FastenersAsia January 2020

Manufacturing Technology

Wafios has a new process for hairpin production

Wafios has developed what is described as “the most flexible machine currently available on the market”, specifically for the production of bent wire hairpins. This flexible new process means that the majority of hairpin geometries for a stator, including the connection assemblies required, can be manufactured in any sequence without the need to change tools. A patent application has been filed for the new process that enables bending work to be accurate, and free of physical damage. The measurement and feedback control algorithms employed ensure that the machine is able to monitor and control itself during production operations. Geometric programming dispenses with the need for the user to program individual CNC axes, and speeds the definition of hairpin geometry. Flexibility depends on the geometric programming of bending parts and/or hairpins. The Wafios controller WPS 3.2 EasyWay also allows users to import 3D geometries automatically with STEP/IGES files. After the coordinates have been imported, the requisite bending program can be produced automatically. There is also the option of integrating and using the simulation tool to run through the complete production sequence of the bending component. The entire process is simulated using a digital twin, including machines, tools and workpieces to create a dependable collision check in advance.

The entire production planning process, including the programming of parts, simulation, definition of cycle time and the collision check, can be performed in a parallel manner at an external programming station. In addition, simulation is used to establish the optimum tool arrangement for the specific bending part. Wafios www.wafios.com ❍ A new process for hairpin production from Wafios

Second Aichelin furnace for fasteners

tight tempering furnace with oil or emulsion hardening baths. Measuring and switching systems are included, along with the process control system FOCOS 4.0 for the new plant (as well as an update of the data acquisition of the existing plant) and a protective gas generator. As with the previous order, the customer provides the loading and unloading device and the component washing machines under their own direction. Aichelin GesmbH, with head- quarters in Mödling near Vienna, is a leading European company for high- quality industrial plants and systems for thermal and thermo-chemical heat treatment of metallic components. Bulten AB www.bulten.com Aichelin Group www.aichelin.com

At 80m length, the furnace plant has a performance of two tons per hour. It is the second industrial furnace plant for the Swedish Hallstahammar site.

Swedish manufacturer Bulten commissioned the Austrian heat treatment specialist Aichelin with the production of a cast link belt furnace for the refinement of high- strength steel screws and nuts. fastener

This is the second 2,000kg/h cast link belt furnace plant supplied by Aichelin to Bulten. Thanks to the positive references at Bulten, the current project was finalised within a few months between the first request and the final negotiation. The plant line measures 80m x 10m and weighs around 180 tons; counting liquids and com- ponents, it can weigh up to 230 tons. Aichelin is delivering the electrically heated high- temperature hardening fur- nace and the protective-gas-

❍ The new furnace at Bulten

FA 14/64

Fasteners ASIA – January/February 2020

www.read-fastenersasia.com