![](\"https:\/\/sw-machines.com\/wp-content\/uploads\/2020\/03\/sw-unternehmen-pressebeitrag-hoechste-qualitaet.jpg\" "\\"sw-unternehmen-pressebeitrag-hoechste-qualitaet\\"")
<\/span><\/div><\/div><\/div><\/div><\/div>Fagor Ederlan Group is an automotive supplier that produces double clutch workpieces for vehicles on SW machining centers<\/h2>\n
Since June 2017, the Spanish automotive supplier Fagor Ederlan S. Coop. Dual clutch transmission and clutch housings manufactured for installation in vehicles. To meet the particularly high quality requirements for the workpieces, the manufacturer has purchased high-precision machining centers from Schw\u00e4bische Werkzeugmaschinen GmbH (SW) for their processing. The company specializes in sophisticated, workpiece-specific manufacturing systems for metalworking. The two-spindle BA W06-22 used are characterized not only by particularly precise machining, but also by extremely short cycle times. This is ensured, among other things, by linear motors in the feed axes, which achieve speeds of 100 m\/min and accelerations of up to 22 m\/s\u00b2, as well as the horizontally arranged synchronous motor spindles. To ensure the highest possible productivity and reduce downtime, Fagor Ederlan uses SW’s Remote Service. This enables remote diagnosis and online troubleshooting by SW service technicians if necessary. The plants are also already equipped for SW life data services for individual condition monitoring in real time. Fagor Ederlan is currently examining the use of these services as part of the introduction of Industry 4.0.<\/strong><\/p>\n For the production of dual clutch transmission housings, Fagor Ederlan needed the appropriate machining centers to be able to produce the required delivery quantities. “Our in-house team responsible for defining the Machining Industrial Model (MIMEK) had previously identified BA W06 SW machines as the most suitable BAZs for machining aluminum powertrain and suspension parts,” explains Inaki Duandikoetxea, Purchasing Manager at Fagor.”<\/p>\n “The main challenge in machining metal parts is to produce the required quality of the component in the shortest possible cycle time,” explains Matthias Dreher, Key Account and Regional Sales Manager at SW. “The advantage of the two-spindle SW machines here is that two parts can be machined in parallel in one work cycle. The quality requirements for transmission and clutch housings are very high,” explains Dreher. As part of a feasibility analysis, SW therefore checked in advance whether the workpieces could be manufactured in two-spindle operation and, above all, within the required tolerances. Analysis of the machining process showed that the two-spindle W06 actually more than met Fagor Ederlan’s accuracy and quality requirements. After a calculation, it was also possible to keep to the cycle time per cycle and thus realize the best possible cost per part.<\/p>\n The special basic concept underlying the BA W06-22 selected for the application at Fagor Ederlan makes a major contribution to this: The machining center, which has two horizontal work spindles with low ramp-up time and high acceleration of the feed axes, is basically designed for 4- and 5-axis machining of light metal workpieces. The monoblock as a supporting machine bed minimizes deflection and ensures optimum force flow between the workpiece and the mold.<\/p>\n To enable the high accelerations of the processing unit with a minimum machine footprint of 19.87 m\u00b2, the monoblock is designed as a steel structure. “The monoblock design was very interesting for Fagor Ederlan, as it ensures uniform temperature stability and also makes transport and installation on site extremely easy thanks to a crane hook solution,” Duandikoetxea explains the advantages of the design. In addition to this, the machining unit has been designed in a “box-in-box” design, which ensures high rigidity with low weight. The entire machining unit is inserted into the monoblock at the rear and the machine room with the freely accessible components is protected from flying chips from the work area by a combination of steel and textile covers.<\/p>\n By using linear motors in the X, Y, and Z feed axes, the BA W06 achieves speeds of 100 m\/min and accelerations of up to 22 m\/s\u00b2. Linear motors have significant advantages over conventional ball screw drives in terms of energy, wear and noise emissions. SW was able to achieve this reliability and precision, among other things, through the gantry drive of the Y-axis used in the BA W06-22: “We electronically coupled two physically separate feed drives Y1 and Y2, each consisting of a drive motor, a direct absolute travel measuring system and a drive controller, on the control side,” says Dreher. “This guarantees optimum positioning accuracy even with off-center loads.” Overall, a position tolerance (Tp) of 0.008 mm can be guaranteed even at the highest machining speeds.<\/p>\n The two synchronous motor spindles of the BA W06, each with an output of 35 kW, have a core spindle with a very low mass moment of inertia. In addition to the high torque of 80 Nm, this enables a spindle ramp-up time of 0.7 s to the maximum speed of 17,500 min-1. This results in an almost constant chip-to-chip time of 2.5 s over the entire speed range.<\/p>\n Even if the quality requirements or tolerances should change, Fagor Ederlan is still well equipped with the SW machines: “The two independent Z axes of the BA W06-22 are decisive for this. Should the quality requirements become so high in the future that they can no longer be realized with two-spindle machines, there is the possibility of carrying out more precise machining with one spindle while the second spindle waits in the background,” explains Dreher.<\/p>\n SW is currently consulting with Fagor Ederlan on ways to embed its machinery in an Industry 4.0 environment. Currently, Fagor Ederlan uses the remote service of Schw\u00e4bische Werkzeugmaschinen GmbH and is considering additionally using SW’s life data services offering. All processes and work steps can be monitored and documented in real time by the SW CloudPlatform. The data obtained is made available to the customer for process optimization or even for improving workflows. Once the necessary sensors have been installed, energy data such as electricity or compressed air consumption can also be visualized and evaluated for sustainable energy management.<\/p>\n Fagor Ederlan is very satisfied with the cooperation: “Our machine park has already included BAZ from Waldm\u00f6ssingen since the end of the 1990s, and they have always worked to our complete satisfaction. The first machines were realized together with the sales representative Daunert Maquinas Herramientas from Barcelona. Since then, the productivity of our machining processes has steadily increased, while maintenance and spare parts costs have been significantly reduced. We now have a considerable number of SW machines in operation worldwide. SW is not just a supplier for us, but a partner that contributes to our global growth,” sums up Duandikoetxea. SW will celebrate its 20th anniversary with Daunert in May 2019.<\/p>\n<\/div><\/div><\/div><\/div><\/div>Higher workpiece output thanks to two-spindle machining<\/h3>\n