夹具故事：制造企业十字路口的助飞器

KTR是一家具备高水平的调研开发能力，专营用于工业的联轴器、刹车、冷却器和液压元件的家族企业，无论是对公司自身和供应商都制定了极为严格的标准。在公司替换机器期间，KTR面临着夹具装置遭受质疑的困境。庆幸的是，在2013年的汉诺威工具机展上，KTR与作为夹具设备制造商的瀚柏格开始接触，并在日后成为了亲密的合作伙伴，逐步优化了制造过程。

本期夹具故事讲述的是 KTR 集团如何凭借新型的机器、精简的流程和新颖的夹具技术，重新起飞的。

从左到右分别为：君特·施莱尔，鲁道夫·迈耶，弗朗兹·约瑟夫·雷德

OFF TO NEW HORIZONS

In 2013 there were extensive upheavals in manufacturing. The stipulations were to reduce idle and set-up times in production in order to further optimize throughput time. Consequently, Günter Schleyer, Production Manager at KTR, was intensively involved with this topic. Several machines were due to be replaced after reaching the limit of their service life. Therefore, we re-examined the clamping area. The important questions for us were: How will we position ourselves in the future, and how do we increase flexibility? Among other things we use machines in floating processes for both series and single-item productions. Here we were at a crossroads: On one hand we required a specialized series production, and on the other hand we needed a fast, flexible cell for the single parts.

追求成长与优化

2013年，制造业发生了巨大动荡。行业开始制定新的规则，要求企业减少生产限制、简化生产流程，进一步优化工作时间，同时减少污染。

因此，KTR的生产经理君特.施莱尔意识到：机器达到使用寿命后必须被替换掉。“我们重新审查了夹具领域，此时我们正处于一个十字路口：一方面我们需要专业的系列生产模式， 另一方面针对单个零件我们需要快速灵活的细胞生产模式。”

他的同事，生产经理弗朗兹?约瑟夫?雷德被指派处理新的夹紧系统。经过调研，他了解了瀚柏格的夹具设备，并在随后的工具机展参观了瀚柏格的展览。

替换金属切割机上的3爪夹盘

02FROM RENTAL TO PURCHASE KTR requested that the responsible Hainbuch Outside Sales Representative, Rudolf Meyer, came to Rheine. Meyer sat down at a table together with both Schleyer and Reder, as well as employees from the manufacturing and design departments and checked which clamping devices could fit with KTR products. However, to become thoroughly acquainted with the products, test their handling, and to see whether the employees could exploit the potential of the clamping devices, the company opted for Hainbuchs rental offer.By the way, the rental was a great thing, adds Telker. Early in 2014 KTR received the Torok manual chuck with a base plate, a clamping head, and a mandrel for the trial phase. For Telker the overall time savings was extremely important. ?How does the system perform in the daily routine? Is it rigid, and can it meet our practical requirements? Can we organize our set-up more efficiently with it? Of course the holding forces and repeatability were highly significant. This is where our manufacturing imposes very high requirements.The result? One manual chuck does is not enough, more parts must be clamped. KTR returned the Torok that had hadbeenrented for test purposes.

从租赁到购买

尽职的瀚柏格海外销售，鲁多夫?迈耶亲自到KTR 所在的城市赖讷，与施莱尔、雷德和生产设计部门的员工共同商议，并检验夹具设备是否符合KTR的产品。

然而，要想彻底地了解产品，还需要测试操作，了解员工是否能发挥夹具设备的潜能。权宜之计，KTR选择向瀚柏格提供租赁 价。2014年初，KTR 收到了用于试运行阶段的带有底盘、卡头和心轴的Torok手动卡盘。

毫无疑问，夹持力和重复性都十分优质的Torok手动卡盘轻而易举通过了测试。在此之后，KTR交给瀚柏格的就是一份购买合同了。

瀚柏格夹具设备具有多样化的联轴器

无论是什么类型的工件都可进行操作

MACHINES WERE CHANGED OVERSTEP-BY-STEP

KTR ordered a clamping pallet with four Hydrok SE hydraulic stationary chucks in the hexagon version along with clamping heads and mandrels for the new machining center announced in 2015 from Hainbuch. Schleyer explains: ?The Hainbuch system is custom-tailored for our products, particularly the flexibility of the clamping heads and mandrels. We do indeed use the clamping heads very intensively; however, we always have special components for which we use their mandrels. At the same time, right from the start we have also planned to use the Hainbuch clamping system for the turning machines that we ordered in 2015. Therefore we use the TOPlus mini chuck. We have a consistent system, whether for turning or milling. Now we are able to change within the modular system and therefore we are much more flexible.? Thanks to the new turning machines in relation with the new clamping tools, some coupling series can be completely manufactured in one clamping set-up.The new investments in the manufacturing are opening up entirely new possibilities for us in thisarea. Now we can bundle different machining steps and thus reduce throughput times. Telker is also sure that the development will move forward in thisdirection. We save a lot of time and gain flexibility.

机器被逐步更新

KTR从瀚柏格订购了一个配有夹头和心轴的六边形四脚Hydrok SE液压固定夹头卡盘，用于2015年公布的新加工中心。

施莱尔解释道：“瀚柏格针对我们的产品，特别是夹头的灵活性和含有特殊部件的心轴进行量身订制了这款卡盘。同时，我们还计划在2015年购置的车床上使用瀚柏格夹紧系统——TOPlus迷你夹具。”由于新机床与新夹具相连，某些联轴器系列可以在一个夹具设定下完整制造出来。

雷德回想起来说道：“对于我们来说，在制造业上的这项新投资完全开启了在这个领域上新的可能性。”

夹头和各种直径的心轴

04ADVANTAGES AS FAR AS THE EYE CAN SEEIn summary, for the KTR Group the expenditure has more than paid off. The required qualities can now be achieved with more simple means. The blanks are clamped in and you are ready to go. Re-clamping and intermediate measurements are unnecessary, and set-up times have been significantly reduced. It was even possible to reduce set-up times for multi-machining operation, and manufacturing processes are better synchronized. Moreover, the handling and reliability of the clamping devices have also shown impressive benefits at all implementation sites.

Use of the Hainbuch clamping systems was a real step forward. Manufacturing has been simplified, tolerances are perfectly complied with, and the shop floor has become leaner and more flexible.

Telker enthuses: With the new clamping deviceswe have been able to gain larger advantages. Consequently, performance has increased substantially. But what about the holding forces? Absolutely secure, even though we are machining at just 5 millimeters.

肉眼可见的优势

对于KTR集团来说，与瀚柏格的合作支出多于回 ：

1.不再需要再夹紧和中间测量，设定时间也大大缩减；

2.多加工操作也缩短了设定时间，制造过程更为同步；

3.此外，夹具设备的操控性和可靠性在其运行的时候也展现出令人印象深刻的优势。

雷德说：“使用海博格夹紧系统是一项真正的进步。制造过程经简化，完全符合偏差，切削技术越来越精简且更具灵活性”。特尔克兴奋地说：“新型的夹具设备使我们拥有了更大的优势，性能也有了大幅度提升”。

夹具的夹持力如何呢？答案是，即使用于加工仅有5毫米的工件，也能绝对安全！