IndustryArena



September 2017HELLER – EMO 2017HELLER in facts and figures: first half-year 2017At a glance: HELLER remains on the road to successThe new HF series: productivity in 5 axesHELLER4Industry: increasing productivity on workpiece levelHELLER and Siemens: new Industry 4.0 applications HELLER4Use: usage model providing a new level of flexibilityThe future of mobility: HELLER is well positioned HELLER short profilePress relationsGebr. Heller Maschinenfabrik GmbHMarcus KurringerHead of MarketingGebrüder-Heller-Stra?e 1572622 NürtingenGermanyPhone: +49 7022 77-5683Fax: +49 7022 77-165683marcus.kurringer@HELLER in facts and figures: first half-year 2017Order intake: EUR 296.9mEurope: 50%North and South America: 15%Asia: 35%Turnover: EUR 254.4mPerformance: EUR 274.5mEmployees: 2,564 Equity capital: EUR 94.5m, ratio: 27%At a glance: HELLER remains on the road to successGlobal economic conditions in almost all markets relevant to us are positive and, according to the IWF, even show a slight upward trend. The economic situation in our industry is also satisfactory. In terms of products and organisation HELLER is well set up and consistently working on further improvements. All in all, we expect a moderate growth as far as the economic development in 2017 is concerned and a continued positive development of business throughout 2017 for HELLER in terms of turnover and earnings.Tailor-made products and solutions – successfully expandedWe are continually and consistently expanding our existing product range. Additionally, we are developing new technologies and processes, successfully launching them onto the market. With the introduction of the new HF?series of 5-axis machines we have taken the next logical step in completing our existing machine portfolio. The target groups providing potential for further growth in order intake are companies from the automotive supplier industry and the general machine industry. Currently, our new HF series is available in two different sizes. In addition to our established portfolio, we are now able to offer a cost-effective range for single-machine business to further expand our market. For project business with our automotive customers we are also offering a highly attractive range of cutting-edge products. This includes our recent developments for crankshaft and camshaft machining, comprising an interesting range of smaller machine sizes. Business with the HELLER CBC technology for the coating of cylinder bores of automobile engines is also developing excellently. Major vehicle manufacturers have already equipped their production facilities worldwide with this systems technology and are producing high volumes or are planning to do so in the coming years at more than 20 locations. Until 2018, a total of 65 systems for the coating of more than 8 million engines worldwide will be in operation. Trend topics like electromobility and Industry 4.0 are very much in our focus at the moment and already being implemented. With HELLER4Industry, launched at HELLER WerkTage 2016, we are offering our customers an expanded solution range for the digitisation of production (Industry 4.0). It provides greater ease of use of the machine, optimal network integration and expanded functionalities and service possibilities. Global network – versatile and close to our customersOur perception is that the economic situation in the machine tool business is stable and we expect a moderate growth as far as the economic development is concerned. Yet, we are closely following the developments of world political events. With this in mind, we need to ask ourselves how we can best distribute the tasks between our individual locations. We are currently working on various scenarios regarding the production and procurement strategy that will enable us to adapt to different world political developments. Our internal processes strongly benefit from HELLER’s global value-creation network, enabling us to utilise capacities across different locations. Additionally, we are intensely working on finalising the new logistics concept. At its heart is the new logistics centre in Nürtingen, consolidating various complex processes that until now had been distributed to several locations, and which will be operated by an external service provider.In the largest Sales operation for Europe, adjustments in terms of personnel and organisation have largely been completed. In terms of service business we continue to offer high customer proximity and efficiency. The new HF series: productivity in 5 axesWith the 5th axis provided by the workpiece, the 5-axis machining centres from the HF?series deliver a significant reduction in idle times in combination with the powerful dynamics and a horizontal spindle for shortest chip-to-chip times. With the machines, HELLER guarantees high productivity in series production and for universal application when machining medium to large batch sizes. At EMO 2017 in Hanover, model HF?3500 for table loading, first presented in 2016 and providing a work envelope of 710x750x710mm and a maximum table load of 550kg, and the new model HF?5500 equipped with pallet changer, providing a work envelope of 900x950x900mm and a maximum pallet load of 750kg, will be taking the spotlight. Machine concept: robust and highly dynamicThe new HF?series comprises 5-axis machining centres proving once again that HELLER genes like productivity, performance, reliability and availability form the foundations of each and every new development from Nürtingen. The HF series combines proven qualities with innovative features. This is also true for the kinematics with three linear axes in X, Y and Z, equipped with absolute measuring systems and two direct driven dynamic rotary axes in A and B integrated into a swivel rotary table. Dynamic because the high speed of the A and B rotary axes is achieved through minimised mass moment of inertia and the use of direct drives. Optionally, the powerful dynamics can be increased further with the “Speed-Dynamics Package”. According to HELLER, it provides 10?% shorter chip-to-chip times. For an additional reduction in idle times, the HF?series provides a high-speed NC tool changer with lift-and-swivel principle. Contrary to comparable machines on the market, HELLER has equipped the new series with a counter bearing as a unique selling point. The use of the counter bearing in combination with a YRT bearing results in high rigidity also in case of high loads. High flexibility was another priority for HELLER in the development of the machine. Therefore the machining centre is either available in table design or equipped with pallet changer.Spindle units: top quality made by HELLERCombined with the 5th axis provided by the workpiece for dynamic 5-sided and simultaneous 5-axis machining, HELLER's typical horizontal spindle, ensuring quick tool changes and short idle times, offers substantial advantages as far as productivity is concerned. The HF provides a wide choice of spindles to suit different applications. Whilst the standard version is equipped with the powerful SC63 SpeedCutting motor spindle with HSK-A63 (18,000rpm, 100Nm), making it ideal for the machining of light metals, the optional PC63 PowerCutting spindle unit (12,000rpm, 201Nm) provides the necessary torque for high-performance cutting of cast iron and steel. As further options HELLER offers motor spindles with HSK-A100. The SC?100 spindle unit (12,000rpm, 201Nm) provides increased stability of tools and high speeds for universal application, whereas the PC?100 spindle unit (10,000rpm, 354Nm) offers high torque for use with large and heavy tools. Work area: adequately dimensioned and ergonomically designedMoreover, the HF?series provides large workpiece interference contours. Contrary to conventional 5-axis machining centres, HELLER's concept is not only based on single-part clamping, but provides the possibility of multiple clamping or the clamping of very large components (e.g. transmission cases using 'window-type' fixtures). To provide sufficient space in the work area, the workpiece interference contour of model HF?5500 was increased by 800mm in height and 900mm in diameter compared to model HF?3500, equalling a difference of 27 percent. What is interesting is that despite the large interference contour there are hardly any limitations as far as the degrees of freedom are concerned. The machine enables swivel movements of the rotary table through 150° (30° to -120°) and with certain restrictions even through 225°. The HELLER HF machining centres leave nothing to be desired when it comes to the disposal of short- or long-chipping materials. This is guaranteed through free chip fall during horizontal machining, steep side walls and stainless steel slat coverings as well as the centrally arranged open chip conveyor.Operation: convenient and practice-orientedWith the HF?series, HELLER is presenting its new HELLER Operation Interface, the new operating panel with 24" screen technology and touch controls, quick access technology in the control and XTENDS optional expansion applications to support the user. The optional work area camera, for example, optimally supports setting and monitoring functions during the CNC process. Automation: efficient and future-proofFor decades, HELLER has been synonymous with efficient production processes and high machining quality. This also applies to the well-conceived connection to all current automation systems. Target groups will be particularly interested in flexible integration into existing production systems. The new machine series is also flexible and customer-oriented in terms of tooling. The new machining centres enable continued use of existing tools from other HELLER machines and the use of manual clamping fixtures. Adaptation of hydraulically operated clamping fixtures is also possible.HELLER4Industry: increasing productivity on workpiece levelIn terms of Industry 4.0, HELLER is focusing on even higher machine productivity and on supporting consistent engineering chains. Core aspects are supplementary machine functions, on-demand services and enhanced service capabilities. On three modules HELLER illustrates the importance of ease of operation, customised workpiece manufacturing and enhanced evaluation of existing data. HELLER4Operation is an easy-to-use, operator-oriented user interface for HELLER machines. The use of touch controls at the tool/workpiece loading station enables fast and robust operation. The second area, HELLER4Services, comprises digital services. The HELLER Services Interface focuses on transparency of manufacturing and maintenance processes. The module forms the basis for evaluations and statistics, thus providing support in reducing machine downtimes. Additionally, the visualisation of specific information, including status displays of axes, spindles or other assemblies, enables users to determine wear and to take preventive measures in order to avoid unscheduled downtimes. The third area, HELLER4Performance, comprises the machine analysis for process and performance optimisation, time-synchronous extraction of real-time data into the internet as well as evaluation and graphical display, using an external cloud platform.For HELLER, the aim of all considerations, possibilities and solutions remains the reduction of the customer’s cycle times, and thus workpiece costs, by providing high productivity. Already today, HELLER is generating added value for the customer through greater ease of use of the machine, optimal integration into the network and expanded functionalities and service possibilities.HELLER and Siemens: new Industry 4.0 applications With HELLER4Industry, HELLER has set the framework for the company’s new Industry?4.0 technologies. In cooperation with Siemens AG, HELLER has now developed new service and will be presenting them exclusively at EMO in Hanover. Both companies have long realised that digitisation was likely to play a key role in the future. HELLER benefits from the partnership with a diversified industrial group like Siemens in many different ways. Siemens is able to draw on a vast knowledge pool from the most diverse branches of industry, enabling the transfer of expertise from one business area to other fields of application.The Industry 4.0 applications are not only directed towards the life cycle but to all key areas of a machine tool. In addition to Services, ensuring high availability as one of the prerequisites for productivity, this also includes operation and performance optimisation of the machine tool. Customers will benefit from the new functions to a much higher degree when the features are able to support them with their specific situation at hand. High-frequency data analytics: optimising processes in real time Together with Siemens, HELLER will be showcasing new features at EMO 2017 in Hanover as part of our HELLER4Industry presentation. For the first time, we will demonstrate an imaging method comparable to magnetic resonance imaging (MRT). HELLER creates new algorithms comparable to the mentioned MRT procedure used in medical engineering and ‘feeds’ them with the signals of a machine tool. A high-resolution image of the workpiece that is displayed at the output end, i.e. the web browser and the operating panel of the machine, without requiring cameras or additional sensors in the machine. In cooperation with Siemens we are currently working on incorporating the knowledge gained based on the machine signals into the function in order to obtain even more meaningful results. By offering high-quality data comparison on the basis of reference patterns this new functionality provides numerous evaluation possibilities for process optimisation.HELLER4Performance: processing manufacturing orders with high profitablityIn order to demonstrate the benefits to customers, HELLER will be presenting three use cases that vividly illustrate how digitisation, networking and intelligent algorithms interact. Among these solutions is an option for the optimisation of the tool assignment in the rack-type magazine, one for increasing the workpiece axis dynamics and the so-called automatic feed control. These are ideas that HELLER has been pursuing for quite some time. But only now – with edge computing – we have sufficient computing power available for processing the data. At the same time, the cloud enables us to evaluate the data and to draw the relevant conclusions, helping us to realise our ideas at such a high level.Use case ‘Rack-type Magazine’With the ‘Rack-type Magazine’ use case focusing on the machine performance we demonstrate how to optimise the tool position inside the magazine. HELLER offers a function for optimising the place assignment in the rack-type magazine according to the requirements of the next workpiece to be machined. Optimum storage place assignment enables a reduction in cycle time by up to 20 percent. This creates tangible added value for customers. Use case ‘Increasing workpiece axis dynamics’In principle, the goal is to adapt the traversing speed of the workpiece axis to the loading weight. Until now, it made no difference whether the machine table was loaded with 2t or only 200kg. HELLER is now in a position to respond to the situation by adapting the dynamics accordingly, i.e. providing increased dynamics for lighter components. Use case ‘Automatic feed control’Of course operators are able to monitor all processes on the easy-to-read dashboard display on our new 24” multi-touch panel. With a single touch of the fingertip, companies can choose to accept or reject the suggestions, e.g. re-assignment of the tool storage places or the modification of the machine parameters. The dashboard provides all the necessary information for making that decision. The same applies to the automatic feed control. The operator can set the limits in which the machine can autonomously adjust the override. In case of fluctuations in stock allowance, the machining speed can be adjusted according to the current spindle-tool-workpiece combination. We have customer examples in which machining time reductions of up to 20 percent have been achieved.Will the numerous functions require additional sensors in the machine? Contrary to other manufacturers, HELLER is taking a different approach, because every additional sensor poses a potential risk in the work area and would reduce availability in case of a failure. The approach is based on the enhanced possibilities to evaluate existing sensors using the additional computing power in the machine provided by SINUMERIK-Edge in combination with the cloud, enabling us to make better use of the data, also using additional information based on dependencies of the sensor signals. As a result, we are generating added value without compromising the availability of the machine. HELLER4Use: usage model providing a new level of flexibilityWith ‘HELLER4Use’, HELLER is now completing the range of HELLER4Industry applications with an attractive operator model for the use of HELLER machining centres. With this model, customers only pay for the use of their machine, helping them to avoid fixed costs. Based on the acquisition and evaluation of the actual machine utilisation, it helps customers to remain successful in the future with advanced technology, whilst maintaining full financial flexibility.Shorter innovation cycles, growing material and component variety and complexity as well as constant cost pressure are posing significant challenges to enterprises aiming to remain competitive. Planning horizons become shorter and shorter whilst planning dependability decreases. How is a system planned today supposed to be able to produce the part range in demand over the next 8 to 10 years? Will today’s solutions still be able to respond to tomorrow’s requirements? How can security of investment be maximised?When purchasing capital goods companies often place the main focus on the initial capital cost. Frequently, the purchasing price plays a more important role than the actual life cycle costs. HELLER4Use guarantees flexibilityHELLER machining centres do not only meet the current needs and requirements of modern production, they also have the capability to be used efficiently and productively throughout their entire life cycle. Therefore HELLER has developed the HELLER4Use model for its machines, offering maximum flexibility in terms of usage and billing. HELLER provides the machine whilst ensuring maximum availability around the clock. Customers only pay for the time during which they are producing, turning fixed costs into variable costs.HELLER4Use builds on the transparency provided by HELLER4Industry. The newly developed HELLER Services Interface provides transparency of manufacturing and maintenance processes. Visualisation of specific information, including status displays of axes, spindles or other assemblies, enables users to determine the wear status and to take preventive measures in order to avoid unscheduled downtimes. With HELLER4Use, the HELLER Services Interface acquires all relevant data concerning maintenance, wear and the evaluation of utilisation and uses them as the billing basis. In order to guarantee maximum utilisation over the entire life cycle of the machine, HELLER provides a full-service range to ensure maximum machine availability. They include measures like regular assessment of the machine condition as part of a manufacturer inspection, the prevention of unscheduled downtimes through preventive maintenance and servicing as well as participation in the HELLER product maintenance programme. Additionally, Integrated Process Monitoring (IPM) for collision monitoring and load evaluation, a maintenance manager keeping a maintenance log as well as the media monitoring are performed for diagnostics of maintenance actions, ensuring that all measures taken during the usage and maintenance of the machine remain transparent throughout. Conclusion: achieving transparency whilst eliminating the risk for HELLER customersHELLER4Use enables customers to use machines in accordance with current requirements at variable costs, ensuring maximum flexibility. The required machine data are collected, evaluated and provided to a digital billing system using the existing HELLER4Industry functionality. HELLER4Use provides flexibility in terms of capital costs: Customers benefit from extremely efficient machines without any capital commitment and with the right to return or to replace the machine, enabling customers to adapt their HELLER machine to changing production requirements according to their needs. As usual with HELLER, customers can count on personalised advice and drafting of the contract to individual requirements as well as quick and hassle-free processing.The future of mobility: HELLER is well positioned Ever since its foundation more than 120?years ago, HELLER has seen itself as an innovative and solution-oriented partner to its customers and will remain so in the years to come. To meet the challenges posed by future mobility, the company has adopted a forwarding-thinking approach.Approx. 75% of the HELLER Group’s business comes from the automotive industry. This includes passenger cars and trucks as well as agricultural and construction machinery. Project business makes up approx. 60 percent of this, with the emphasis on cylinder blocks and heads, crankshafts and camshafts as well as transmission and chassis components. So what are the options for a machine tool manufacturer looking back on a history of more than 120?years having practically grown up with the combustion engine and considering the fact that the future of mobility is said to be electric, thus resulting in a significant decrease in the number of machined components?“The combustion engine is far from dead. Rather, we believe that in the near future, the mobility concept will comprise a combination of downsized combustion engines and electric drives,” says Manfred Maier, COO of the HELLER Group. “Our core competency will enable us to remain a sought-after partner for potential customers in the years to come. At the same time, we will increasingly search for new applications and complementary technologies.”Development New Business & Technologies explores the possibilitiesIn response to the changing situation, HELLER has adapted its corporate structures accordingly. Development New Business & Technologies explores applications that will not immediately turn into key revenue contributors, yet are likely to gain significance in the future. The team’s experts are looking into the possibilities of additive manufacturing or new materials such as CFK. CBC, or CylinderBoreCoating, is a technology based exclusively on HELLER machining modules and an excellent example for the innovative complementary technologies expanding the company’s existing machine portfolio; CBC is based on the twin-wire arc spray technology used by Daimler and BMW. So far, the coating technology is the only method providing the necessary process dependability for use in high-volume production. From 2017 onwards, Daimler will use it in the production of approx. one million 4- and 6-cylinder engines per year at their facilities in Untertürkheim (Germany). Until 2018, a total of 65 systems for the coating of more than 8 million engines worldwide will be in operation.HELLER manufacturing solutions are ready for the futureWith its broad and flexible range of products and applications, its know-how in application and service, an extensive global customer base from the most diverse industries as well as production, sales and service locations around the world, machine manufacturer HELLER has the capabilities to provide solutions for today’s and tomorrow’s manufacturing tasks. “Mobility, and also the machine tool industry, will definitely see changes but will continue to play a significant role in the future,” Maier affirms.HELLER short profileFounded in:1894 in Nürtingen2016 workforce:2,576 (including apprentices)2016 order intake:EUR?527m56% Europa, 20% North and South America, 24% Asia2016 turnover:EUR?538m2016 equity ratio:29.9%2016 investment volume:EUR?12.4mChairman of the Board:Berndt HellerHELLER Group Managing Directors:Klaus Winkler, CEOManfred Maier, COO Dieter Drechsler, Projects & ApplicationsPatrick Rimlinger, OperationsDr. Jürgen Walz, DevelopmentRegional Managing Directors:Peter Weber, HELLER Europe Andrew Parkin, HELLER AsiaKeith Vandenkieboom, HELLER North AmericaAlfredo Griesinger, HELLER South AmericaFields of business:4-axis and 5-axis machining centresMill/turning centresFlexible manufacturing systemsMachines for crankshaft and camshaft machiningCBC systemsServicesProduction locations:Germany (Nürtingen)United Kingdom (Redditch)USA (Troy/Michigan)Brazil (Sorocaba)China (Changzhou)Sales/Service locations:EUROPEGermany (Hattingen, Salem, Goslar, Saarbrücken, Nuremberg, Nürtingen)Italy (Verona)France (Paris)Poland (Posen)Spain (Barcelona)Sweden (V?rnamo) Switzerland (Niederbüren)Slovakia (Vráble)Russia (Moscow) NORTH/SOUTH AMERICAMexico (Querétaro)Brazil (Belo Horizonte)ASIAChina (Beijing, Chongqing, Shanghai)India (Pune) Thailand (Bangkok)Singapore ................
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