DESMA highlights industry 4.0 in a historic steel mill

In small groups, visitors were taken to an exclusive venue by shuttle bus - a former steel mill in the west of Düsseldorf - where they were welcomed in a cool lounge. On 400 m², the company had built up an entire machine park. In the spacious hall, visitors experienced individual presentations of DESMA technology live. DESMA experts demonstrated the systems and explained the technical details.

On 15 October, DESMA invited the press and VIPs to the opening. In his speech, DESMA Managing Director Dr. Harald Zebedin explained the complex challenges facing the company. Uncertainty is the new megatrend. The automotive industry and world trade are undergoing a radical change and DESMA is also feeling the effects. Nevertheless, the targets set out remain achievable. By 2022, a market share of 50 per cent or about € 180 million in sales is sought to be achieved, DESMA wants to gain at least 50 new customers per year and generate sales of € 50 million in the business of customer service, spare parts, rebuilds and mould making.

Sales Director Harald Schmid explained: “DESMA is a hidden champion, that is an unknown global market leader.” He said it was on its way to becoming a mechanical engineering service provider that integrates itself into the processes of its business partners. This reorientation is supported by the SmartConnect4.U Eco System presented at the K for the first time.

Necessary changes in uncertain times                                       

Dr. Stefan Loheide, Head of Research and Development at BOGE Elastmetall GmbH, gave a comprehensive overview of the economic factors of influence in his presentation on the trends in automotive development. The economic focus is shifting towards the East, resources are becoming scarcer and new mobility solutions are urgently needed, but it is not yet clear what they will look like. The future has become more confusing and this creates uncertainty. BOGE faces its challenges with a consistent change strategy. Applied to the development department of an automotive supplier, this does not only mean managing the existing business optimally, but also initiating a regulated process for improvement and innovation at the same time. This makes it easier to react flexibly to changing conditions.

Experience technology first hand

The particular focus of the systems on show was on making production more flexible, for example by converting systems at short notice. One exhibit was a D 968.250 ZO Benchmark 750 S3 with FlexCell. It was impressive to see how quickly the DESMA technicians on site disconnect the FlexCell automation cell from the machine in just a few simple steps and how easily the 3-ton cell was then be manoeuvred on an air cushion. In less than three minutes it was reconnected - again ready for operation. The system produced a moulded rubber article with an overmoulded SmartIdent RFID chip - for the first time.

Another D 968.250 ZO BENCHMARK 750 S3 with QuickLock quick clamping system was also installed in the Glühofen hall. This machine is the first to produce moulded rubber articles with overmoulded SmartIdent RFID chips. The mould is changed in just a few minutes. The mould clamping is ensured even in the event of a power failure or a complete drop in hydraulic pressure. A mould change with a hot mould was presented live.

Aside from that, the focus of the machines on show was on efficiency and performance. In addition to a number of other features, a 969.300 SEALMASTER S3 was equipped with a hydraulic PerformanceKit. This significantly improves all movements of the mould carrier and the hydraulic core lifters. As a result, cycle times are reduced by 2.5 to 5 seconds, depending on the motion sequence.

The fourth system on display, a D 969.100 Z S3 with FIFO-C high-pressure injection unit and PartnerFlexcell, is an example of efficient small series production. The swing-out extruder unit facilitates a quick change of the mould or compound, made possible by the FIFO-C injection system with 100 cm³, 2,450 bar with integrated PlastControl. If required, the plasticising screw can be very quickly removed for inspection or cleaning. In HTV silicone applications, the new Cartridge+ plug unit allows the material to be changed easily and largely without losses.

This system was presented with a PartnerFlexCell, which was equipped with a collaborating six-axis robot system and offered a new CE-compliant safety concept as well as three-dimensional scanner protection. This enables robots, machine and people to work together without mechanical safety guards. Besides, the design of the PartnerFlexCell allows its easy transfer to other machines. Thus, either pure machine operation or plant operation is possible by switching over. This machine also used a ZeroWaste ITM system with a mould for the production of small rubber-metal articles. The metal parts are fed into the mould by the robot.