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

LaserControl at Playmobil.
As the business approaches its 40th wedding anniversary, some 2.6 billion Playmobil figures currently inhabit the planet. Many new numbers are released yearly, placing high demands on the in-house mould store. To achieve maximum performance in unmanned, automatic procedure, Playmobil’s numerous machining centres have been using LaserControl determining systems of Blum-Novotest already for 15 years.

” For Playmobil figures, hundredths of a millimetre matter,” states Attila Britting, head of Playmobil’s internal mould store in Zirndorf near Nuremberg. “The purpose in developing the shot moulds is to create finished plastic products that call for basically no rework– which is essential because an everyday manufacturing of around 10 million specific components and also over 100 million numbers a year. Consequently, the mould separation should also be a high-precision operation, to ensure that there are not any burrs on the specific parts or the finished number.”

And not the very least, the moulds are defined for exceptionally high volumes, manufacturing runs of 200,000 to 300,000 pieces from one mould are no rarity. The needed efficiency can only be attained by partly automated production alongside the typical two-shift procedure. So a range of machines functions over night on ready jobs. To perform these tasks, numerous of the machining centres are outfitted with pallet changers and device publications with the ability to hold as several as 120 devices. The equipments even maintain running unmanned over the weekend. The Blum-Novotest systems are mounted 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 aid geobra Brandstätter to create injection-moulding devices successfully and in premium
After every device change, the laser automatically determines the size as well as radius of the tool before machining, and also after machining checks for damage and also wear. Thus, our skilled workers no longer have to pre-set the tool in the pre-setting tool. A brand-new tool is merely shrink-fitted into the owner and also measured at machining rate after suitable. This guarantees that the device information in the device is correct, mathematical errors or data analysis errors can no more take place. Further attributes include high-speed automated compensation for the thermal expansion of the whole machine as well as for spindle variation. Incorrect tool information can have expensive repercussions such as malfunctioning tools, declines, or machine standstill. A pin harmed by an accident will certainly cost at least 18,000 Euros to change.

Without a tracking system to spot worn or broken tools, automated manufacturing is hardly possible. The LaserControl system’s breakage screen makes certain that damaged tool detection runs quickly after every machining step. Depending upon the programming, the machining centre can then either exchange the tool for a twin or notify the on-call solution staff, that can log in to the machine over the Internet and also monitor the workshop through a cam. At Playmobil, as many as 4 of the key tools are kept in the device changer, which suggests that the automated overnight jobs run extremely accurately.

We mainly make use of steel with a high chromium material because it reveals the least wear throughout the huge quantity manufacturing big. It does create significant tool wear throughout reducing, nevertheless. That is why it is very important to watch on the running times of the specific tools. The BLUM laser measuring systems do this very well.

Blum-Novotest enables the numerous shot mould to be generated in ultimate high quality.
In the manufacture of extremely complicated injection-moulded tools, hundredths of a millimetre matter: All single components are precisely matched per other.
High-precision dimension in an unclean environment positions a major obstacle, and also cooling is vital to the manufacturing procedure. To secure the optical system from being soiled, the measuring system is mechanically sealed off from the coolant by a pneumatically operated shutter piston during machining. The revolving device is likewise cleaned with compressed air prior to measuring in order to make sure that the measurement is not impaired by swarf, dust or cooling lubes. Throughout dimension, a stream of barrier air offers defense against dirtying.

The LaserControl systems have truly been their money’s well worth at Playmobil. The systems are virtually upkeep cost-free; and also, after more than 10 years in continuous operation, the seals look like brand-new. Above all, nevertheless, the specialists have actually never been let down by the laser systems and also have actually experienced only advantages in regards to solution, as well. “We have actually had only good experience with BLUM lasers– as well as we save working time because there is no need for pre-setting”, Marco Mendl, team leader CAD/CAM/NC, summarises. “The precision of the LaserControl systems is remarkable, also. Based on our experience, its repeatability is within less than two thousandths of a millimetre. As well as for us, something is for sure: Without the BLUM laser systems, this degree of automation would certainly not be feasible.”

Based in Zirndorf near Nuremberg in the Franconia area of southerly Germany, geobra Brandstätter GmbH & Co. KG is the manufacturer of Playmobil, and also as such Germany’s largest plaything supplier. The Brandstätter Group operates manufacturing centers in Germany, Malta, Spain as well as the Czech Republic. It utilizes greater than 3,700 individuals worldwide, and in 2012 created complete sales of 591 million Euro. At the heart of the multi-award-winning toy principle are the 7.5 centimetre high Playmobil figures, which are marketed in over 30 historic and modern themed collection to greater than 80 nations all over the globe. Approaching their 40th wedding anniversary, there are currently some 2.6 billion Playmobil figures populating the planet. Together with premium plaything quality ‘Made in Europe’, considering that the year 2000 the cutting-edge company has likewise been making LECHUZA state-of-the-art plastic planters.