Production Areas Powertrain Precision metal removal is as important as the design, choice of material, and assembly. Only if all processes are performed with precision will a high-quality and long lasting powertrain product be created. Success requires milling, drilling, broaching, grinding, honing, heat treating to the tightest tolerances and surface finish, and precise and safe handling, all at short cycle times. Powertrains need the highest levels of precision and repeatability in machining and assembly. Nobody offers more ways to achieve the precise motion and control needed to build world-class powertrains. Challenges Machine parts to tolerances measured in micrometers Achieve high repeatability so every part is identical Obtain longer life and greater reliability in the harsh machine tool environment Shorten cycle and changeover times to produce more parts more hour Eliminate rework of machined parts Streamline post-machining assembly operations Rexroth Solutions High-speed machining at 0.000001 mm accuracy - Our digital intelligent servo and CNC controls have a long history of making machine tools faster, simpler, more reliable, and, most of all, more precise. The IndraMotion MTX CNC system handles complex multi-axis applications with ease, and it scales from standalone machines to sophisticated multi-station machining and manufacturing centers. In addition to traditional CNC functions such as milling, turning, and grinding applications, the MTX can handle 5/6 axis high-speed machining, tube/wire bending, laser and punch presses, and plasma and water jet machines. For very precise applications, both the IndraDrive and MTX can be configured to 1 nanometer (0.000001mm) interpolation accuracy. The MTX tightly integrates a very fast multitasking PLC, minimizing control based delays, with a performance CNC that is capable of controlling up to 64 axes (32 of them could be spindles) across up to 12 independent channels (processes) of motion control. The answer for programmable closed-loop and hydraulic CNC - The HNC is more than an electronic control brought to the service of advanced hydraulics. It was designed specifically for precision position and velocity control of hydraulic applications—by hydraulic engineers who understand the peculiarities of hydraulic systems. When used with the digital fiber-optic SERCOS interface, the HNC can work together easily with an MTX CNC controller and electric servo drives performing precision interpolation. This combination enables the user to harvest the maximum machine and process benefits by choosing the best technology for the application - all from one vendor without any finger pointing. Electric DC press-fit systems - With a range from 0.6 – 50 kN (100 - 11,250 lb), our electric press-fit systems offer precise control of force and travel, with systems available with up to 40 channels. Programmable setpoints offer wide flexibility, while integrated sensor systems permit immediate conversion to different workpiece types. The system includes data feedback for production tracking and safety record keeping. Hydraulic press-fit systems - Hydraulic press-fit systems allow a low cost-per-axis, while offering excellent control of axis position and pressure. With positioning accuracy of 40 microns and force tolerance under 1%, our hydraulic press-fit systems use the HNC-100 controller and have position and force transducers integrated directly into the axis to provide process control and verification. Pneumatic press-fit components - We make it easy to achieve precise press-fit pneumatics. Our pneumatic press-fit drive offers integrated force intensification to provide up to 34,000 lbf from 90 psi air pressure in a 10” diameter footprint. Tandem cylinders increase output force up to four times, while requiring one port to extend and one to retract. We also offer high-pressure air/oil intensifiers that intensify pressure/ force for press operations by a factor of 10 or 25. TS assembly conveyors - Get the most out of your floor space with the Rexroth’s TS-Series of conveyors, the world’s leading workpiece pallet-based, nonsynchronous assembly conveyors. Power-and-free technology carries pallets on twin strands of belt, flattop chain, or roller chain. The open center design provides access to the workpiece from all sides and allows easy mixing of manual and automatic operations on the same line. Twenty-six different pallet sizes and an extensive range of modules for stopping, positioning, and transferring workpieces provide maximum layout flexibility for optimum workflow and space utilization. You can construct “cycle-independent” stations or loops to accommodate fluctuating production quantities and to balance cycle times between workstations. Pneumatic parts-present sensing - Part-present sensing in harsh environments is fast and reliable with our turnkey pneumatic system. The MS01 offers precise measuring accuracy up to 0.01 mm. The new compact system controls the presence, position, shape, and dimensions of tested objects. The object is scanned using an air jet from a sensor nozzle. Simultaneous evaluation of the previously defined pressure sends an output to the user in the form of electrical signals. These signals are processed by the machine control system and displayed on the module. The control system either releases the workpiece for processing or stops the process, immensely improving the quality of the tested objects, avoiding errors, and saving time and money. ISO 15407-2 Valves - We offer a wide range ISO pneumatic components, including new ISO 15407-2 plug-in valves. The simultaneous pneumatic and electrical connection for the valve is done on the base plate to make exchanges of valves faster, easier, and safer. Adding to the flexibility of the line are manifold threaded ports in both NPT and ISO-G (BSPP). Valve functions include single and double solenoid plus unique double 3/2 valves, allowing two functions from the same valve position, saving space and expense. Sandwich regulators are available for lateral and vertical stacking.