Die casting solutions. Shaping the future of mobility, globally. Innovations for a better world.

Transcription

1 Die casting solutions. Shaping the future of mobility, globally. Innovations for a better world.

2 We are committed. For your success. Every die casting manufacturer has individual needs. That s why Bühler strives to cater exactly to your specific requirements and offers tailor-made solutions for different industries. The requirements of the automotive industry especially are unique, demanding high quality standards. New trends are emerging constantly, such as driverless cars and e-mobility. Also, regulations are getting stricter, and the pressure to reduce fuel consumption is ongoing. Lightweight construction using efficient aluminum die casting plays a key role in tackling these issues. Bühler is ready to support the die casting industry and you through the upcoming trends. Every second car uses light-alloy parts made on Bühler machines. Bühler has already supplied more than 7,000 die casting systems to the global market. Nearly 1,000 foundries are relying on Bühler every day. Die casters around the globe trust Bühler solutions to make parts for automobiles, motorcycles, ATVs, electronics and appliances. Bühler s know-how stems from more than 90 years in the industry. In order to meet your requirements even better and offer you a sustainable advantage in today s competitive marketplace the company invests up to 5 percent of its turnover in research and development. 2

3 Participate in the growth of e-mobility and light weight design.

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5 Bühler cell solutions. Be ready for the future. The Bühler Carat, Evolution and Ecoline S series feature highly productive casting cells. These integrated cells offer you a one-stop solution, including equipment, automation and service. Complete die casting cell solutions form an essential basis for all die casters who want to stay competitive. They combine state-of-the-art technology with the best automation solutions, specifically developed for the die casting process. Peripheral equipment includes ladling devices, sprayers, robots, partmarking units as well as a fully integrated vacuum systems. The DataView control system redefines the human-machine interface. Its intuitive touch-screen simplifies all activities including machine setup, monitoring and diagnostics. Integrated die casting cells help to optimize quality, productivity and cycle time for an increased uptime at reduced costs. The cells provide information about the process in real time and are ready for an industry 4.0 environment. Bühler puts your individual needs in the center of attention and offers you customized solutions, integrated project handling, top quality, fast response times, and global availability. Be it optimized production quality, minimized downtime, higher cell efficiency, or a reduced cycle time that you are looking for, Bühler will find the answer to your question and provide the right solution for you. 5

6 A global presence for a local service. And your investment protection. Proximity is key. With an extensive global service network Bühler is on the spot immediately. Qualified specialists provide hands-on support, knowing the regional market requirements and the needs of die casters. Bühler supports you in all stages of your investment: from planning to startup and throughout the entire life cycle of your equipment. The company believes in a strong local presence and therefore operates 3 die casting production hubs, 3 revision hubs, 4 application and test centers as well as 92 service stations around the globe. Thanks to tailor-made service offerings and in-depth understanding of local requirements Bühler can help you increase the overall productivity of your systems at any time. BuhlerPrince (USA) Excellence in customer service is Bühler s top priority. That s why the technology and solutions provider continuously launches initiatives to further reduce the reaction times to your enquiries: unbureaucratic assistance, straight forward communication and immediate support are guaranteed. However, only the best people can deliver the best quality and service Bühler knows about the importance of constantly investing in developing the skills of its employees. You can count on full-range services performed by Bühler s own technicians located within close proximity to you. Die Casting competence center Bühler subsidiaries and service stations 6

7 Bühler Uzwil (Switzerland) Bühler Wuxi (China) Bühler is represented in over 140 countries with more than 10,600 employees. 7

8 All the service you need. Drive your business forward. Bühler supports you over the entire life cycle of your equipment with individual service and reliable support. Engineering. Based on your component data and your cell requirements, Bühler s engineering specialists will create casting cell layouts. They will determine the required machine size, create an optimal automation and finishing concept, including the robot simulation. Additionally, the experts conduct a cycle time analysis in order to point out your production figures and manufacturing costs engineering at its best, customized solutions for you.. Training. The success of your company and the performance of your die casting cells depend on well-trained employees. Bühler offers an extensive range of course programs around the world where experts pass on their hands-on experience and know-how. In addition, customized classes are provided directly at your site sharing expertise to master the future successfully.. Maintenance and technical support. Service packages can be adjusted to your production batches, thus preventing downtime, loss in production efficiency or product quality. The packages range from individual services to a complete outsourcing of maintenance. To ensure a high uptime of your plant, a fast and reliable technical repair service is available via Bühler Helpline for you worldwide, 24/7.. Retrofits and revisions. Buying a new machine isn t always the best solution. With specific upgrades and conversion kits, outdated machines are able to perform to the current standards of technology and efficiency. Whether it is a software upgrade, the integration of additional functions or a complete overhaul, Bühler experts will work with you to find the best way to remanufacture your die casting machine a cost-efficient alternative to new investments.. Process optimization. Using their vast experience Bühler engineers analyze your foundry and show you potential for improvement. The results of realized process optimizations are impressive: when manufacturing a motor block, for example, an OEE improvement of 5 percent, based on a production of 200,000 units per year, can easily lead to savings of more than 80,000 Euros an investment that pays off. Competence centers and test facilities. Bühler competence centers are equipped with complete die casting cells and provide the perfect setting to test and improve your products and processes. In-house laboratories, including a CT scan, offer a broad range of analyses and testing of different alloys, supporting you with latest technology, expert knowledge and advice never stop improving your products and procedures. 8

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10 The highlight of our collaboration. Your success story. ŠKODA AUTO. Thanks to the two largest die casting cells ever installed in the Czech Republic, ŠKODA AUTO has substantially increased productivity. ŠKODA AUTO made the decision to buy Bühler technology to increase its capacity for engine blocks and gear housings. Besides the need to be more productive they also chose Bühler because of their well-known Swiss accuracy. The project was quite challenging for the Bühler team since they faced a very short delivery time as well as a tight time frame for the installation and hand-over. When the technology was delivered, Bühler could finish the commissioning of the first cell within eleven weeks. After the two Bühler Carat machines were put into operation, ŠKODA AUTO improved its production capacity significantly. It was planned to achieve a cycle time of 130 seconds with these machines; currently, the cycle time is 125 seconds. In cooperation with Bühler experts the team continues to work on improvements to increase productivity even more. Zhejiang Huashuo Technology Co., Ltd. Zhejiang Huashuo Technology Co., Ltd. entered the die casting industry in They invested in Bühler solutions to differentiate themselves from the competition and to offer the best quality. Zhejiang Huashuo Technology Co., Ltd., based in Eastern Chinese Ningbo, started its production of die cast automotive parts in To set themselves apart they decided to focus on maximum quality and reliability. Everyone in the industry knows that Bühler machines are the best. Of course, our customers are well aware of that as well, says Wang Hongbioa, founder and owner of Huashuo. Today the enterprise generates more than 50% of its turnover with aluminum parts which are delivered to renowned OEM suppliers. After the initial investment in ten Ecoline machines in 2010, Wang continues to choose Bühler equipment. Besides Huashuo s high quality standards, the long service life of the die casting systems and the prompt Bühler customer service were decisive arguments. 10

11 FCA US LLC Etobicoke Casting Plant. Producing complex structural components within the existing building led the FCA US Etobicoke Casting Plant to invest in Bühler. FCA US chose Bühler for technology, functionality and worldclass customer service. The advanced controls on the Carat machine delivered new capability to the plant. Andreas Bahr, Tooling Engineering Manager: What drove the decision to go with the Carat was the programming capability and the virtually unlimited modification capability of the shot profile. Beyond the technical advantages of the Carat, its hydraulic clamping mechanism is far shorter than other machines with similar locking force. This was important because these machines were installed in an existing building with limited space. Finally, Bühler supported the installation with local service technicians and backup support from BuhlerPrince, the North American location for Bühler in Holland, MI, USA. The operations at the Etobicoke Casting Plant also profited from the knowledge of the Bühler process engineers who helped to decrease the cycle time by 20%. For Bahr the cooperation with Bühler is really a perfect partnership. Pierburg. Bühler and Pierburg, respectively Rheinmetall Automotive, are linked by a longstanding partnership. Since 1982 the Group has ordered 68 cold-chamber die casting machines. Since its beginnings more than 100 years ago, the company Pierburg has ranked among the drivers of innovation in the automotive industry. In 1986, the company was acquired by the Rheinmetall Group and in 1998 it merged with Kolbenschmidt to form today s Rheinmetall Automotive AG. For decades, the automotive supplier has placed great confidence in Bühler. High-performance die casting cells, competent and comprehensive technical support, and a strong local customer service team have convinced the Group to invest in Bühler technology over and over again. Lutz Plasmeier, who is responsible for the plant technology for Pierburg, as Senior Manager Industrial Engineering Casting & Machining says: Technologically the die casting process with regulated shots from Bühler is unmatched. No other company is able to achieve this level of reproducibility. 11

12 Bühler AG CH-9240 Uzwil Switzerland Die casting solutions en 0118 T F die-casting@buhlergroup.com buhlergroup.com/die-casting