106739725
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106739725
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Requirements Specification machining-centre
Drilling of holes in mainshaft at Scania
Technical questions
Commercial questions
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Index
1
2
General ................................................................................................................ 3
Scope of delivery .................................................................................................. 3
2.1 Tooling system ................................................................................................. 3
2.2 Clamping fixtures .............................................................................................. 3
2.3 Cycle time ......................................................................................................... 3
2.4 Robot loading ................................................................................................... 4
2.5 Programming .................................................................................................... 4
2.6 Acceptance-test ................................................................................................ 4
2.7 Training............................................................................................................. 5
2.8 Machine layout ................................................................................................. 5
2.9 Equipment for machine accuracy test ............................................................... 5
2.10 Production support............................................................................................ 5
3 Process description .............................................................................................. 6
3.1 Pre-machining .................................................................................................. 6
3.2 Process an parameters to be machined ........................................................... 6
4 Additional operation on retarder shaft 1747589 ................................................... 6
5 Time schedule ...................................................................................................... 6
6 Product ................................................................................................................. 7
6.1 General ............................................................................................................. 7
6.2 Operation sheets .............................................................................................. 7
6.3 Material ............................................................................................................. 7
6.4 Weight of parts ................................................................................................. 7
7 Prerequisites for the operation ............................................................................. 7
7.1 General ............................................................................................................. 7
7.2 Emulsion ........................................................................................................... 8
7.3 Floor specification ............................................................................................. 8
7.4 Available space................................................................................................. 8
7.5 Lubrication and hydraulic oils ........................................................................... 8
8 Function description ............................................................................................. 8
8.1 General information of the utilization of the machine ........................................ 8
8.2 Technical availability ......................................................................................... 8
9 Control system ..................................................................................................... 9
9.1 Communications ............................................................................................... 9
10 Safety ................................................................................................................... 9
10.1 TFP ................................................................................................................... 9
10.2 Emergency stop ................................................................................................ 9
10.3 CE marking ....................................................................................................... 9
11 Miscellaneous ...................................................................................................... 9
11.1 Scania Production System ................................................................................ 9
11.2 Content of quotation ....................................................................................... 10
Appendices:............................................................................................................... 10
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106739725
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106739725
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Godkänd/Approved by
Lagringsdata/File
Reg nr/Reg. No.
Se sidfot
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1
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General
Scania in Södertälje has one line for machining of the mainshaft to the gearboxes.
This specification concerns a numerically controlled machining centre for drilling,
milling and deburring of the radial lubrication holes in the mainshaft.
2
Scope of delivery
The machine should be delivered as a turn key solution and will be installed
in the line, loaded by the already existing robot.
The actual operation is described in the enclosed operations sheets.
Additional the shaft must be indexed before drilling and burrs must be
removed from the holes
2.1
Tooling system
The preferred tooling system is HSK 63.
1 set of tools must be quoted so all parts can be machined in the
specification.
The tool magazine in the machine must have room for minimum 15 tools.
The supplier must quote a solution of tool-breakage control. The toolbreakage control system should not touch the tools.
Solid carbide drills are used today and needs an emulsion pressure of
minimum 40 bars and a spindle speed of min 10000 rpm.
2.2
Clamping fixtures
The quotation shall include clamping fixtures for all specified parts. The parts
is recommended to be clamped between centres (A and B in operation
sheets) so the indexing can be made without difficulties. The holes will in the
future be drilled in other angles than 0 and 180 degrees but always
perpendicular to the centreline.

The fixtures must be possible to change over between all parts with smaller
changes.

Priority shall be given to minimising the number of mounting devices in
order to keep the change over times.
2.3
Cycle time
The quotation shall include a cycle time calculation containing:
-Machining-time
-Indexing-time
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-Clamping and unclamping
-Loading and unloading
-Chip to chip tool changing time
The required cycle time, measured floor to floor, must be below 2 mintues
and 30 seconds measured on the part 1776321.
2.4
Robot loading
The mainshafts is transported to the operation on a conveyer system. A robot
takes the part from the conveyer and loads the machine. The robot is using
diameter 80.3 mm on part 1776321.
The machine must be prepared for robot- loading and unloading and
communicate via I/O interface.
The signals to be exchanged are not defined but can be discussed.
The fixture must be prepared for robot handling of parts to facilitate the loading and unloading.
The robot is using the diameter Ø90 or Ø80 on either side of the flange side depending on part
number.
2.5
Programming
Machining programs must be written for all parts in table 1 in section 5.1. Price for
first program and additional programs must be separated.
The structure of the programs should be approved by Scania.
2.6
Acceptance-test
The requirements for acceptance test at the supplier are shown in Scania’s
“Technical directives for production equipment”, dated 2004-01-22, chapter K.
The part 1776321 will be used to evaluate the capability and quality control of the
process. The capability will be analysed before delivery from supplier and after
installation at customer works before taking over. All measurements in the
operation sheets will be evaluated.
The dimensions can be measured in a CMM or an altimeter.
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Additional the two holes drilled in the splines (diameter 6 mm) will be checked by
visual inspection so that no damages is done on the tooth flank. The hole must be
drilled between the two flanks.
During the capability test, the floor-to-floor time will be compared with the cycle
time calculations made by the supplier.
2.7
Training
The price for suitable training for operators and maintenance’s personnel
should be quoted separately. It should clearly be stated how many persons
and days are included in the quotation.
The training shall be located both at the supplier and at Scania (Södertälje). It
must be specified in the quotation what language will be used for the training.

2.8
At the supplier all necessary training to run the machine including
safety, must be included.
Machine layout
The machine must be encapsulated and sealed in a way that chips and cutting
compound or emulsion do not leak onto the floor or into the air.
It must be possible to connect the machine to a central oil mist deflector system.
A survey layout of the machine must be sent in DXF or DWG format together with
the quotation so that Scania can insert the machine in the layout.
2.9
Equipment for machine accuracy test
Before machine acceptance is done a machine accuracy test will be done
according to chapter K3 in TFP 2004. Necessary equipment must be quoted
to carry out a test according to the ISO-standard for the actual machine.
2.10
Production support
The supplier should quote one week of production support after start of production
in order to secure the start up. The calculation should be based on one person on
day shift.
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Process description
3.1
Pre-machining
The shaft is pre-machined in 3 operations. The part is centred and cut to length,
deep hole drilled, turned and milled before the actual operation. The status on the
mainshaft is shown on the 1st page in operation sheet.
3.2
Process an parameters to be machined
The actual dimensions to be machined are described in the enclosed
operating sheets in appendix 1.
The part is not oriented (indexed) before it is loaded into the machine by the
robot.
1. The part must therefore be indexed to a fix rotation angle to avoid
damaged splines when drilling the diameter 6 holes.
2. Drilling, chamfering and milling must be made according to the given
dimensions in the 2nd and 3rd page in the operating sheets.
3. Finally the outgoing burrs from the transversal holes must be
removed.
The robot will unload the part onto the conveyer when the machining is
finished.
4
Additional operation on retarder shaft 1747589
The part 1747589 is enclosed in this operation as a new part for this project.
This will be machined in Södertälje in the future and a possible solution to
mill the keyway must be developed.
The dimensions to be machined is given by the drawing “milling operation” in
appendix 11. The pre-machining is given by the drawing “retarder shaft
turning” in appendix 12.
All costs for this operation must be quoted separately.
5
Time schedule
The supplier must specify the required delivery time from order to the following
activities:
 Pre-inspection
 Pre-acceptance
 Installation and commissioning
 Final acceptance test
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The supplier must specify the time needed for installation of the equipment at
customer plant.
6
Product
6.1
General
The actual parts for this operation have the following part numbers and drawing
numbers. The dimensions for the specific operation can be fined in the enclosed
operation sheets.
Mainshaft
Partnumber/
Operating sheet
H-Axel
H-Axel
H-Axel
H-Axel
H-Axel
H-Axel
H-Axel
Table 1
6.2
1382978
1387295
1387296
1776321
1776322
1476200
1778017
Gearbox
GRS900 / GRS920 /
GRS890
GR900
GR801
GRS945 / GRS906
GRS886
GR875
GR905
Weight
Material (kg)
92216
92216
92216
92216
92216
92216
92216
15,1
16
11,82
18,87
14,43
15,5
20
Operation sheets
The operation sheets describe the dimensions that should be made in the
operation and tolerance to be used in the capability study. The radial holes are to
be drilled and chamfered with the specified tolerances.
6.3
Material
The specification for the material is 92216. The content of alloys is 20MNnCrS5.
See table 1.
6.4
Weight of parts
The weight of parts is specified in table 1 in section 5.1.
7
7.1
Prerequisites for the operation
General
The purpose for this investment is to improve the present capacity and quality.
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The machine must be able operate wet with water based emulsion and must be
sealed so that no leakage with emulsion occurs. Leakage is a safety issue while
many operators are injured every year through slippery floors.
The foundation must be self-supportive and need no anchoring to the floor. All
machine feet and any foundation supports are to be included in the quotation.
7.2
Emulsion
The machine must be able to be connected to the central emulsion system. The used
emulsion is water-based with 6-8% Quaker 8662. The pressure in the central system
is 1.9 bars. The emulsion specification is to be found in appendix 10.
7.3
Floor specification
The supplier has to specify if the machine require a special foundation made for
the machine. Demands of flatness and floor pressure must be specified.
7.4
Available space
A layout with the available space is included in the quotation in appendix 2.
7.5
Lubrication and hydraulic oils
In order to reduce the number of suppliers of oil and lubricants Scania has a
list of preferred products in appendix 6, which the supplier should use if
possible. The supplier is always responsible for the warranty also with the
preferred Scania product.
If the list does not include the suppliers preferred product it should be
specified in the quotation.
8
8.1
Function description
General information of the utilization of the machine
The machine shall be prepared for fully automated production. The machine is to
be integrated in a line were a conveyer system transports the parts between the
machines.
It must also be possible to operate the machine in manual mode with manual
loading.
8.2
Technical availability
The technical availability requirements are 97% at three shift production 5400
hours/year.
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Control system
The preferable control system is Siemens 840 D. If a Siemens system is
chosen the quotation must fulfil the technical requirements for the control
system in appendix 3.
A specification of the components must be done in appendix 4.
9.1
Communications
A communication with the conveyer system through I/O must be possible.
10 Safety
10.1
TFP
The equipment has to comply with Scania’s “Technical directives for production
equipment”, dated 2004-01-22 in appendix 8 and the amendment to the TFP valid
from 2005-12-01 in appendix 9. All deviations from Scania’s directives must be
listed in appendix 5 and quoted with a price to fulfil the directives.
10.2
Emergency stop
There must be a safety signal interface between the robot cell and the machine.
The machine must be stopped according to the regulations in TFP B1.2.4. Detail
will be discussed.
10.3
CE marking
The machine must be CE marked by the supplier. See the TFP L 2.2.
The interface between the robot and the conveyer system will be CE marked by
Scania.
11 Miscellaneous
11.1



Scania Production System
Equipment must be easy to maintain. From a general maintenance
perspective but also from a perspective with a larger amount of
operator maintenance.
Visualize. The “signals” for the equipment must be readily accessible
and very clearly designed and implemented. E.g.; the level in the fluid
level indicators must be easy to observe without open any doors or
such.
Much design effort should be put into ensuring that the surfaces on, in,
and around the machine are kept as “clean” as possible. There must
be a minimum of floor-mounted peripheral equipment, accumulation
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surfaces, narrow or tight spaces, etc. Flushing air nozzles must be
available by the operator doors.
11.2
Content of quotation
In order to have the valuable information available in the quotation, Scania
requires that appendix 7 is used.
Appendices:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Operating sheets of parts for operation.
Layout of mainshaft machining line.
Specification of requirements for control systems.
Specification of components list.
Template (deviations from Scania TFP 2004 2004-01-22).
Lubrications at Scania.
List of basic data for machine.
Scania Technical Regulation for Production Equipment dated 2004 22 nd January.
Amendment to TFP valid from 2005 1st December.
Emulsion specification Quaker 8662
Milling operation on retarder shaft drawing: “bd_1747589_sparfrasning”
Pre-machined retarder shaft drawing: “bd_1747589_svarvning”
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