The specialized facility dedicated to the fully automated processing of wood fiber insulation boards spans approximately 400 square meters and has necessitated extensive research and development efforts. EBAWE Anlagentechnik GmbH, a subsidiary of PROGRESS GROUP, specializes in manufacturing machinery for the precast concrete components sector. Within a mere two years, the company has introduced the I-System, a production line designed for the fully automated handling of insulating materials. The various stations within this system are powered by linear technology from HIWIN GmbH, incorporating a total of 13 linear tables and modules equipped with belt and spindle drives, along with over 60 linear guideways, all installed by the drive specialist based in Offenburg at the new XXL facility.
The eco-friendly wood fiber insulation boards, which are processed individually, serve as displacement bodies for the end customers of EBAWE Anlagentechnik GmbH in the precast concrete industry. Weighing up to 30 kilograms, these insulation boards significantly reduce the volume of concrete required in composite walls. This not only leads to a decrease in cement usage during the production of concrete components but also contributes to cost savings and promotes efficient utilization of raw materials.
The XXL system’s individual stations effectively process each panel, incorporating milled and water-jet cut grooves and notches for cables and pipes, as well as inscriptions. Consequently, each processed panel emerges as a distinct and unique item.
The modular design of the I-System enables it to be tailored to a diverse array of customer needs. This flexibility allows for customization across various processing operations and materials. “This is a plant in a different dimension,” states Florian Bischoff, the design department team leader at EBAWE Anlagentechnik GmbH. The newly engineered I-System comprises eight stations dedicated to the storage, separation, adhesion, labeling, and cutting of insulation materials, in addition to milling and water jet cutting. “The primary challenge, aside from the design complexity, was to ensure seamless interaction among the individual stations,” remarks Florian Bischoff. The emphasis was particularly on cycle time, with a custom-made plate exiting the facility every 15 seconds.
The linear technology incorporated features a stroke length of nearly 40 meters.
The linear axes, which include a total stroke length of 14 meters and 25 meters of linear guideways, utilize a rack and pinion drive to facilitate the dynamic movements necessary for achieving minimal cycle times.
Notably, the HIWIN HD double axis integrated into the I-System functions as a transfer unit, comprising two toothed belt axes from the HM-B series and an extensive synchronizing shaft. Over a stroke of 7 meters, this double axis efficiently transports raw panels into the processing line at intervals of 15 seconds. The ready-to-install system is distinguished by its exceptionally long slide and high moment load capacities in the axial direction.
The linear axes that were installed were meticulously designed by the collaborative efforts of the design teams from both partners. “Through close coordination, we determined the dimensions, slide lengths, gear ratios, and motors,” states Florian Bischoff, the design team leader at EBAWE Anlagentechnik GmbH. The flexible sizing tool from the drive specialist HIWIN played a crucial role in this process. “The ability to save the current project status online in real time allowed both parties to work on the project simultaneously. This capability greatly impressed us and significantly streamlined our work, making it not only easier but also faster.”
In recent years, HIWIN GmbH has established itself as a specialist, particularly in the domain of long linear axes. For instance, toothed belt axes can achieve strokes of up to 16 meters, while linear motor axes can extend to approximately 48 meters. Additionally, linear axes with rack and pinion drives are available with customizable strokes in millimeter increments.
In certain instances, EBAWE opts for HIWIN linear guideways in lieu of linear axes, paired with a rack and pinion drive. The design team leader at EBAWE Anlagentechnik GmbH notes, “The unit is inherently flatter and more compact than any linear axis could ever achieve,” thereby elucidating the rationale behind the integration of linear guideways within the system. The incorporated ball recirculation guides are notable for their impressive load capacity and rigidity.
HIWIN’s linear technology is also advantageous due to its compatibility with various accessories. “The processing of fiberboard inevitably generates a significant amount of chips and dust, which we had to consider in our drive technology design,” explains Bischoff. Consequently, all installed linear axes are fitted with a sealing air connection. The overpressure generated within the axis effectively prevents the intrusion of dust and chips, thereby considerably prolonging their operational lifespan. Additionally, the linear guideways are safeguarded against dust and dirt ingress through a cover strip and specialized wipers of types SW and ZWX. “We were fortunate to benefit from the extensive expertise of the HIWIN technicians, who provided us with exceptional guidance,” remarks Florian Bischoff.
Sustainability considerations were also integrated into the design: the chips generated during milling are extracted and collected for potential reuse. “A compact linear axis from HIWIN, specifically an HM40B, is utilized for the transportation of the extraction unit,” states Florian Bischoff, Team Leader of Design Engineering at EBAWE Anlagentechnik GmbH.
EBAWE Anlagentechnik GmbH and HIWIN GmbH, a specialist in motion technology, have established a successful and enduring collaboration. “HIWIN has been an exceptionally professional partner for us over the years. It was evident that we would collaborate closely on this significant project as well,” states Florian Bischoff, Design Team Leader at EBAWE Anlagentechnik GmbH. “Rapid response and reaction times are crucial for such initiatives.
” The manufacturer of precast concrete components also commends the user-friendly nature of the online tools: “The sizing tool and CAD configurator are remarkably intuitive. Additionally, if we encounter any inquiries, the technical staff at HIWIN, both in the office and on-site, are always ready to assist us promptly.” The delivery timelines from HIWIN are particularly noteworthy: “In the realm of special-purpose machine construction, this represents a significant advantage, enhancing our competitiveness. HIWIN has consistently excelled in this area, which undoubtedly contributes to the benefits of our partnership,” remarks the design team leader at EBAWE with a smile. HIWIN not only excels in the standard segment but also stands out in the development and construction of specialized solutions, impressing customers across Europe with its tailored products.