SPECIAL-PURPOSE MACHINES FOR THE MANUFACTURE OF PHOTOVOLTAIC CELLS AND E-MOBILITY

Jonas & Redmann Automationstechnik GmbH in Berlin was founded in 1989 as a service provider in the field of special machine construction. The demanding projects all concern the automation of production in the solar panel industry, the medical sector, vehicle construction and battery manufacture. With 450 employees, Jonas & Redmann is a dedicated partner for its customers, from product conception through design and production to service. In order to be able to react quickly and flexibly, the company has built up its own machining department, which includes eight machine tools from DMG MORI. Jonas & Redmann has been working with products from this machine tool manufacturer since 1994. The latest model, a DMF 200 | 8, was procured for the high-precision machining of long profiles, sheets and support frames.

The concept of the DMF has optimized our cutting over the long term. The design even allows us to machine over-long workpieces that extend beyond the working area.

Frank Polak (left), responsible for communication
Yilmaz Öztürk (right), mechanical manufacturing manager
Jonas & Redmann Automationstechnik GmbH

Customized automation solutions for e-mobility and the medical sector

Automated production is the surest way to remain productive and competitive in a global market. “Such solutions are extremely complex, especially in high-tech industries”, explains Frank Polak, responsible for communications at Jonas & Redmann. “Depending on the requirements of the products our customers manufacture, we design individual solutions that range from simple fixtures to complex handling and assembly systems to fully automated production lines.” Jonas & Redmann can implement even the most demanding projects within a year. In the founding years, the enormous upswing in photovoltaics shaped the day-to-day business.
The manufacture of solar panels is one of the company's main business areas, says Frank Polak, alongside the medical sector, automotive engineering and the production of energy storage systems: “The strong growth in e-mobility has resulted in the latter two areas increasingly overlapping.” As a direct supplier to major manufacturers, Jonas & Redmann is involved in new development projects at a very early stage.

PRODUCTION EXCELLENCE FOR GREEN TECHNOLOGIES

• Automated handling solutions
  for crystalline silicon wafers used in the production of solar panels
• Production equipment for energy storage systems in e-mobility,
  e.g. for battery cell production or the assembly of battery modules

DMF 200 | 8
THE NEW MOVING
COLUMN SERIES

• Maximized rigidity due to 3 linear guideways in the X-axis
• Constant milling performance due to consistent overhangs
• Excellent surface quality and accuracy due to direct drives in the Y-axis and Z-axis, as well as integrated cooling
• Maximum machining flexibility thanks to B-axis milling head with ± 120° swivel range
• Large working area with travels of X=2,000 / Y=800 / Z=850mm
• Patented and innovative tool changer, fast, collision-free and positioned behind the machine table for safety

Rapid response through in-house machining

Jonas & Redmann procures a large proportion of components for the automated systems from suppliers. They are assembled at the headquarters in Berlin. This is also where final acceptance takes place. In addition, the company has set up its own machining facility. “It allows us to compensate for capacity bottlenecks and process urgent orders,” explains Yilmaz Öztürk, head of mechanical production. Machine tools from DMG MORI have been operating here reliably for many years, both for turning and milling, and include 5-axis DMU 50s and an NL 2000 for turning.

DMF 200 | 8: Maximum and constant rigidity thanks to 3 linear guideways in the X-axis

n 2021, extra capacity in the profile machining area was needed. A large working area was required for the workpieces, which were long in many cases. DMG MORI had the right model in the product range with the DMF 200 | 8, which was new at the time. “Thanks to the 3 guideways in the X-axis, the new DMF center makes powerful, high precision machining possible. This is consistent throughout the entire working volume”, says Yilmaz Öztürk, assessing the machine concept. With the speedMASTER spindle, which achieves a rotational speed of 15,000 rpm, Jonas & Redmann machines aluminum, steel and stainless steel as well as plastics. One reason for the outstanding rigidity of the DMF 200 | 8 is the one-piece gray cast iron machine bed, the 3 linear guideways in the X-axis and the previously mentioned consistent overhang in the Y-axis. A comprehensive range of cooling measures also ensures high, long-term thermal accuracy.

Safe machining of long workpieces

A highlight of the DMG MORI traveling column concept is the innovative and unique tool changer behind the worktable. Yilmaz Öztürk adds: “This allows us to use the entire clamping surface for entire frameworks without the risk of collision.” The DMF 200 | 8 also provides process safety due to its guideways, which are outside the working area. “Wear is therefore reduced to a minimum.” The Machine Protection Control (MPC 2.0) technology cycle completes the attributes of the DMF 200 | 8 by offering a high degree of process safety. The aperture for loading lengthy components through the side panel is considered a bonus: “When we open it, we can clamp parts that are longer than the 2,300mm table.”

 

INNOVATIVE TOOL CHANGING OUTSIDE THE WORKING AREA

DMF – long-term chip removal optimization

Jonas & Redmann moved into a large new building two years ago in which all processes from design to manufacturing and assembly can be carried out even more efficiently. In this connection, the DMF 200 | 8 was an investment based on long-term metalcutting optimization. We want to press ahead with this: Yilmaz Öztürk says looking ahead: “We will gradually modernize our mechanical manufacturing with innovative solutions similar to the DMF 200 |　8 to increase our capacity and particularly our productivity. We will definitely also be taking a look at the new DMF 300 |　11 with its 1,100mm Y-axis.”

Note: Organization names and titles are current as of publication timing.

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