In mechanical engineering, ball screw drives are an important drive element for dynamic and precise positioning tasks. The main areas of application are machine tools such as lathes, on which workpiece or tool carriers are positioned, but also presses, injection molding machines and many others. Each application requires its own special ball screw drive. In order to do justice to this degree of specialization and to be able to manufacture even small quantities cost-effectively, the Black Forest threading technology specialist Kammerer Gewindetechnik is now using a digital assistance system.

The software called "ValueFacturing" from MR Maschinenfabrik Reinhausen networks production data and optimizes manufacturing and assembly processes. This should lead to time savings when programming and setting up the machines, cost savings in terms of inventory and tool consumption as well as increased productivity.

Machining a ball screw nut © Chamber

Previously, Kammerer's turning/milling centers, i.e. CNC-controlled lathes, were programmed by the employees themselves for the individual production steps of the ball screw drives. The programs created could also be reused for repeat parts. For orders with small quantities and new parts, however, the machines often stood idle because reprogramming, measuring and re-equipping the machines with the respective tools took a lot of time.

"The possible solution was to introduce a CAM system, a tool database and a presetting device," says Martin Huber, responsible for lean management and order control at Kammerer. "When networking the different systems, appropriate interfaces are required. From our experience, we knew that a large number of interfaces would always cause problems, for example with software updates, which would then bring the entire system to a standstill."

Networking of all systems and players involved
With the ValueFacturing assistance system now being used by Kammerer, all systems and players involved in the production process are networked. The software is integrated into production and assembly as a web server and connected directly to all existing systems. The control systems of all systems involved in the production process can communicate directly online. The software has access to real-time data; a statistics portal enables the utilization of the machines to be viewed at a glance. In order to gain initial experience with the new software, the launch at Kammerer took place in a small area with six machines. The other areas and the statistics are to be implemented at a later date.

Optical tool measurement © Chamber

Before commissioning the digital assistance system, MR carried out a detailed process analysis at Kammerer to analyze the various systems (CAM, PPS, EPR), machines, tools and production processes. "It took over three years from the first contact to the decision-making process and the conversion of the first machine, which is not unusual for projects like this," says Martin Huber. "After we had obtained a quote from MR, the experts from Reinhausen first analyzed our production. Together, we selected the CAM system and the tool database. MR provided a lot of advice in the process. We then got started in autumn 2019 with the first NC programs for testing and filling the tool database. We converted the first machine in March 2020."

ValueFacturing networks four systems
Martin Huber is delighted with the benefits of the new system: "The NC programs are now created externally at a programming station and no longer by each worker themselves, which saves a considerable amount of time. This also guarantees a standardized programming method as well as optimized travel paths and cutting data. The tool inventory at the respective machine will be significantly reduced. The tools are stored in a central location, which should lead to an overall reduction in inventory and consumption. The interface problem between the individual systems is a thing of the past. ValueFacturing now networks four systems: the TopSolid CAM system for programming the lathes and milling machines, the Wintool tool database for managing the tools, the Zoller presetting device for measuring the tools, and the machines on which our ball screws and other components are manufactured. Ultimately, we can now offer our customers a greater variety of parts that we can produce faster and more cost-effectively." as