Resilience through technology integration

(left): Example of various coupling rings, which are used in tooth clutches or tooth brakes, for example; (right): gearSKIVING a coupling ring made of a special bronze alloy on the CTX beta 800 TC.

The 125 company employees develop and manufacture a diverse range of couplings, brakes, linear actuators and complete system solutions for customers in almost every sector – from agriculture through robotics to the food industry. After 105 years at the original location in Bochum, Mönninghoff has now built a new, modern plant to ensure the continuation of optimal operation along the entire process chain. In production, the company has been relying on machine tool technology from DMG MORI since 2010. Further investments in machining centers and turning machines followed the installation of an NT 4300. The latest acquisition is a CTX beta 800 TC with Robo2Go. Mönninghoff also uses numerous DMG MORI technology cycles for their gear production.

Design and manufacture of complex drive components

“The structural transformation in the Ruhr district over the last few decades meant we had to come up with something new,” explains Charlotte Finger, managing partner of Mönninghoff. Until the 80s, the company had generated over 90 percent of its sales in mining. Since then, it has continued to develop a special niche in drive technology.

After Mönninghoff had outsourced special gear manufacturing to another firm – Chemnitzer Zahnradfabrik – in 1992, the company was free to concentrate on its core expertise: The design and manufacture of sophisticated and complex coupling and braking systems. “These are almost exclusively special solutions, which we often develop in cooperation with our customers,” explains Charlotte Finger. Mönninghoff is well known throughout industry for this expertise and is generally involved in project developments at an early stage. For a long time now, the company has not considered itself simply a supplier but rather a technology partner for its customers.

Optimal machine utilization thanks to gear cutting cycles from DMG MORI

“Our coupling components all have different gear teeth, which used to be manufactured using special gear cutting machines,” explains Timon Lubek. “The Technology Cycles from DMG MORI allow us to machine the same products, switching rings for example, on conventional turn-mill centers like the CTX beta 800 TC to the same quality on the same machine and sometimes even faster. The experience of the Mönninghoff specialists has repeatedly been incorporated into the continued development of the Technology Cycles. Manufacture of gear components now only requires a maximum of two clampings.

This results in shorter throughput times, reduced internal transportation and less waiting time. The high flexibility is another benefit: “If there are times we don’t need to produce gears, the machine can be used for other purposes to make sure it’s utilized in the best way possible.”

gearSKIVING 2.0 and DMQP tools from Horn

gearSKIVING 2.0 is one Technology Cycle that Mönninghoff uses intensively. It can be deployed to manufacture straight and helical external or internal spur gears, splines and also herringbone gears on turn-mill centers. The cycle controls the synchronization and the tool path. “This makes us ten times faster than when broaching,” adds Timon Lubek. He points out the tools they use are from Horn. The tool manufacturer is a long-term and DMQP-certified technology partner of DMG MORI. Crown gears are also manufactured by fly cutting on turn-mill machines such as the CTX beta 800 TC. The automatic calculation of the tool path is taken care of by the crownHOBBING Technology Cycle, which DMG MORI implemented in a second phase. Gear shaping takes place in a third phase using the gearSHAPING Technology Cycle. Timon Lubek adds: “Automation solutions make 6-sided complete machining of components like these easier. It also enables quality control to be integrated right from the first component.” The integration of technology is very important to Mönninghoff. This is the reason why Timon Lubek values the long-term partnership with DMG MORI: “In order to be even more successful, we use practically every technology cycle that provides us with added value in programming and machining – from gear cutting and generation through to broaching and grinding. And in cases where this isn’t enough, we jointly develop new bespoke cycles that enable us to machine our special components, or make it easier to do so.” The company would like to maintain this in the future, not only to ensure it can manufacture efficiently, but also to be a technology leader. Charlotte Finger also sees a lot of potential in the new manufacturing possibilities: “Automation solutions and technology integration are the ideal way for us to sustainably increase capacity and thus keep our production site in Germany competitive.”

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