Automatic light alloy-wheel machining: Dugar + Schuster relies on Industry 4.0

In 2018, the machine tool manufacturer Dugar + Schuster launched a fully automatic production cell for light alloy-wheel production. In addition to the high-performance vertical lathe RDM 4, which had been established in 2015, the automation also integrates any other machine and equipment and is designed as a “turn-key” solution according to customers’ requirements.
 The automation is not only planned and installed in Dugar + Schuster’s German premises, but also tested until the final delivery to the light alloy-wheel producer.

Thus, our company meets its challenge for high quality. 
The special features of the Dugar + Schuster automation are the digital networking of all participants in automation. Thanks to the virtual control room programmed by Dugar + Schuster, the customer also has the option of controlling several production cells from any place. The evaluation of the machine data is effected by the specially developed software, the connection to a cloud system offers the maximum possible flexibility.
When it comes to wheel programming, Dugar + Schuster relies on a CAM system that allows the postprocessor to optimize the turning process. 3D wheel models are created and with the tool data of the partner Paul Horn, a simulation of the turning process is carried out, which can then be used as a generated working program in the machine.

Through an automated pre-check of the CNC program, errors can be detected. Specially designed detection algorithms that are activated during the machining process, offer the highest level of safety by detection of tool breakage and protection against collisions. 
A very important topic in the development of Dugar + Schuster Automation is preventive maintenance. In the virtual control room and the cell control, all machine data such as produced number of wheels, failures, alarms or maintenance times are recorded.
Programmed maintenance intervals also facilitate spare parts procurement and manpower planning. Machine breakdowns can be identified more quickly.
A highlight of preventive maintenance: The clamping chucks of the V-Lathe can be equipped with NFC sensors (Near Field Communication).

Thus, for example after repair, the relevant data of the chuck, such as workpiece height position, are automatically transmitted to the V-lathe.
Dugar + Schuster GmbH & Co. KG was founded in 1974 and is owner-managed with headquarter in Langenfeld, Germany. In addition to machine sales and service in the light alloy-wheel industry since 1976, Dugar + Schuster launched in 2015 its first own high-performance V-lathe model RDM 4 on the market. With continuous further development, the first fully automated production cell for light alloy-wheel machining was delivered in 2018 to a well-known producer in Germany, who purchased 3 cells in the meantime.

Picture credits: Horn/Sauermann