【夹具故事】“偷心城”里的小投入，大效应

两家德国制造企业和一个高效夹具之间的故事。...



德国工业化起步虽晚，发展却迅速，工业化和机械制造水平早已居世界领先地位，到如今“德国制造”仍是世界顶级的代名词。德国制造企业究竟有多厉害？产品有多先进？本期创新案例是关于两家德国制造企业和一个高效夹具之间的故事。接着几期会有一系列德国制造企业和夹具的精彩内容。为求资料真实准确，部分内容我们将以英文原文呈现，如需中文译文，请微信留言索取哦~在德国奥登林山（欧洲硅谷、偷心城市、德国最美大学城——海德堡所在地）的布亨，坐落着自动化技术翘楚韦斯公司（Weiss GmbH）面积为22,000 m²的生产基地。韦斯公司自1967年起开始专注于自动化技术部件的开发和生产，是自动化方案的领衔企业之一。其用户主要来源于专用机械和工具、汽车和汽车零部件、医疗技术和机床等行业。

韦斯使用自有机床制造出各种尺寸的传输凸轮，只有不断提高制造效率才会满足日益增加的需求。韦斯的工具管理主任舒斯特说：必须缩短设定和闲置时间，且要优化精准度，缩短加工时间以降低整体时间。

为与“小投入，大效应”的口号保持一致步调，韦斯提供了8个经过验证的采用高效夹具提高机床切削加工效率的方案。其中在使用位于马尔巴赫（德国著名诗人、剧作家席勒的故乡，到处都是葡萄园和果园）的瀚柏格公司的创新型夹具设备后，公司能够大幅度缩短设定和闲置时间，同时明显地提高了精准度和可靠性。Looking for new clamping device solutions at EMO Hannover, Schuster came into contact with Hainbuch, the Marbach-based clamping device manufacturer. Apparently, this initial contact at the exhibition was promising right from the start.

Within a short time it resulted in a “large retrofi tting project. The upgrading of eight older machine tools through high-precision clamping devices with high repeatability and high holding forces, with short set-up.韦斯和瀚柏格的相遇起源于2013年的汉诺威工具机展。瀚柏格是拥有60多年历史的老牌专业夹具设备制造商，不断地开发新的夹持解决方案，致力于节省安装时间及成本、灵活性、生产力、能源效率及安全。展会上的初次接触在一开始就带来希望，短时间内就带来了大型改造项目，通过使用具有高重复性、高夹持力、高精准度的夹具设备，韦斯公司的八台旧机床具有简短的设定时间，其性能得到提升。Together with Hainbuch Regional Sales Manager, Joerg Tittel, the existing clamping situation–conventional 3-jaw chucks–was promptly analyzed and appropriate solutions were found. The result–special customized clamping devices for the eight machines. Complete conversion was accomplished a little under one year after the initial contact at EMO Hannover 2013.

For the smaller machines the main effect was not so much the shorter clamping set-up time, rather it was having“for the first time, the possibility of using new tools from Mitsubishi Materials (MMC) due to the high holding forces of the chucks”.

On the other hand, the most significant factor for the large machines was the significantly shorter set-up times. Thus, the complete package of innovative clamping devices and a more effective quick change-over fixture paid for itself within a very short period of time. The Toplus clamping system ensures precision and high holding forces.The Centrotex quick change-over system ensures quick change-over of the various components.韦斯公司将瀚柏格区域销售经理约尔格蒂特尔提供的夹紧方案——传统式３爪夹具进行快速分析，并找到恰当的解决方案，制造出专为八台机器定制的夹具设备，在汉诺斯工具机展初次接触后的第二年里完成了一个小小的转变。回顾舒斯特的陈述：我们能立马从这个转变中获得好处。



The large transport cams are soft machined with indexable insert tools. Here as well, the high holding forces, the stability, and the precision of the chucks enable optimal metal removal rates. Viktor Gruslak, Acting Department Manager responsible for cam milling states:“With the old fi xtures we had set-up times of between two and three hours for a complete conversion. Now we calculate ten to thirty minutes.

“We still have to align the tailstock. Replacing the Hainbuch chucks takes only fi ve to ten minutes–even for the large ones.”Asked whether clamping device providers other than Hainbuch were contacted, Schuster responds:”At that time we were extremely thorough in looking over the off ering at EMO Hannover 2013, but the Hainbuch solution was the solution that was best suited for our parts.” The trials, which were subsequently run with Tittel,”confirmed our decision lock, stock, and barrel”.

On his first walk-through of the manufacturing facility, Hainbuch Regional Sales Manager Tittel, “immediately recognized the potential–and was able to reinforce his recommendations in the practical trial. When a 3-jaw chuck is converted to the Hainbuch system, at first this is unusual for some operators.

“Often you do not trust yourself to increase feeds and other metal removal rates to the levels that the new clamping device allows.” An operator is indeed limited by the system pressure of the clamping hydraulics, but even when testing the limits, “the clamping device still had more to offer”.大型运输凸轮软使用可转位工具进行加工。在这里，夹头的高夹持力、稳定性和精准度能够得到最佳金属去除率。负责凸轮铣削的代理部部长维克托·Gruslak表明：使用就装置我们需要2-3小时的设定时间来完成转换，现在只需要计算10-30分钟。

The clamping technology expert had already run his trials “with tools from all well-known manufacturers and could thus give the user a tip–and for hard milling the Mitsubishi tools are simply some of the best on the market”. However, in the normal case the customer would make the selection.

The benefit for the user is the high machining capacity, the precision, and the process reliability: “For milling with interrupted cut in particular, our clamping technology offers a high degree of rigidity and vibration dampening, through the hybrid chuck used, a steel body with a mineral cast insert.”夹紧技术专家已使用所有知名制造商的工具展开试验，因此能够给用户一个建议：对于硬铣削，三菱工具仅仅是市场上最佳工具中的一个。对用户来说，其好处是高水平加工能力，精准，可靠。特别是对于断续切削加工，通过使用插有矿物铸件的钢制混合动力卡盘，三菱夹紧技术提供了高度刚性和减振性。‍‍‍‍‍‍‍

舒斯特总结了一年多的工作经验：“只能与可靠的合作者执行这类项目。” 对于用户韦斯来说，唯一的影响就是适应和整合控制器中的夹具液压，以便靠液压进行夹紧和松开。对于舒斯特来说，与瀚柏格合作的这个项目是与小投入、大效应一致的成功案例。

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