By Order of OPEL Germany we offer subject to prior Sale and based on our actual T&Cs: Connecting Rod Machining Line (600 pcs per hour) 2 off Camshaft Machining Lines (Cycle Time: 60 sec) Crankshaft Machining Line (Cycle Time: 1,5 min) Cylinder-Block Transfer Machining Line Ex-Cell-O (Cycle Time: 60 sec) Cylinder-Head Machining Line (partly) GROB (Cycle Time: 30 seconds) This Machinery and Equipment is in use for the machining of components for 1,9 and 2,2 Liter 4-Cylinder Aluminium Petrol Engines. New: 1994 2004 / Production stopped May 2011 1) Connecting Rod Machining Line: - Capacity: 1.200.000 ConRods per year (1 shift) - Cycle time: 24 seconds per 4 ConRods (600 per hour) - Man power required per shift: one - CNC system of equipment: FANUC NEMATRON Consisting of: - AMT Sorting + Loading Station - 1(2) GARDNER GRC 1000 vertical double disc grinders for pre- and final- grinding of ConRod surfaces >>> 1 off 2 machines to be replaced due to GM Re-Use - 3 off MAUSER flexible transfer lines for machining of big and small eye of ConRods, min/max centerdistance of eyes: 130 165 mm - MAUSER laser + cracking unit with ATLAS COPCO bolting and screwing station - DUERR washing machine - VAN DONGEN weighing station with classification Overview:
Fotos of single units and machines by order of operations: AMT station + first GARDNER first MAUSER transfer line CNC panels second MAUSER transfer line
MAUSER laser cracking unit and screwing / bolting station third MAUSER transfer line DUERR washing machine VAN DONGEN measuring/classification
Connecting-Rod Line Operations Machining by Operations: Pos Machine Operation 1 GARDNER double disc grinder rough grind both sides 2 MAUSER Transfer Line I rough bore crank diameter and chamfer both sides 3 MAUSER Transfer Line I core drill pin diameter and deburr datum side 4 MAUSER Transfer Line I prefinish bore crank diameter 5 MAUSER Transfer Line I finish bore pin diameter and chamfer sides 6 MAUSER Transfer Line I measuring crank and pin diameter and center distance 7 MAUSER Transfer Line II spotface bolt seats (1st step) 8 MAUSER Transfer Line II pilot bore bolt holes and chamfer 9 MAUSER Transfer Line II drill bolt holes thru 10 MAUSER Transfer Line II spotface bolt seats (2nd step) 11 MAUSER Transfer Line II step ream bolt holes and minor tap diameter 12 MAUSER Transfer Line II tap bolt holes 13 MAUSER Transfer Line III laser fracture notches 14 MAUSER Transfer Line III fracture cap from rod 15 MAUSER Transfer Line III brushing joint faces 16 MAUSER Transfer Line III install bolt and pretorque 17 MAUSER Transfer Line III relax, blow off and torque bolts (25Nm + 100deg) 18 MAUSER Transfer Line III fracture break-out detection 19 MAUSER Transfer Line III press pin bushing 20 GARDNER double disc grinder finish grind both sides / Machine to be replaced due to GM Re-Use!!! 21 MAUSER Transfer Line IV spotface and chamfer pinend, datumside -A- 22 MAUSER Transfer Line IV spotface and chamfer pinend, side opposite -A- 23 MAUSER Transfer Line IV if required: drill oil bore in pinend 24 MAUSER Transfer Line IV mill lock slots 25 MAUSER Transfer Line IV fine bore crank diameter 26 MAUSER Transfer Line IV fine bore pin diameter 27 MAUSER Transfer Line IV measuring crank and pin diameter and center distance 28 DUERR washing 29 VAN DONGEN weighing an classification
Connecting Rod Line Layout: AMT loading VAN DONGEN DUERR washer GARDNER grinder final measuring + sorting 1 st MAUSER transfer line 2 nd MAUSER transfer (half) 3 rd MAUSER transfer line GARDNER grinder (ReUse) 2 nd MAUSER transfer (half) MAUSER laser, cracking, bolting line
2) 2 off Camshaft Machining Lines: - Cycle Time: 60 seconds - CNC system of equipment: FANUC NEMATRON and SIEMENS SINUMERIK 840D List of Operations and Machinery in Camshaft Machining Lines I and II Operation Process Machine YoM Line I Line II Line I Line II Line I Line II OP 05 OP 06 facing + chamfering BECKER ULM single station BECKER ULM single station 2000 2000 OP 10 OP 11 hardening + tempering AEG ELOMAT EM 8/80/10/P AEG ELOMAT EM 8/80/10/P 2000 2000 OP 20 OP 21 pre-grinding bearings LANDIS 500 SE LANDIS 500 SE 2000 2000 OP 30 - OP 31 end machining and slot 65 66 grinding BECKER ULM 7-Station BECKER ULM 7-Station 2000 2000 OP 70 OP 71 final grinding bearing LANDIS 500 SE LANDIS 500 SE 2000 2000 OP 72 grinding of guide bearing SCHAUDT ZEUS M R 11 2004 OP 75 grinding of guide bearing LANDIS 3LB THRUST 380x680 2000 OP 72 grinding of guide bearing SCHAUDT ZEUS M R 11 2004 OP 76 grinding of guide bearing, inlet LANDIS 3LB THRUST 380x680 2000 OP 77 grinding of guide bearing, outlet LANDIS 3LB THRUST 380x680 2000 OP 80 OP 81 cam lobe roughing + finishing LANDIS 3L CAM LOBE 380x680 LANDIS 3L CAM LOBE 380x680 2000 2000 OP 80 OP 81 cam lobe roughing + finishing LANDIS 3L CAM LOBE 380x680 LANDIS 3L CAM LOBE 380x680 2000 2000 OP 80 OP 81 cam lobe roughing + finishing LANDIS 3L CAM LOBE 380x680 LANDIS 3L CAM LOBE 380x680 2000 2000 OP 80 OP 81 cam lobe roughing + finishing LANDIS 3L CAM LOBE 380x680 LANDIS 3L CAM LOBE 380x680 2000 2000 OP 80 OP 81 laser marking VECTORMARK VECTORMARK 2000 2000 OP 90 OP 92 finishing of bearings SUPFINA TP 90-6 TAPE SUPFINA 721/1 2000 2004 OP 100 OP 101 washing VAILANT ELAN DUERR 42-EX-HD 2000 2004 OP 110 A OP 110 B final + complete measuring ADCOLE 1310 ADCOLE 1310 2000 2000 OP 110 C final + complete measuring ADCOLE 1310 2000 2000 OP 180 OP 150 handling unknown Unknown 2000 2000 Off-Line Measuring ADCOLE 911-24 2003 Off-Line Measuring HELIOS HELIO-SCOPE 750 2003 Off-Line Ultrasonic Washer Unknown 2003
Fotos of single units and machines by order of operations: BECKER facing + chamfering AEG ELOTHERM ELOMAT LANDIS centerless grinder BECKER flexible Transfer Line LANDIS centerless grinder SCHAUDT ZEUS M
ADCOLE 911-24 measuring (off-line) LANDIS 3LB THRUST LANDIS 3L CAM LOBE SUPFINA super finishing VAILANT washing machine ADCOLE 1310 final measuring
Camshaft Line Layout (first part of operations): BECKER AEG ELOTHERM LANDIS BECKER Transfer Line BECKER AEG ELOTHERM LANDIS BECKER Transfer Line Camshaft Line Layout (second part of operations): LANDIS SCHAUDT LANDIS LANDIS LANDIS ADCOLE VAILANT LANDIS LANDIS SUPFINA ADCOLE LANDIS LANDIS SUPFINA ADCOLE LANDIS SCHAUDT LANDIS LANDIS LANDIS ADCOLE DUERR
3) Crankshaft Machining Line: - Cycle Time: 1,5 minutes - CNC system of equipment: FANUC NEMATRON and SIEMENS SINUMERIK 840 D Consisting of: - Loading station - 2 off NTC horizontal machining centers for end machining (facing + centering) - HELLER DRK 400 turn-broaching machine - VDF BOEHRINGER VDF 315 DM-2 turn-broaching machine - HEGENSCHEIDT 7893 deep rolling machine >>> To be replaced due to GM Re-Use! - 2 off NTC horizontal machining centers - 3 (4) off HONSBERG LAMB MACH 1 500 T twin-spindle horizontal machining centers for deep hole drilling operations >>> 1 off 4 machines to be replaced due to GM Re-Use! - NAXOS RMBO 400 multi-wheel journal grinder - 2 off NAXOS KBO pin grinder - 1 (6) NILES-SIMMONS N 20 CNC Lathes >>> 5 off 6 CNC Lathes to be replaced due to GM Re-Use! - ABB robot deburring cell >>> To be replaced due to GM Re-Use! - HOFMANN full-automatic balancing line - HOFMANN manual re-work balancing station - SUPFINA super finishing line (3 stations) >>> To be replaced due to GM Re-Use! - DUERR washing machine - HOMMEL WERKE final testing + measuring line - Unloading and storing Fotos of single units and machines by order of operations: Loading Station NTC HMC (2 off) HELLER DRZ 400 VDF BOEHRINGER 315 DM-2 NTC HMC (2 off) (3 of 4) Honsberg Lamb Mach 1 500T
NAXOS RMBO 400 NAXOS KBO 400 (2 off) ABB robot deburring Cell HOFMANN balancing line Hommel-Werke final measuring General Information: - Lines may not stay complete, since single Assets and Units will become Re-Used by GM! - Inspections by appointment only! Location: OPEL Kaiserslautern / Germany - All Equipment becomes offered in this Brochure are AS IS, WHERE IS and subject to prior Sale! - Although Information has been given from sources deemed reliable, MAYNARDS make no warranty or guarantee, expressed or implied, as to the accuracy of the information contained herein. - All offers are subject to approval by the Seller and subject to acceptance of Sellers OFFER TO PURCHASE. - This Sale is based on the Terms & Conditions of GM OPEL and MAYNARDS.
Crankshaft Layout (1 st and 2 nd half of operations): Upper row: Loading station 2x NTC HMC 2x NILES SIMMONS N 20 Mid row: 3x NAXOS UNION Honsberg Lamb Lower row: 3x NILES SIMMONS N 20 ABB robot cell Upper row: NILES HELLER VDF BOEHRINGER HEGENSCHEIDT Mid row: 3x Honsberg Lamb 2x NTC HMC Lower row: HOFMANN balancing SUPFINA (line of 3 units) Duerr Hommel
4) Cylinder-Block Transfer Machining Line: - Cycle Time: 60 seconds - CNC system of equipment: FANUC NEMATRON Consisting of: - Line for the Machining of 4-Cylinder Aluminium Engine-Blocks - 12 off ExCellO Transfer Machining Lines for Milling, Drilling and Tapping Operations - GEHRING Honing Line - 5 off FROEHLICH In-Line Leak-Testing Units - 3 off BEYSS In-Line Washers - Loading Units, Conveyors and Handling Equipment
OPEL Engine Block Machining Line (Layout, Part 1 of 3 / OP 05 OP 80)
OPEL Engine Block Machining Line (Layout, Part 2 of 3 / OP 87 OP 155)
OPEL Engine Block Machining Line (Layout, Part 3 of 3 / OP 160 OP 210)
5) Cylinder-Head Machining Line: - Cycle Time: 30 seconds - CNC system of equipment: FANUC NEMATRON Consisting of: - Line for the Machining of Aluminium 4-Cylinder-Heads - GROB Transfer Lines for Milling, Drilling and Tapping Operations - OP 30 and OP 130 GROB flexible transfer line for machining of camshaft main bearing bores - OP 25 consisting of twelve (12) 4-Axes Horizontal Machining Centers >>> to be replaced. All machines become Re-Used by GM! - OP 95 consisting of four (4) 4-Axes Horizontal Machining Centers >>> to be replaced. All machines become Re-Used by GM! - Loading Units, Conveyors and Handling Equipment Loading OP 10 OP 20 Operation (OP) 30
OP 40 OP 50 OP 60 OP 65 OP 90 OP 100 OP 130 OP 110 OP 140
Layout of Cylinder Head Machining Line (Part 1 off 3):
Layout of Cylinder Head Machining Line (Part 2 off 3):
Layout of Cylinder Head Machining Line (Part 3 off 3): Further information under: europe@maynards.com, Tel +49 174 3210116