Development and manufacturing of injection systems for large engines in the Off-Highway-Segment

L‘Orange is part of the business unit Power Systems of the British Rolls-Royce group and is a specialist provider of components and complete injection systems.
We are using a state-of-the-art, 28,000 m² large facility with drilling, milling, turning and grinding machines of several well-known brands. Today, six different types of machines (of which we have several machines) are verified by NCSIMUL Machine.
An end-to-end process with a CAD / CAM system from PTC, as well as tool management and NC simulation have supported our production since 2010.

Our production is focused on the customer. We respond to customer requests and develop specific solutions. In this process, we deal with a wide range of various systems and are challenged to make the best possible use of our machines.
Our customers are accustomed to a fast delivery with the highest quality and a fair price so, of course we want to meet these requirements also in the future.
Innovative strength is essential, both for the customer and for us, as the demands have been growing throughout the years: Previously, where the components had to withstand a pressure load of as much as 1,000 bar, today it is as high as 2,000 - 2,500 bar.

First, of course, the collision safety and the fact that the simulation is based on the NC code and not on a source code. This helps us to avoid errors and minimize set-up times.
Our development and production are located at different locations. For a smooth collaboration, we needed an end-to-end data traffic to improve the quality of the virtual simulation for the production, including a successful integration to our other systems. With NCSIMUL Machine this was a given.
The 3D quality of the graphic simulation is outstanding.

Before: high set-up times on the machine, manual programming (which partly took days), no collision safety, and the risk that a machine might stop during the night shift, for example because of syntax errors.
Today: thanks to our seamless data traffic between construction and production, our conditions are better. With NCSIMUL, we benefit from error-free NC programs. Changes can be made quickly and easily.
Machining with fast and short movements, we program the machines exclusively via the system. Otherwise we would lose too much time on the machine.
Another advantage is that the NCSIMUL verifies the NC code, which is sent to the machine. Everyone can use this also for his or her individual development by loading the program, which has run on the machine into NCSIMUL, and see where further optimization is required. The simulation also covers the smallest errors.

Our contact persons at SPRING Technologies are now mainly located in Böblingen, which for us is practically around the corner.
We also appreciate that the communication among our technology partners is working, whether it is between the NCSIMUL team and the other CAM and tool management providers, or the consulting of ESC.

We are currently expanding our production with new rotary milling cells, for which we will also need virtual machines. Today, we are glad that our company had decided for NCSIMUL.

Our vision of intelligent CNC machining: seamless transitions between the systems, In-Process-measurements, zero-point adaptations with touch probes, end-to-end tool geometries…