WZL Machinery

   

Within the scope of the various research projects, the WZL has a large number of machine tools, machining centers and robots that differ significantly in their specifications. In the following, you will find a corresponding compilation with information on the respective properties. The machines are assigned to the respective departments. Via these departments you will also find the contact persons you can turn to for further information.

 

Machine information

Machine/test stand Department Features
Surface/Profile grinder
Blohm Profimat MT 608
Grinding
  • spindle drive power: Ps.max = 44 kW
  • spindle speed: ns.max = 8,000 min-1
  • table feed speed: vw.max = 25 m/min
  • table acceleration: aw.max = 1 m/s2
  • grinding wheel holder: 127 mm
  • dressing unit: standing & rotating
  • cooling lubricant: oil, emulsion
Edge Computing Cluster
Datalake
Forming Technologies
  • 6 x 2 processors with 20 cores each
  • 6 x 360 TB HDD memory
  • 6 x NVIDIA P100 á 3584 CUDA Cores
  • 1,568 TB main memory
  • 3.84 TB SSD memory

Horizontal machining center DMG MORI NHX 5000 2. Gen.

Cutting Technology
  • spindle power: P = 37 kW
  • max. Speed: n = 15000 1/min
  • max. Torque: M = 250 Nm
  • tool holder: (BAZ) HSK-A63
  • x-axis travel: lx = 730 mm
  • y-axis travel: ly = 730 mm
  • z-axis travel: lz = 880 mm
  • max. Workpiece diameter: d = 800 mm
  • max. Workpiece diameter: d = 800 mm
  • max. Workpiece weight: m = 500 kg
  • table size: 500 mm x 500 mm
  • control: Control M730UM with CELOS
  • special features: Pallet changer

Lathe
DMG MORI NZX 1500 | 800 STY3

Cutting Technology
  • spindle power: P = 2* 25 kW
  • max. Speed: n = 6000 1/min
  • largest turning diameter: d = 320 mm
  • bar passage: d = 52 mm
  • travel X/Y/Z: 210/110/810 mm
  • powered tools 12,000 1/min, 7.5 kW, 21 Nm to n = 3400 1/min
  • high pressure unit: 80 bar / 35 l/min
  • control: Fanuc F31iB
  • bar feeder: l = 1200 mm

Lathe
DMG MORI NEF 600

Cutting Technology
  • spindle drive power: 28 kW (at 100% ED) and 37 kW (at 40% ED)
  • max. spindle speed: 2500 min-1
  • max. torque: 590 Nm (100% ED)
  • max. turning diameter: 600 mm
  • max. workpiece weight: 600 kg (tailstock)
  • travel X = 398 mm, Z(tailstock) = 1150 mm
  • max. workpiece length: 1250 mm
  • high-pressure aggregate
Lathe
DMG MORI CTX Beta 800 Linear
Cutting Technology
  • spindle power (40 / 100 % ED): P = 34 / 25 kW
  • max. speed: n = 5000 1/min
  • driven tool: n = 5000 1/min
  • max. torque (40 / 100 % ED): M = 380 / 280 Nm
  • largest diameter: d = 410 mm
  • control: Siemens 840D sl Operate
  • special features: CELOS
  • tailstock
EMAG PT Smart 1500 EDM/ECM Processes
  • Machine for electrochemical machining

  • 2 axes: linear feed (vertical) and oscillation

  • Processing variants: DC-ECM and PECM

  • Electrolyte: Aqueous NaNO3 solution

  • Maximum electrolyte rinsing pressures: >25 bar

  • Integrated electrolyte preparation

  • Constant and pulsed power supply

  • Max. current: 1500 A

Grinding/turning machining centre
EMAG VTC 100 GT
Grinding
  • main spindle drive power: Pmax = 11,5 kW
  • main spindle speed: ns,max = 3.000 min-1
  • workpiece diameter: dw,max = 100 mm
  • workpiece length: lw,max = 400 mm
  • KSS: emulsion and oil
  • technologies: hard turning and grinding

Horizontal machining center Ex-Cell-O XHC 241

Cutting Technology
  • spindle power: P = 40 kW
  • max. speed: n = 24000 1/min
  • max. torque: M = 54 Nm
  • tool holder (BAZ): HSK-A63
  • max. workpiece diameter: d = 600 mm
  • control: Sinumerik 840D
Flow grinder
Extrude Hone AFM Vector 150
Grinding
  • medium cylinder size: dm = 150 mm
  • medium flow rate: V̇m = 19 l/min
  • medium pressure: pm = 24 to 163 bar
  • opening: H = 50 to 555 mm

External broaching machine
Forst RASX 8x2200x600 M / CNC

Cutting Technology
  • scraper force: 80 kN up to 30 m/min, 20 kN between 30 and 150 m/min
  • broaching speed: 0,5 - 150 m/min
  • broaching tool shank width: max. 1''
  • stroke length: 2200 mm
  • max. broaching tool length: 1800 mm per broaching track
  • number of clearing tracks: 3
  • control: Siemens 840 DSL
  • workpiece table width: approx. 600 mm
  • dividing table: Walter RTMN 250 (10 inch)
  • force measuring platform
Die-sinking EDM machine GFMS FORM2000 VHP EDM/ECM Processes
  • Machine for precision machining

  • Dimensions working area: 600 x 400 x 450 mm³

  • Maximum tool weight: 50 kg

  • Maximum workpiece weight: 800 kg

  • Dielectric: Hydrocarbon based oilheld ionofil IME-MH
    Tool holder: Carl Hirschmann clamping system (Erowa adapter available)

  • 4-axes: x,y,z and c-axis
    z-axis thermostabilised

  • Surface qualities of Ra < 0.1 µm possible

5-axis milling machine
Hermle C50 U

Cutting Technology
  • spindle power: P = 39 kW
  • max. Speed: n = 18000 1/min
  • max. Torque: M = 240 Nm
  • x-axis travel: lx = 1000 mm
  • y-axis travel: ly = 1100 mm
  • travel Z-axis: lz = 750 mm
  • largest diameter: d = 700 mm
  • tool interface: HSK - A 63
  • control: Heidenhain
  • internal cooling: 80 bar emulsion / air
  • special features: Blum - Laser
Tool grinding machine
ISOG Technology S22p-turbo
Grinding
  • number of axes: 5
  • spindle power: Pmax = 15 kW
  • spindle speed: ns,max = 8.000 min-1
  • axis feed: vf,ax = 20 m/min
  • workpiece speed: nw,max = 800 min-1
  • grinding wheel diameter: ds,max = 150 mm
  • dressing unit: rotating
  • KSS: emulsion and oil

5-axis milling machine
Makino D500

Cutting Technology
  • spindle power (40 / 100 % ED): P = 18.5 / 15 kW
  • max. Speed: n = 22000 1/min
  • max. Torque: M = 200 Nm
  • x-axis travel: lx = 550 mm
  • y-axis travel: ly = 1000 mm
  • travel Z-axis: lz = 500 mm
  • working area size: 650 mm x 500 mm
  • tool holder (BAZ): HSK-A63
  • control: Fanuc
Wire EDM machine Makino U6 H.E.A.T. EDM/ECM Processes
  • Water based wire erosion system with bipolar anti-electrolysis generator

  • Split-V wire guide

  • Flushing pumps with higher capacity (2 pumps)

  • 4-filter filtration system

  • H.E.A.T. Technology for high machining speeds despite poor rinsing conditions

  • Additional booster unit with higher discharge energies for use with wire electrodes with a diameter of 0.4 mm

  • Rotary spindle for rotary erosion of shafts from the company Carl Hirschmann

  • Swivel axis for machining of rotary components from the company Carl Hirschmann

Turn-mill center
Mazak Integrex i-400
Cutting Technology
  • power turning spindle: P = 30 kW
  • max. Speed: n = 3300 1/min
  • max. Torque: M = 1400 Nm
  • max. Milling spindle speed: n = 12000 1/min
  • max. Torque: M = 120 Nm
  • x-axis travel: lx = 615 mm
  • y-axis travel: ly = 260 mm
  • travel Z-axis: lz = 1077 mm
  • travel W-axis: lw = 1026 mm
  • largest diameter: d = 658 mm
  • tool holder / WKZ changer: Capto C6 / 72 seats
  • control: Mazatrol
  • internal cooling: 70 bar

Vertical machining center Mazak VTC 800/30

Cutting Technology
  • spindle power: P = 35 kW
  • max. Speed: n = 18000 1/min
  • max. Torque: M = 95 Nm
  • x-axis travel: lx = 3000 mm
  • y-axis travel: ly = 800 mm
  • travel Z-axis: lz = 720 mm
  • working area size: 3500 mm x 820 mm
  • control: Siemens 840D sl

Mazak Variaxis i-600
5-axis milling machine

Cutting Technology
  • spindle power: P = 37,5 kW
  • max. Speed: n = 18000 1/min
  • max. Torque: M = 152 Nm
  • x-axis travel: lx = 510 mm
  • y-axis travel: ly = 910 mm
  • travel Z-axis: lz = 510 mm
  • largest diameter: d = 700 mm
  • control: Siemens 840D solutionline

Horizontal machining center
Scharmann DBF 630

Cutting Technology
  • spindle power: P = 35 kW
  • max. Speed: n = 3500 1/min
  • max. Torque: M = 1700 Nm
  • x-axis travel: lx = 850 mm
  • y-axis travel: ly = 700 mm
  • travel Z-axis: lz = 800 mm
  • table size: 630mm x 630mm
  • tool holder: HSK 100
  • control: Siemens 840D
Centerless grinding machine
Schaudt Mikrosa Kronos S250
Grinding
  • spindle drive power: Ps,max = 15 kW
  • spindle peripheral speed: vs,max = 80 m/s
  • workpiece diameter: dw = 1,5 - 35 mm
  • grinding wheel dimensions: d x bs = 450 x 250 mm
  • control wheel dimensions: d x br = 250 x 250 mm
  • dressing unit: standing and rotating
  • KSS: emulsion
Vibratory grinding machine
Rösler round vibrator R 125
Grinding
  • connected load: Pmax = 0.75 kW
  • speed unbalance motor: nu,max = 1.500 min-1
  • volume of working tank: VA = 125 l
  • width of working container: bA = 210 mm
Circular grinding machine
Studer S41
Technology Planning and Grinding
  • spindle drive power: Pmax = 15 kW
  • spindle drive power (HSG) Pmax = 30 kW
  • spindle peripheral speed: vs,max = 50 m/s
  • spindle peripheral speed (HSG): vs max = 203 m/s
  • grinding wheel dimensions: d x bs = 500 x 50 mm
  • grinding wheel dimensions (HSG): d x bs = 400 x 40 mm
  • workpiece speed: nw = 1000 min-1
  • dressing unit: standing & rotating
  • KSS: emulsion and oil
Gerber Brush polishing machine BP-Smart Forming Technologies
  • uniform machining without preferred direction due to oscillating rotary table
  • influence on the brushing result by brush duration, bristle feed,
  • polishing brush and rotation speed
  • workpiece diameter: 1-250 mm
  • workpiece height: 1-200 mm
  • brush speed: 60-600 min-1
  • resolution infeed: ±0.1 mm

3D-printer
Raise 3D Pro2
Automation and Control
  • electronically driven lifting system in extruder head
  • increased torque power and double gear drive
  • filament run-out sensor
  • high-temperature silicone heating bed with 4 + 9 points Lock system
  • air filters
  • printing technology: FDM
  • filament: 1,75 mm
  • construction volume (W×D×H):
    • single extrusion print: 305×305×300 mm
    • dual extrusion print: 280×305×300 mm
  • ultimaker 3 extended (marlin mod)
  • printing technology: FDM
  • construction volume (WxDxH):
    • single extrusion print: 215 x 215 x 300 mm
    • dual extrusion print: not available
  • filament: 1,75 mm
  • PEI coated heating bed with 3-point mounting
  • conversion to OpenSource Marlin Firmware
Collaborative robot
Bosch APAS
Automation and Control
  • capacitive sensor skin
  • centric (all-purpose) gripper
  • mobile robot
Flexpicker
IRB 360
Automation and Control
  • parallel kinematics
  • pick-and-place tasks
  • load capacity up to 1kg
Collaborativ robot
Franka Emika Panda
Automation and Control
  • seven axes
  • load capacity up to 3 kg
  • range: 885 mm
KUKA KR6/KR16/KR30 Automation and Control
  • industrial robots from KUKA
  • typical fields of application: handling, assembly, application of
  • adhesives, sealants and preservatives, machining
  • classical programming
  • load capacities from 6 to 30 kg
  • working radius of max. 2000 mm

KUKA LBR iiwa 14 R820 Automation and Control
  • sensitive robot
  • suitable for collaborative operation
  • seven axes
  • load capacity of 14 kg
  • range of 820 mm
Robot-based machining - HORuS-demonstrator
  • 6-axis vertical articulated arm robot
  • machining spindle for milling, drilling
  • CNC control architecture

Universal Robots UR3/UR5/UR10

Automation and Control
  • collaborating robots from Universal Robots
  • flexible use
  • easy to program
  • loads from 3 to 10 kg
  • working radius of max. 1300 mm
ICECAT – Industrial Control by Edge and Cloud Computing for Automation Technology Automation and Control
  • test bench for the use of cloud and edge technologies in industrial environments within the framework of the Cluster of Excellence "Internet of Production"
    • use the cloud to optimize process steps Aggregation of information
    • use of Edge Devices to control the process flow of the entire process and the cells
  • focus on control of automation processes by means of digital shadows
    • adaptive control through provision of product data and direct use of measured values
    • use of status changes to control the process
  • abstraction of the completion process in windshield production in five automation cells
    • stock
      • intelligent provision of discs
      • detection by camera
    • handling
      • UR 5 for transporting the discs
      • control of the UR 5 by product information
    • cleaner
      • abstraction of the cleaning process step
      • use of Kuka LBR iiwa for force-controlled shutdown of the disk and return of the TCP position for subsequent processes
      • intelligent workpiece carrier system for the identification of the disc
    • primer
      • abstraction of the application of the primer
      • use of Kuka Agilus fivve to apply the primer based on the measured values from the cleaner process
      • intelligent workpiece carrier system for the identification of the disc
    • quality management
      • camera for identification and optimization of the contour of the primer

iCellFactory

Automation and Control
  • platform for research into the fully automated cultivation of induced pluripotent stem cells
    • adaptive, reconfigurable machine arrangement
      simplified exchange of components through standardized interfaces
  • automated process planning and monitoring by using digital twins of components and products
    • adaptive management of existing resources based on the current plant status
    • self-description of individual plant components and their respective capabilities
  • input of definitions of processing steps that can be carried out by biologists without necessary knowledge of automation technology
  • dynamic robot path planning
    • camera-based recognition of storage positions
    • simulatively secured planning of robot routes for goods transport between plant components
Gear honing machine Gleason-HURTH 150SPH Gear Technology
  • outer diameter from da = 5 mm to da = 150 mm
  • module: mn = 0.5 mm to mn = 4 mm
  • maximum tooth width: bmax = 50 mm
  • maximum workpiece speed: nWst = 10,000 min-1
  • maximum tool speed: n0 = 3,000 min-1

Klingelnberg P16 Gear Technology
  • CNC-controlled measuring machine
  • outer diameter: 160 mm
  • 4-axis path control
  • 3D measuring system

Klingelnberg P65 Gear Technology
  • CNC-controlled measuring machine
  • outer diameter: 650 mm
  • 4-axis path control
  • 3D measuring system
Gear hobbing machine Gleason/Pfauter P400 Gear Technology
  • rigid and thermally stable machine structure
  • directly driven machine axes
  • for workpieces up to a module of 8 mm
  • diameter: 400 mm
  • maximum realizable tool spindle speed: 900 min-1
Profiroll PR15HP Gear Technology
  • rolling forces: F = 150 kN
  • spindle speed: to n0 = 120 min-1
  • module: approx. mn < 3.5 mm
Gear grinding machine Klingelnberg Höfler Viper 500 KW Gear Technology
  • outer diameter: da = 500 mm
  • maximum spindle speed: ns = 17.000 min-1
  • feed speed: vf = 20,000 mm/min
Lathe VDF DUS 560 Gear Technology
  • conducting analogy experiments
  • determination of material coefficients for the used cutting force models
Internal circular grinding machine Mitsubishi ZI20A Gear Technology
  • axis cross angle: ∑ ≈ 20-35°
  • cutting speeds: vc ≈ 20 m/s
  • outer diameter: da = 200 mm
Gear hobbing machine Liebherr LC180 Gear Technology
  • maximum speed: nmax = 9400 min-1
  • module: mn = 3 mm
  • workpiece diameter: da2 = 180 mm
Universal gear test stand Gear Technology
  • consists of three electrical machines
  • 4-quadrant operation
  • measuring room certified according to DIN ISO 3744
  • detection of sound pressure, structure-borne sound, rotational errors and angular acceleration