremely well.

Blum-Novotest enables the several injection mould to be produced in ultimate quality.
In the manufacture of highly complex injection-moulded tools, hundredths of a millimetre count: All solitary components are exactly matched per other.
High-precision dimension in a dirty environment postures a major difficulty, and air conditioning is important to the production process. To safeguard the optical system from being stained, the determining system is mechanically sealed off from the coolant by a pneumatically operated shutter piston during machining. The rotating device is also cleaned with pressed air prior to determining in order to make certain that the dimension is not harmed by swarf, dirt or cooling lubricants. During measurement, a stream of barrier air provides protection versus staining.

The LaserControl systems have actually really been their cash’s worth at Playmobil. The systems are virtually maintenance cost-free; and, after greater than ten years in continual operation, the seals resemble brand-new. Most importantly, nonetheless, the professionals have never been pulled down by the laser systems as well as have actually experienced only advantages in terms of solution, as well. “We have actually had only good experience with BLUM lasers– as well as we save working time because there is no requirement for pre-setting”, Marco Mendl, group leader CAD/CAM/NC, summarises. “The precision of the LaserControl systems is amazing, as well. Based upon 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 certainly not be possible.”

Based in Zirndorf near Nuremberg in the Franconia region of southern Germany, geobra Brandstätter GmbH & Co. KG is the producer of Playmobil, and as such Germany’s biggest toy supplier. The Brandstätter Team runs production facilities in Germany, Malta, Spain and the Czech Republic. It utilizes greater than 3,700 people worldwide, and also in 2012 created total sales of 591 million Euro. At the heart of the multi-award-winning toy idea are the 7.5 centimetre tall Playmobil figures, which are marketed in over 30 historic and modern themed collection to more than 80 nations around the globe. Approaching their 40th anniversary, there are currently some 2.6 billion Playmobil figures populating the earth. Alongside costs toy high quality ‘Made in Europe’, given that the year 2000 the innovative company has actually also been producing LECHUZA high-grade plastic planters.