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

LaserControl at Playmobil.
As the company approaches its 40th wedding anniversary, some 2.6 billion Playmobil figures currently occupy the earth. Several new figures are launched annually, placing high needs on the internal mould shop. To accomplish optimal effectiveness in unmanned, computerized procedure, Playmobil’s countless machining centres have been using LaserControl measuring systems of Blum-Novotest already for 15 years.

” For Playmobil numbers, hundredths of a millimetre matter,” states Attila Britting, head of Playmobil’s internal mould shop in Zirndorf near Nuremberg. “The purpose in building the shot moulds is to produce completed plastic things that need virtually no rework– which is important in view of a daily manufacturing of about 10 million private parts as well as over 100 million numbers a year. Subsequently, the mould splitting up must also be a high-precision procedure, to make sure that there are not any burrs on the specific components or the finished figure.”

And not least, the moulds are specified for very high volumes, manufacturing runs of 200,000 to 300,000 pieces from one mould are no rarity. The required performance can just be accomplished by partially automated manufacturing alongside the regular two-shift operation. So a range of devices works over night on prepared tasks. To implement these tasks, numerous of the machining centres are outfitted with pallet changers and tool magazines with the capability to hold as lots of as 120 devices. The equipments also maintain running unmanned over the weekend break. The Blum-Novotest systems are mounted in the machining location of the automated DMG five-axis machining centres.

BLUM laser measuring system in the Playmobil mould-making shop
BLUM laser gauging systems help geobra Brandstätter to produce injection-moulding tools effectively and in premium
After every tool modification, the laser immediately determines the size as well as distance of the tool before machining, and also after machining look for damage as well as wear. Hence, our skilled workers no more have to pre-set the tool in the pre-setting tool. A new tool is simply shrink-fitted right into the holder and also determined at machining speed after fitting. This ensures that the device information in the device is proper, numerical mistakes or data reading mistakes can no more happen. Additional functions include high-speed automated compensation for the thermal development of the whole device and for pin variation. Inaccurate tool data can have expensive consequences such as faulty devices, declines, or maker interruption. A pin harmed by a collision will certainly set you back a minimum of 18,000 Euros to change.

Without a surveillance system to detect worn or busted devices, automated production is hardly possible. The LaserControl system’s damage display makes sure that broken tool detection runs promptly after every machining step. Relying on the shows, the machining centre can after that either exchange the device for a twin or notify the on-call solution team, who can visit to the machine online as well as keep track of the workshop via a web cam. At Playmobil, as numerous as four of the trick tools are held in the device changer, which means that the automated overnight jobs run really accurately.

We mostly make use of steel with a high chromium material because it shows the least wear during the large volume manufacturing big. It does trigger substantial 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 determining systems do this very well.

Blum-Novotest makes it possible for the several injection mould to be generated in ultimate top quality.
In the manufacture of highly complex injection-moulded devices, hundredths of a millimetre matter: All solitary parts are exactly matched to every other.
High-precision dimension in a filthy environment positions a significant obstacle, and cooling is essential to the manufacturing procedure. To safeguard the optical system from being dirtied, the determining system is mechanically sealed from the coolant by a pneumatically run shutter piston throughout machining. The revolving device is also cleaned up with pressed air before determining in order to make certain that the dimension is not harmed by swarf, dust or cooling lubricants. During measurement, a stream of obstacle air supplies protection versus staining.

The LaserControl systems have actually really been their money’s worth at Playmobil. The systems are almost upkeep free; and also, after more than 10 years in continual procedure, the seals resemble brand-new. Above all, nonetheless, the specialists have actually never been let down by the laser systems and have actually experienced only good things in terms of service, also. “We have had just excellent experience with BLUM lasers– and also we conserve functioning time because there is no need for pre-setting”, Marco Mendl, group leader CAD/CAM/NC, summarises. “The precision of the LaserControl systems is amazing, also. Based on our experience, its repeatability is within less than 2 thousandths of a millimetre. And also for us, something is for sure: Without the BLUM laser systems, this level of automation would not be feasible.”

Based in Zirndorf near Nuremberg in the Franconia area of southerly Germany, geobra Brandstätter GmbH & Co. KG is the supplier of Playmobil, and also because of this Germany’s largest toy producer. The Brandstätter Team runs production facilities in Germany, Malta, Spain and also the Czech Republic. It employs greater than 3,700 people worldwide, and in 2012 produced total sales of 591 million Euro. At the heart of the multi-award-winning plaything idea are the 7.5 centimetre high Playmobil numbers, which are marketed in over 30 historical as well as modern themed series to more than 80 countries around the world. Approaching their 40th anniversary, there are currently some 2.6 billion Playmobil numbers occupying the planet. Alongside costs toy top quality ‘Made in Europe’, because the year 2000 the ingenious organization has also been making LECHUZA high-grade plastic planters.

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