Optimizing Mold Changes with ROEMHELD

While die transport carts are readily available on the market, many of them offer limited functionality, particularly in scenarios requiring optimized mold changes within constrained spaces or with heavy loads. However, automotive supplier ElringKlinger has taken a different approach. The company recently adopted a compact model from ROEMHELD,  tailored to meet their specific requirements.

ElringKlinger AG, a prominent automotive supplier with over 10,000 employees across 45 global locations, operates from its headquarters in Dettingen/Erms, Baden-Württemberg, Germany. At this facility, the company specializes in producing cylinder head gaskets, maintaining its position as a world market leader in this segment. Additionally, ElringKlinger manufactures specialized gaskets for engines, transmissions, and exhaust systems, along with lightweight plastic components such as oil pans and cam covers. Notably, the lightweight construction/elastomer technology division represents the company's top-selling segment. Tobias Gerst, production engineer within this division, highlights the company's steady growth over recent years, necessitating the need for additional space and prompting a search for innovative solutions to overcome cramped conditions.

In cramped spaces, such as those housing two injection molding machines operating in three shifts, ElringKlinger encountered challenges during mold changes. These machines, positioned at an angle of approximately 120° to each other, produce transmission gaskets with elastomer sealing lips. Every eight to nine days, a mold change is required, a task previously tackled using standard transport carts until a more efficient solution was sought.

With a Standard Changing Cart as a temporary measure, the existing transport carts, utilized until recently, proved inadequate for handling high mold weights or maneuvering within limited space constraints. As a result, mold changes were physically demanding and often required manual adjustments to accommodate the restricted space. Recognizing the need for an alternative solution, Gerst searched for a specialized changing cart tailored to their unique requirements.

Handling Heavy Molds Effortlessly

The steel molds used by ElringKlinger weigh up to one ton and have varying base dimensions. The new changing cart needed to accommodate both small and large molds while also fitting through narrow doorways. Additionally, Gerst sought a system that allowed molds to be moved in multiple directions, eliminating the need for complex maneuvering during mold changes.Top of Form

After extensive research, Gerst discovered ROEMHELD, a leading manufacturer specializing in setup time optimization for the plastics processing industry. ROEMHELD's die changing cart RWA 1600, equipped with hydraulic ball bars and an electrohydraulic lifting platform, proved to be the ideal solution. This cart facilitates easy movement of dies in any direction, ensuring efficient mold changes while prioritizing operator safety. Special customization options, including additional roller bars and a smaller plate size, were incorporated to meet ElringKlinger's specific requirements.

ROEMHELD typically provides three standard versions of their product, featuring four, six, or eight ball bars, each capable of bearing a load of 1600 kg. Following thorough discussions, Gerst opted for a customized version with nine roller bars. This tailored solution guarantees secure support for even the smallest molds utilized by ElringKlinger, with a minimum of two bars ensuring stability. Additionally, the production engineer requested a smaller plate, measuring 850mm in width and 750mm in depth, further aligning the solution with the company's specific needs.