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True to our motto "one step ahead", with GEISS you are always one step ahead - not only today, but also in the future. Because our machines are equipped with the latest technology and furthermore, they are designed in such a way that they can be upgraded at any time in the future.

We offer you a technology which is based on the flexible and high-performance basic concept of parametrics. The parametric principle is realized by the CIM technology (Computer-integrated-manufacturing).

For you as a customer, this means that you can choose the machine size that best suits your needs. So you are always "one step ahead".

 

To be able to work continuously on the development of our technologies we specifically invest in our technical equipment. Only in this way, can we consolidate or even increase the speed and level of our innovations.
In the course of a reorganization, we dissolved our steel profile storage in order to have only one single manufacturing strategy.

  • lasers
  • folding
  • milling
  • welding and
  • painting

The idea of GEISS, everything from one source, has proven itself also in-house in the best way and guarantees a flexible and consistent production of customer orders.

We are offering you technology, which is based on the both flexible and high-performance basic parametric concept. The parametric principal is realized through the CIM technology (computer integrated manufacturing). This means for you as a customer that you can decide on your optimal machine size. In this way you are always

“One step ahead”.

Therefore, the parametric system is the key to the success of GEISS.
GEISS AG uses the principal of the parametric draft in all production sites and in Computer Integrated Manufacturing (CIM).
Parametric designed machines can be adapted in size and in degree of automation. If a variable is changed, the construction worksheets enable an automatic adjustment of the other components and measurements. The necessary scaling is realized through special self-developed software, which covers the whole production process.

The “digital factory” of GEISS AG with an almost 100% vertical integration reaches so far, that the programming is no longer done at the machines themselves.
All program structures are automatically written offline by special software.

The parametric design, which covers all production phases, makes the organization very flexible.
As a result of the preliminary work in the design and the sophisticated production processes, it is now irrelevant which machine size or optional equipment you have ordered. To enable a continuously variable machine size GEISS does not use a standard steel profile for the machine frame but manufactures a special profile made from steel and aluminum sheet metal.
In this case, the lead-time for a cutting machine from our ECO series is less than 6 weeks.

Advantages of the parametric designs on one view:

  • Selection of an arbitrary machine size
  • Continuing development of all series
  • No difference between standard and special sizes, as “special developments” don’t exist anymore
  • Absolute optimization of the support profiles, as individually designed profiles are bent on press brakes without resorting to standard profiles
  • Selection of an enormous number of free options, which enable the optimal equipment of each machine
  • The development of the parametric design is the strongest weapon for us and for our customers.

We build our customer machines exclusively in our own company and use our own machinery exclusively.

 

Laser trimming

One key plant – or maybe even the key plant – is the laser. The cutting of the sheets is the first step in our manufacturing. Everything has to go smoothly here, as the whole of the following production depends on the quality and the productivity of our laser plant.

  • lasers
  • folding
  • milling
  • welding and
  • painting

As there has been further development in the field of laser technology – automatic unloading and more over a clear improvement of the laser output – we decided on a new machine. Within three months the company   TRUMPF Laser- und Systemtechnik GmbH in Ditzingen  was able to deliver.

Since the start of January 2000, a fully automatic TR 4000 which is able to cut, unload and stack operates unattended day and night. Through this, we are able to produce accuracy to the highest level and are able to keep short delivery times regardless of our order situation.

Bending machine

Our bending machines of company TRUMPF stands for wide experience and industry leading innovations.
In so-called bottom bending, or folding, the sheet metal is bent by a controlled downward movement of the pressing beam.
Here the flat sheet is pressed by an upper tool into a V-shaped lower tool (die) and formed in a straight line.
The back gauges ensure the exact position of the workpiece.

Here an angle measurement system ABC laser supports the bending process, so that the first part is already perfect.

We are always profiting from a high part quality, the advantage of flexibility, innovative tools, thoughtful automation solutions as well as intelligent software from Trumpf.

Usability and ergonomics are paramount: the machine supports the operator at work.
With these machines, we are precisely manufacturing both simple and complex parts in every format and especially economical.

 

CNC processing

 

The CNC cutting machine (Computerized Numerical Control) which we are using in our machine shop, utilizes the newest control technology allowing us to automatically manufacture pieces with high precision also for complex projects.

Welding


Welding robot

Our five automated welding robot systems from Cloos are available with a wide range of proven and innovative welding processes for manual and automated welding requirements.

With a software from IGRIP, which as is specially optimized for GEISS, it is possible to generate automatically complex welding programs and welding processes for every machine size within minutes.

With these welding robots, we are manufacturing precisely and economically exactly the quality, which fits the customers’ requirements.

The welding robots support the welders in all their work and it is impossible to imagine the production without them.

Customer molds and tools are produced exclusively on the company's own machine park and refined in tool making.

 

CNC machining for tool making

 

CNC Trimming in Production

In modern production where demanding contours and geometries are important, path control is the main issue.  The software of choice is Siemens, 840D sl control.  Path control applies small traversing movements on machines with at least two axes controlled simultaneously.  Individual axes are interpolated enabling the tool to follow the corrected, programmed path exactly.  This means that independent movements of different axes are synchronised by the CNC control.  The interpolation of at least three axes is standard in CNC trimming and this type of control is also called 3D path control.

 

Programming

The CNC Trimming process requires machines to be programmed, entering codes to instruct axis movements and which tools to be used in order to achieve the desired contour.  During programming a distinction is made between ‘on machine programming’ and ‘offline programming via an external PC’.  Direct machine programming requires the operator to enter the corresponding codes directly into the machine control whilst offline programming uses an external programming PC to send the codes to the control.  Earlier controls would mainly be programmed directly on machines using so called G codes.  This code, standardised DIN/ISO, represents a universal machine language, regardless of manufacturer.  In modern production the operator is supported by dialog orientated programming.  Programming is made simple by means of graphics, querying parameters and other information.  Machine programming on the CAD/CAM workstation is extremely relevant for mould making.  Existing 2D geometries or 3D models are ‘translated’ into machine readable programs, using pre and post processors.  This significantly reduces programming efforts, unit costs and ensures greater safety regarding geometries created on the work piece.

 

Advantages of CNC Milling

The advantages of CNC controlled machining lie in the production of extremely complex, three dimensional geometries.  The flexibility of this manufacturing process also plays an important role.  A saved program enables series parts to be manufactured without human intervention which lowers labour costs and keeps unit costs competitive.

Pneumatic Cylinder Motor
 

Pneumatics are simple and inexpensive although compressed air is said to be less efficient.  In recent years this had led to discussions and an increased search for alternative technologies, i.e. electric motors.  However, practice shows that depending on the application a decision must be made as to which drive technology is the cheapest in terms of energy and economy.  In most cases general statements are not possible.  That is why we continue to use various pneumatic drives/cylinders in different areas of application.

Direct Drives

 

Direct Drives, Ball Screw

A direct drive is a special type of servo drive.  Electrically speaking modern versions are 3 phase, brushless synchronous motors with permanent excitation.  The geometry of the motor is optimised for increased forces instead of high-power output.  Direct drive technology executes the desired movements directly without conversion, using mostly rotating movement sequences.  To reduce copper losses and keep electrical time constants low, these motors also have more poles than conventional servomotors.  In short, the torque or power output is optimised instead of the efficiency of these motors.  The most important selection criteria is the acceleration capacity of these motors.  There are a number of reasons for using this modern drive technology for both rotary and linear movements.  Besides its performance, the secondary advantages are the often decisive mechanical design.  Examples of motivations are:

 

  • Fast acceleration 
  • High dynamics (ratio max./min. speed)
  • Improved rigidity and damping
  • Better accuracy and repeatability
  • Improved reliability
  • Improved efficiency
  • Good uniform behaviour across a wide range of temperatures
  • No wear & tear parts – longer service life
  • Reduced noise
  • Hollow shaft
  • Short motor length, smaller motor cross section
  • Size and shape

 

Linear Drives

 

Linear Motors

Linear drives enable direct and vibration free power feeds in the machine slide at the highest speed and path accuracy.  Developed for the highest speeds and dynamic acceleration, linear motors achieve an increase in area throughput of at least 30% and up to 100% when cutting model surfaces with several direction changes.  It is not the rapid traverse, although impressive, but the substantial axis acceleration that counts.

 

Linear drives have been successfully used on Geiss trimming machines without problems since 1998.  Since then over 70 machines have been supplied with this high-quality drive technology.  The basic design concept of the Geiss trimming machine – portal construction with fixed machine table – has proven to be the ideal prerequisite for the use of these drives.  The economic advantage for the user is obvious: Cycle times can be reduced by half in most cases and maintenance expenses are greatly reduced. It is evident that the lifespan of this system far exceeds that of conventional drives!

 

Advantages at a glance:

  • Extreme dynamics with high acceleration and highest speed, regardless of the travel length
  • Completely free of play with extreme precision on contour machining and far superior than rack and pinion drives.
  • High reliability due to no wear and tear parts, machine access and longer service life.
  • Unaffected by dirt and virtually maintenance free.
  • Short cycle times and high productivity.

 

Area of application:

  • Trimming of vacuum formed plastic parts
  • In model making
  • Ultrasonic cutting of non-trimmable parts
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Torque Drive
 

Torque motors are round motors designed for extremely high torque output.  The rotation axes have impressive speeds: 600 or 900 angular degrees per second rapid traverse speeds in both axes.  The acceleration is 1,800 or rather 360˚/sec²!  This is a new performance class for plastics and aluminium processing.  The rotational axes no longer limit fast simultaneous movements and during circular horizontal radii.

Indirect Drives

 

Rack and Pinion Drive

    On a rack and pinion drive the rack is a straight machine element with a row of teeth into which a gear wheel engages.  The stroke or travel path of a rack and pinion drive is calculated from the middle section of the sprocket of the driven tooth gear, the so-called pitch circle diameter and the number of revolutions.  Similarly, the speed (or feed rate) of the rack is obtained using the speed.  In the rack and pinion drive, the gear axis rotation is perpendicular to the direction of the rack placement.

    Example of motion conversion:

    • Generating a straight-line motion using an electric motor.

       

      Ball Screw Drive

       

      A ball screw drive (KGT) is a screw drive and nut packaged as an assembly with recirculating ball bearings.  Both parts have helical grooves which together form a helical tube filled with balls. The interlocking connection is made via the balls and not the thread groove and dam/wall but via the balls.  When the screw and nut turn, the balls roll in their tube and move towards the front end of the nut.  From there they are usually picked up by an external tube parallel to the threaded shaft, led to the back of the nut and placed back into the tube.

      In comparison to a conventional screw drives with surfaces sliding on each other of which 50% to 90% of the power input is converted into heat; the ball screw drives have

      • Less friction due to the rolling movement (lower drive power, increased possible movement speed)
      • Less stick slip behaviour (higher positioning accuracy)
      • Lower wear

      Hydraulic Drive


      Basic principle: A pump driven by a motor (=hydraulic pump) generates pressurised oil flow (volume flow, flow rate) which is directed to an oil consumer (hydraulic cylinder or hydraulic motor).  There the pressure energy stored in the flow is converted back into mechanical energy.  Such systems are known as hydrostatic drives, or also Hydrodynamic drives.  Geiss AG mainly use hydrostatic drives, also known as hydraulic drive or hydraulic system.

      Advantages of hydraulic solutions are:

      • Increased force and power can be applied in a small space
      • Smooth and stepless controlled speeds, even under load
      • Quiet operation, fast and smooth reversal of movement
      • Simple and safe overload protection
      • Long service life and maintenance friendly due to a hydraulic oil  

      self-lubricating system on the sliding parts

       

      In comparison to a robot, CNC machines score with a more accurate path control.

      Not all products are the same. The image comparison shows a considerable difference in quality with the final product when it is manufactured with different machine systems, like this inner car door.

      As clear the differences, as easy the explanation:
      Robots have a point-to-point control, accordingly the machine is forced to exactly approach the “taught” points. However, the path between the points is not taken into consideration. As a result, this path can vary depending on the speed and mass of the transport. Any path control is completely missing.

      Whereas a CNC machine continuously controls its path and records the so-called “lag”, which can be randomly placed. This means that the tool of a CNC machine moves within an individually given tolerance range. If this is left for any reason, the machine stops automatically and signals with an error massage that something out of the norm is happening.

      Bullet point interpolation: A robot mostly has six concatenated rotary axes. For interpolation of a straight path – which is the most common and the easiest to control – a CNC machine has to Interpolate one to three axes with each other. A robot, on the other hand, has to move all six axes and therefore has to smooth them in a complicated manner.

      The images are showing the result: The path of the robotic cut piece are bumpy and unclear. The path driven by a CNC machine is exact and even and almost two sizes more precise. Thereby the track speed is three times higher and the CNC path is permanently controlled.

      Our offer would not be complete without comprehensive services. We support you quickly and cost-efficiently worldwide. We are there for you with our online fault diagnosis at any time. Efficiency in communication, fast response, high automation and optimized storage systems characterize the modern structures of the company to achieve our goal: Innovative technology for “one step ahead” that paves the way for many.

      Spare parts for your machines are stocked at GEISS for at least 10 years. Due to the high vertical range of manufacture, a much longer subsequent delivery time must be considered for some cases. The purchase of first class components from international operating manufacturers enables a fast spare part delivery worldwide.

      We are offering a worldwide service regarding, service visit, commissioning, purchase of spare parts and optimization of existing machines. Our specialists are available for questions and problems over 80 hours a week by telephone. For technical problems, our remote diagnosis has especially proven itself.

      We are offing individual training in the field of thermoforming as well as CNC processing for optimal usage of your machine. Talk to us. 

       

      CAD/CAM –Systems

      Modern parametric CAD/CAM systems (Computer Aided Design / Computer Aided Manufacturing) support the new construction, promote variant construction and exceed the sole data processing of geometric by far.

      For almost 40 years, parametric CAD/CAM systems have been on the market and have also been used at GEISS since then. The train of 3D users has massively gained speed and ground. New functions are helping with the construction of components.

      Since 1989, GEISS have counted on company TEBIS in the field of mould, tool, model and prototype construction, as TEBIS CAD/CAM systems are especially made for the requirements of those fields and great importance is attached to professional and extremely efficient CAD/CAM technologies.
      Complex tools, such as refrigerator containers, technical twin sheet parts, milling fixtures for the automotive industry etc. must be manufactured in a short time with as little rework as possible. Meanwhile, all tools at GEISS are constructed with the Tebis system. Tebis is used both for programming the CNC processing machines and for creating any required cutter paths for post-processing (plastic parts, airbag weakening, etc.).
      The GEISS mechanical engineering design office works with the worldwide successful MEDUSA product family, which offers complete solutions for the creation of drawings. This product family is based on a platform-independent core, which guarantees with an also platform-independent user interface the highest flexibility regarding the operating system.
      We are using EPLAN on a Microsoft user interface for the preparation of electrical plans as well as for the complete planning of electrical projects. The phase oriented and parameter-controlled system is based on the familiar working methods of the designers. It supports all project phases and achieves highest efficiency even for complex tasks with many features and automated functions while being easy to use. As the market leading solution, EPLAN developed to the global standard for CAE.

      CIM systems

      Due to the great variety of systems, it is impossible to imagine the computer integrated product development process (Computer integrated Manufacturing) without one. Starting with the customer inquiry, which is processed electronically, through the parametric construction, the resulting production programs, the automatic ordering of necessary components directly at the supplier up to the customer specific machine data for the final product, GEISS attaches importance to a high degree of automation-.

      Thereby the following for CIM concept typical elements are used:

      CAD (computer aided design): All construction is made with the help of a computer aided CAD program. This method is still used to create wiring diagrams. In the future, the data for automatic schematic generation will come from the construction parametric.

      • CAM (Computer aided manufacturing): The production processes are electronically controlled based on the specifications of scheduling and design.
        Processing programs are automatically created. Based on the automatically generated processing program the production is started and controlled.
      • PPS (Production planning and control): In the PPS system, order initiations, ordering and scheduling at GEISS are automatically suggested and monitored.
      • The interlinking of all processes with the help of a specifically configured and an optimized network through specific ports enables a smooth
        communication of the individual  areas.
      • CAT (Computer aided testing): in some specific areas computer aided tests and simulations are made to lower the costs and improve the quality.

      With the help of these methods even serial plants with quantities of one can be produced economically and effectively.

      Linear encoders for driven tool machines

      The current position of the feed and drive unit is usually measured directly at the load point, usually on the slide of a linear drive. Therefore, the measured value is not affected by temperature, wear, dirt, slope errors, spindle and coupling backlash, elastic deformation etc. Absolute or incremental measuring methods are used.

      HEIDENHAIN linear encoders for numerically controlled machine tools are universally applicable. They are suitable for machines and plants on which feed axes are traversed in a controlled manner  – i. e. for milling machines, processing centers, boring mills, lathes and grinding machines. The beneficial dynamic behavior of the linear encoders, their high permissible traverse speed and acceleration in measuring the direction makes them suitable use on highly dynamic conventional axes as well as for direct drives.

       

      In indirect measurement,

      the rotations and angular positions of the axis, the drive motor, or the drive shaft are recorded with a rotary measuring system. Together with the specific data (spindle pitch) of the drive spindle, the traversed path is calculated.

      Tolerances and deviation, that occur depending on the structure of the axes for example through gear, spindle, coupling backlashes, temperature variations expenditures, wear, dirt, tooth belt extensions and slope errors all affect the measured value negatively. The advantage over to a direct measuring system is that it is a more cost effective system.

      Absolute or incremental measuring methods are used.

       

      Absolute measuring method

      With the absolute measuring method the position value is immediately available after starting the measuring device or machine and can be retrieved from the following electronic at any time.

      A procedure to determine the reference position is not needed. This absolute position information is a generated scale graduation, which is built as a serial code structure or is constructed from several division or code tracks. A separate incremental track or rather the track with the finest graduation structure is interpolated for the position value and used at the same time to create an incremental signal.

      Strengths:

      • The absolute position value is already available after turning on of the machine, which means that a reference drive is unnecessary.

      Challenges:

      • Higher total cost in comparison to the incremental measuring method

       

      With the incremental measuring method, the division consists of a regular grid structure. The position information is gained through counting of the single increments (measuring steps) from an arbitrarily set zero point. As an absolute reference is needed to determine a position, the scales and measuring tapes have a further track, which carries a reference mark. The absolute position of the scale, which is determined by the reference mark, is allocated to exactly one measuring step. Before it is possible to establish an absolute reference or the last selected reference point is recovered, the reference mark must be traversed.

      1. Source of light
      2. Condenser
      3. Scanning reticle
      4. Glass scale
      5. Photodetector

      Strengths:

      • Long measuring track easily possible

      Challenges:

      • Reference drive necessary to determine position

      Part offset determining

      With the help of a camera (SIMATIC MV440) the zero offset of a part in comparison to a reference point can be determined.

      This solution has the advantage of saving time as opposed to a position measurement with probes.

      As long as the accuracy requirements of the desired solution remain at a low level, this option can be used. The accuracy to determine the position with the camera is dependent on the factors light, contrast and surface.

      The accuracy in the determination of the position is +/- 0.02mm and in the twist +/- 0.02 degrees.
      With the camera (SIMATIC MV440) it is also possible to do a workpiece recognition.
      It is possible to determine which workpiece is involved and at which position relative to the camera the found workpiece is located.

       

      Compact spot finder IR camera Xi 400, a new innovative feature.

      The newly developed Xi 400 IR camera is a further milestone in the constant development of the thermoforming machines of the GEISS AG. The Xi 400 measures temperatures from -20 to 900 degrees and the excellent optical resolution makes it possible to capture reliably the single temperature differences of the plastic before the forming, compare the actual value with the target value for each individual element and read out the resulting differential value.
      This procedure makes it possible to adjust the individual heater elements much faster and more effectively to the heater settings required for the product.

      With that, GEISS offers its customers a further solution to optimize the quality of the products and to increase productivity.

       

      Experts have long known it: automated processes are optimizing work processes and are saving time and money. To realize a fully automatic production we are offering an addition to the step less adjustable window plate system.

      The automation is rounded off by the GEISS produced automated tool changer. Instead of 30 to 180 minutes retooling time, with this system only needs a few minutes.

      The profitability check proofs: With approx. 500 tool changes per year, annual savings of 76,000 euros can be achieved at investment costs from 44,000 euros.

       

      THE FIRST TT-IN-ONE IS IN USE - CHANGEOVER EFFORT STRIVES TOWARDS ZERO!

       

      News from the first TT-in-one plant. The run in of the TT-in-one is completed and the machine runs well to our Danish customer’s; Staal & Plast Danemark, 5740 Ringe on the Island Fünen; satisfaction for some months. The customer decided upon this machine, as it is offering the highest flexibility. For the manufacturing of planting tables for market gardens a machine was needed, which could process a big number of different components. Due to different international standards, the table shapes are similar but different however, in their exact measurements.

      The customer has approximately 300 different external dimensions of components in its range. It must also be possible to process two plates simultaneously. The flexibility of the TT-in-one convinced the customer. To solve this task specific combination tools have been developed for the vacuum mould. In addition, there is a combination tool, which functions as a universal milling fixture. For retrofitting only the moulding die has to be changed.

      Both transfer machines as well as the turning machine have been designed in such a way that only programmatic changes have to be made at the CNC trimming machine – there are no retrofitting costs.

      The success of the new equipment proves to us how trendsetting the idea of TT-in-one machine really is. In regard of its flexibility it can be developed even further – a new idea is already forming: the combination e.g. with our tool change machine which would completely automate the tool change overprocess of this complex plant.  

       

      Customer feedback:

      Mr.Hennig Sörensen, former CEO of Stal & Plast: “Our range comprises planting tables for greenhouses of big dimensions. We wanted these planting tables – made of plastics that beats metal in this area of application – in a size that worldwide was not available: 6250 x 1800mm. We were planning to buy the vacuumforming machine and to care for the automation by ourselves. But the offer of GEISS company surpassed all expectations. Hence we handed the complete project over to GEISS. We trusted that GEISS would find a solution. The result after six months proves that our decision was right.”