New rotary transfer machine for cylinder core production
WILKA Invests in State-of-the-Art Rotary Indexing Machine for Cylinder Core Manufacturing
Since August, the new core processing center "RT 100-12" from Pfiffner, the world leader in rotary indexing machines, has been in operation at WILKA Schließtechnik GmbH in Velbert – and it is already indispensable.
With the RT 100-12 rotary indexing machine from Pfiffner, WILKA has acquired one of the most flexible, productive, and precise machines for the manufacturing of turned and milled parts. This machine enables WILKA to meet the growing demand for high-quality cylinders and to cover the increasing product variety.
Equipped with the latest "Industry 4.0"-ready CNC control system from Bosch, the RT 100-12 now takes over the cylinder core production area at WILKA, previously covered by four different CNC machines. The multi-station capability, combined with 12 rotating workpiece spindles and CNC axes, ensures a high level of flexibility and significant optimization potential for the closure technology manufacturer. This includes machine cycle times, accuracy, clean sorting, order management, evaluation possibilities, and automation levels.
The requirements WILKA had for the machine manufacturer were extremely high, especially in terms of accuracy. For illustration: a part at WILKA consists of up to 210 features, such as drillings and milling operations. These must always be manufactured within a tolerance of two hundredths of a millimeter according to WILKA's specifications. This results in 4,410 production steps, all of which had to be defined and programmed by Pfiffner.
"Given the very high diversity of parts, we faced the challenge of balancing flexibility and productivity," explains Uwe Krause, Managing Director at Pfiffner. "Although it wasn't easy, we were ultimately able to successfully complete the project."
The numbers support Krause’s statement: Just two weeks after the 16-ton machine was installed in Velbert, the first parts that were within tolerance were produced. Since the final acceptance, the RT 100-12 has been operating with an impressive availability of around 98%, producing 2,000 to 2,500 highly precise parts per day, depending on the configuration. The cylinder core production time was optimized from 60 seconds to 13 seconds per core. "The possibilities the RT 100-12 offers in terms of automation and digitalization have never been fully exploited in any other project as much as with WILKA," adds Uwe Krause proudly. "WILKA is using a high-tech solution at the highest level."
Originally developed for the production-heavy and complex requirements of the automotive parts supply industry, the RT 100-12 has been used for several years in the hardware industry and, now, with WILKA as a pioneer, it is also used in the lock industry for the first time. The RT 100-12 represents the largest single investment in WILKA’s history. One reason why Andreas Linnemann, Technical Director at WILKA, paid close attention when selecting the manufacturer: "We searched for a reliable partner for a long time, one who understands both the diversity and complexity of our industry, and specifically our products, and who can ensure smooth operations and transparent communication."
Pfiffner has already proven its ability to meet these expectations in previous joint projects with WILKA.
"We have come to appreciate Pfiffner as a reliable machine manufacturer and, above all, a partner in every aspect. From management to project management to the installers, everyone at Pfiffner is committed to providing us with a flawlessly functioning machine," adds Linnemann.
Although no official plans for further joint projects between Pfiffner and WILKA have been announced, both companies are certain: the foundation has been laid. Of course, WILKA’s medium- to long-term growth goals will also support further investments in new technologies.
About K. R. Pfiffner AG
K. R. Pfiffner AG, headquartered in Switzerland, specializes in rotary indexing machines and is one of the largest manufacturers in the world. Since its founding 50 years ago, Pfiffner has developed into the world’s leading provider of rotary indexing machines through engineering expertise, practical solutions, and extensive market knowledge, offering secure, turnkey solutions for customers.