When trained precision mechanic Harald Jursitzky founded BEB Fertigungscenter GmbH & Co. KG as a contract manufacturer in 2002, a fully automated flexible manufacturing system was still a topic for the future. Years later, BEB invested in a system that combines economical manufacturing, automation and the handling of skilled labor shortages. CHECKitB4 adds virtual verification of NC programs to this system.

Initial situation

BEB is based in Margarethen am Moos in Lower Austria and specializes in turned and milled parts in small batches. Since its foundation, the company has regularly invested in new machine tools. BEB sees itself not only as a contract manufacturer, but also as a development partner for its customers. One challenge remained the shortage of skilled workers in the region.

Automation as the answer

BEB has been working on the automation of machine tools for years and has built up substantial know-how. For Harald Jursitzky it was clear that competitiveness is only possible with efficient and automated processes. That is why BEB invested in a flexible manufacturing system.

Flexible manufacturing

The decision was made for a special solution from MAP in combination with PAL-TEC. At its core is a MAP LPZ630, a high-speed milling center with linear drives for 5-sided machining. A pallet rack with 96 spaces supplies the machine automatically with workpieces. The pallet system, the LPZ630, the host computer and the control must work closely together.

ESPRIT and Pimpel

Since entering combined turn-mill machining, BEB has relied on ESPRIT. Pimpel supports BEB with ESPRIT, postprocessors, multi-part clamping, zero point shifts and subprogram technology. Pimpel’s own software development is equally important for BEB, especially CHECKitB4.

CHECKitB4 as a success factor

The LPZ630 is equipped with a Siemens control. CHECKitB4 virtually maps this machine and works with the real Siemens kernel of the original machine. BEB can carry out the run-in and checking of NC programs calmly before the real machine and detect problems in advance.

Virtual reality before the machine run

Before BEB manufactures on the machine, fixtures are designed, parts are programmed, tools are simulated, collision contours are defined and machining operations are checked virtually. This allows BEB to go to the real machine with a high level of confidence. The virtual machine does not work like a simple graphical simulation, but with the control behavior of the real machine.

Everyday operation

All skilled workers at BEB can operate CHECKitB4. Only a few actions are required to start the virtual machine. This makes the digital twin not a special tool for individual experts, but a practical part of the manufacturing process.

Setup times and run-in

With CHECKitB4, programming and run-in can be performed virtually while the real machine is producing. At NC start, it is not the spindles and turrets of the real machine that move, but the 3D parts of the machine room simulation. Due to the direct coupling to the NC axes of the control, the movement sequence corresponds to the real machine.

More preparation on the PC

The more complex the parts become, the more important CHECKitB4 is for BEB. Because of the high capacity of the flexible manufacturing system, programs have to be brought to the machine safely and quickly. Today, a large part of parts manufacturing at BEB takes place on the PC, while the machine cuts almost without an operator.

Result

Previously, BEB had to program for two days, set up for half a day and manufacture for two days. Today programming is still done, but setup time is practically eliminated by CHECKitB4 and manufacturing time has, according to BEB, been cut in half. The investment in the flexible manufacturing system only unfolds its full value together with software that virtually verifies NC programs.

User

BEB Fertigungscenter specializes in modern CNC manufacturing. From simple drilling operations to complex multi-axis turn-mill parts, BEB uses different technologies and combines them with automated workflows.