Engineering passion

Powerful systems for trimming of complex plastic components

Final molding machiningFacts and figures2

Our machining techniques at a glance:

Punching Robot milling Automation

For many years, our tools and sys - tems have been successfully used by customers all over the world. This includes almost all suppliers in the automotive interior trim sector, as well as well-known car manufacturers and various other plastics-processing industries.

We are going to advise you in all areas of trimming technologies and, in doing so, pay special attention to your individual task.

We can provide perfect solutions for every purpose to you. We evaluate the feasibility of the project and analyze the machine's capacity by simulating and presenting the cost-efficiency of the process.

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Powerful systems for trimming complex plastic components

In mass production, stable and fully automated processes are very important for parts to be manu-factured cost-effectively. KraussMaffei offers you comprehensive solutions for trimming your prod-ucts. Our portfolio ranges from engineering and prototyping to manufacturing premium-quality individual devices, tools and systems, as well as creating reliable complete solutions that can be integrated for mass production.

We are your specialist for all types of punching, flexible trimming systems using industrial robots and automation of trimming systems. Take advan-tage of our expertise in all trimming technologies.

Your benefits at a glance:– Proven technology– Individual, process-neutral advice– The most cost-effective solution for

every task

Loading station

Our complete solutions for punch&dieIntegrated systems

Automation of trimming systemsKraussMaffei provides complete integrated systems with robot-aided handling. The trim line is fed by an industrial 6-axis robot. After the punching process, areas that cannot be punched are milled automatically (including milling the airbag weaken-ing line). The second robot delivers the finished part to a conveyor that takes it to the next process.

Cutting technology process– Component loading guided by robots– Precise punching operation– Automatic waste transport– Interlinked punching and milling– Flexible milling– Introduction of special processes

(predetermined breaking point for airbags)– Component transfer to follow-up processes

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Milling cell

Punch tool

Transport of finished components

Handling robot

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The technology

Tool fixing area, width [mm] 2500

Tool fixing area, depth [mm] 1200

Maximum opening width [mm] 2200

Maximum stroke [mm] 1200

Closing speed [mm/s] 250

Press force [kN] 500

Tear-open force [kN] 150

Punching speed, adjustable [mm/s] 10 – 30

Upper punching tool weight [kg] 6000

Lower punching tool weight [kg] 6000

Hydraulic circuits 4 – 6

The options

Table width [mm] up to 3000

Table depth [mm] up to 1500

Closing speed [mm/s] up to 400

Other

Pivoting receiver for ergonomic feeding

Expansion for up to six hydraulic circuits

Hydraulic power unit on the machine

Loading from two sides possible

Automatic loading by robots

Air/air-heat exchanger with ventilator

Final molding machiningPunching press

Punching pressPrecision press with highly accurate guidance

KraussMaffei's precision press is ideally capable of punching plastic components thanks to its fast table drive and highly accurate guidance. The punching press is guided by a column-block system. The machine has extremely short cycle times and can be excellently used as part of integrated lines.

Your benefits: – Low punching tool wear– Short cycle times, ideal for high-volume

production– Low maintenance costs– Can be used for several product

generations– Efficient waste disposal even for large

production volumes

Typical punch&die tool Punching press with interchangeable punch tool

TrimStar2 with integrated mold

The TrimStar2 is a compact punching machine with integrated punching device. The features that make this machine special is that despite its compact design, the main cut is driven by the ram and the subsequent cuts are made by hydrau-lic sliders with corresponding punching knives. Loading occurs ergonomically

on the receiver that is folded downward, which rotates upwards by approximately 60° (adjustable) to the punching position for the actual cut. Then, the guided ram is lowered to the cutting position. Thanks to this working method, the TrimStar2 has compact dimensions. The belt conveyor for waste removal can be flexibly arranged

to the right, left or the rear, depending on your needs.

Design basics– Compact design– Ergonomic loading– Precise punching equipment with highly

precise guiding properties– Optimized waste removal

TrimStar2 – punching machine with integrated toolPrecision technology for interior components

Your benefits: – Small installation area and low height– Short cycle times– Very easily accessible– Efficient removal of punching waste for

high-volume production– High level of cutting quality– Hydraulic and electric components

integrated on the rear

Punch tool Hydraulics and electrics

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RoutingStar milling cellRobot milling cell for flexibly trimming complex plastic components

8 Final molding machiningMilling cell

The technology

Robots Up to three ABB IRB 2400/16 Optional: FANUC, KUKA, STÄUBLI

Milling spindles High-frequency spindles up to 60,000 rpm

Power range 1-36 kW

Control ABB IRC5 with KraussMaffei user interface on a teach pendant Optional: PLC machine control system

Changing the Automatic tool-changer station that can be equipped machining tools externally without interrupting the process

Milling measurement Milling length measurement using laser-light barriers

Vertical turntable Turns in under four seconds

Waste management Integrated waste transport systems Optional: Chips and dust extraction

Your benefits: – Very compact design– Robust, mobile machine construction– Ideal ergonomics and accessibility – User-friendly machine control system– Optimized waste transport– Improved emission protection

(noise and dust) – Low-maintenance machine technology– Sophisticated safety engineering

The robot milling cell is optimally designed to trim complex plastic compo-nents. As a mobile cell, the system can be quickly repositioned in production and can be used again within the shortest possible time.

Design basics– Simple modification of the trim lines– Standardized, proven machine

components – Automatic component fixing– Process-parallel component loading

(vertical turntable)– Modular machine design– Lean-production concept possible

The RoutingStar is mainly used with two cooperating robots. As a result, simple dividing cuts through to complex 3D milling operations on, for example, instrument panels, can be made easily in short cycle times. To optimally use the machine's capacity, the insert times and accessibility of the individual robots have already been verified and coordinated in the planning phase through simulations.

Loading and operating area of the milling system (ergonomics and user-friendliness)

Technology rack on the machine base frame (mobility)

Example configuration of a RoutingStar (compact machine design)

Scoring tool on the robot and product-holding system

The ScoringStar is a compact industrial robot system for weaking the airbag section of the skin of instrument panels. To do this, a robot-guided tool developed by KraussMaffei is used to weaken the skin using cold knife process. The skin is holded by a special fixture. The standard

version of the scoring star uses a rotary table. This allows the machine to be equipped while it continues to process the material. Depending on requirements, various products can also be loaded on one system.

Design basics– Tolerance compensation of the robot and

fixtures system thanks to a special active principle (scoring tool)

– Reliable technology with complete process monitoring and documentation

ScoringStar – Foil weakening system for airbag systemsLife-saving technology

Your benefits: – Flexibly set the design of scoring marks– Mobile, space-saving system – Short cycle times – Very high processing accuracy and

repeatability in the residual wall thickness

– Standard industry machine components

ScoringStar with a simple processing table Standard is the rotary table version

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10 Final molding machiningFurther information

Further informationwhich might also interest you

Are you looking for complementary solutions for final molding machining or information on the following topics? – Airbag weakening for injection molding

materials– Deburing– Ultrasonic cutting– Automated quality checks– Interlinked systems

Then please contact us. We would be happy to prepare solutions and concepts which are specially tailored to your need.

Our brochures and flyers – for example, on fiber composite solutions and com-posite processing – can be found online at www.kraussmaffei.com. On request, we will also be pleased to send you infor-mation and technical data for our products free of charge.

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The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in dark blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.

KraussMaffeiA strong brand in a unique global group

Cross-technology system and process solutions Whether in Injection Molding, Reaction Process Machinery or Automation – the KraussMaffei brand stands for pionee-ring and cross-technology system and process solutions in plastics processing worldwide. For decades, our expertise, innovative ability and passionate commit-ment to plastics engineering have been your competitive edge. As a cross-indus-try system provider, we offer you modular and standardized systems as well as solutions customized to your needs.

There for you around the worldWith our worldwide sales and service network, we offer our international customers an excellent basis for a successful business relationship. Due to the close proximity to our customers, we are able to answer your individual inquiries very quickly. We work out the best possible technical and economical solution for your product and production requirements together with you. Test our machine technology for your applications and let our experts put together an indivi-dualized service package for you.

Individualized serviceOur employees from customer service, application technology and service help you with your questions and needs on every topic dealing with machines, sys-tems and processes – around the globe, quickly and with a high level of expertise. We have developed an extensive custo-mized service spectrum with our lifecycle design, which accompanies you throug-hout the entire lifecycle of your machines and systems. Take advantage of the per-sonal interaction and flexibility we offer in our practically oriented seminars. We carry out customer-specific trainings either at your location or at our sales and service locations.

You can find additional information about KraussMaffei at: www.kraussmaffei.comKraussMaffei Group

Comprehensive expertise

Unique selling proposition Technology3

The KraussMaffei Group is the only provi-der in the world to possess the essential machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology.

The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our com-prehensive and unique expertise in the industry.

You can find additional information at: www.kraussmaffeigroup.com

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In mass production, stable and fully automated pro-cesses are very important for parts to be manufac-tured cost-effectively.

KraussMaffei offers you comprehensive solutions for trimming your products. Our portfolio ranges from engineering and prototyping to manufacturing premium-quality individual devices, tools and systems, as well as creating reliable complete solutions that can be integrated for mass production.

We are your specialist for all types of punching, flexible trimming systems using industrial robots and automation of trimming systems.

Powerful systems for trimming complex plastic components