If a workpiece weighing "only" 2 tons is to be produced from 20 tons of raw aluminum, a lot of swarf is produced in the process - which then has to be removed as quickly and safely as possible in order to avoid congestion and meet the required production times. This also reduces the burden on the environment: The savings achieved by recycling 18 tons of recyclable material by type amount to 252,000 kwh and correspond to 92,000 kg of CO2 per workpiece compared with production using primary aluminum. Kabelschlepp GmbH-Hünsborn has successfully met this challenge, which is not easy to solve technically, on behalf of its Dutch customer VDL Groep.
95% machining volume: even for the professionals at Kabelschlepp, this is an astonishing figure that can only be met with a sophisticated concept for the removal of residual material. It's good that the experts have the necessary know-how and many years of experience. It is also helpful that they were involved by the customer VDL at a very early stage: namely, already at the time of hall planning. As a result, the waste disposal system could already be included in the foundation layout at low cost - later interventions and disruptive technology in the production area could thus be avoided. Following a detailed planning phase, a complex central chip disposal system including container management was installed in 2021, which thanks to its intelligent control system makes an optimum contribution to the safety and functionality of the complete production plant. The total order volume amounts to approximately 1 million euros.
The workpieces manufactured by VDL Groep are required in an innovative process for the production of modern high-performance chips. However, Kabelschlepp's conveying concept is also modern and innovative: "A unique and absolutely individual system in this form was created for several machines and materials, which also ensures cooling lubricant preparation and smooth container loading," says Michael Diebel, Chief Operating Officer (COO) of Kabelschlepp GmbH-Hünsborn. "Our approach here was to consider residual material disposal and the recyclable material cycle as an important part of the complete value chain."
The focus was also and above all on ideally coordinating the processes with the machine controls in close cooperation with the customer. Only in this way can the plant become "intelligent" - and make a significant contribution to the successful production of the special components. The degree of automation of the interfaces allows, for example, container removal for each truck without specific tools.
The customer benefits in several ways: There is only one solution partner for the complete residual material disposal. The multiple use of the same modules also reduces complexity in operation and maintenance. Last but not least, the uninterrupted, unmanned residual material removal allows a very fast return on investment (ROI). Accordingly, VDL is very satisfied with the solution: "The system is proving itself optimally in operation. Kabelschlepp has designed and implemented a system that meets our high requirements right down the line."
The project in detail
- Three conveyor sections with optional residue disposal of FE and non-ferrous metals as well as integrated cooling lubricant separation
- Central duo-container loading with fill level optimization
- 12 coordinated individual conveyors
- Optimal control by a monitoring and control unit
- Networking with the machine controls in coordination with the function and safety concept, visualization of all operating states
- Speed-controlled conveyors, adjusted to an optimum operating point
- High flexibility through partially automated bypass section