The Swiss machining firm Zwicker has geared itself up for the future with a five-axis Heckert 800 X5 MT machining centre and a supplementary linear pallet system. This fully-automated production unit allows the company to be highly flexible and productive, and to use that new flexibility to tap into new markets.
Since being founded in 1994 in Engelburg, near St. Gallen in Switzerland, Zwicker Präzisionsmechanik AG has maintained an upward curve of success. With 25 employees, the service provider focuses on machining challenging precision parts made of metallic materials, predominantly aluminium and steel. Markus Zwicker, who took over the management of the firm from his father Othmar in 2015, reveals the recipe for success: "We deliver the quality our customers demand and can be relied on to hit deadlines — all at competitive prices".
Markus Zwicker has no doubt that specialisation is required to survive in the highly competitive market in the long term: "We need to set ourselves apart from other providers with our services. We achieve this with precision machining." Around one year ago, the company added another performance feature to its services. As part of its building expansion, Zwicker invested in a large machining centre with 800-mm pallets. "This means we can now also machine large parts with a diameter and height of up to one meter cost-effectively. At our site, that's really something special", states the master mechanic, who owes his expertise in part to his diploma thesis during his intensive course at University of St. Gallen.
In choosing the machine, the key factors were quality, flexibility and process reliability, with the firm eventually deciding on a horizontal Heckert 800 X5 MT machining centre. Markus Zwicker was in no way prepared to compromise on these points. He explains: "With this machining centre, we need to be able to produce high-precision results and offer very flexible services. For cost-efficiency reasons, the machine also needs to work around the clock. As such, a linear system for pallet handling and maximum safety throughout the entire process are indispensable."
Those responsible for the machine determined that they required a horizontal, five-axis milling centre with a fast-rotating table for effective turning. A pallet storage system was also made a prerequisite so that the machining centre could be operated fully automatically during unmanned shifts. The specifications also included a large tool magazine. The machine also needed to have an angular head and a replaceable, CNC-controlled U axis to handle demanding contours such as valve seats. Another requirement was a vacuum clamping table in order to clamp thin-walled aluminium parts without warping them.
Growth through automation and flexibility
Markus Zwicker
"The combination of highly-dynamic 5-axis machining and turning operations means we can efficiently handle the complete machining of large and complex workpieces."
Reducing the required clamping positions and eliminating additional machining work on other machines saves time while also improving manufacturing precision.
Linear pallet system for automated 24-hour operation
For Zwicker, there is no doubt that such a high-end machining centre must be able to deliver three-shift operation, which is why it was stipulated from the outset that it should be equipped with an automated pallet system. Erwin Fässler, Starrag Area Sales Manager for Switzerland and Austria, recommended the Schuler Loadmaster loading system, which could be very flexibly adapted to the demanding installation requirements.
It did not take long for the customer to decide on this system. Schuler developed a suitable system layout for the narrow space conditions restricted by columns. To make the best possible use of the available space, 15 storage slots were installed over a total of three levels. If necessary, another machine can even be connected.
