Betonwerk Jungwirth GmbH based in Lower Austria is striking a new path when it comes to the extension of their pallet circulation plant in the municipality of Rappottenstein. The plant was commissioned by Ebawe Anlagentechnik GmbH, a company of the Progress Group, in 2005 and is comprehensively expanded now. Apart from doubling the number of pallets from 39 to 78, the reinforcement production was automated and new software was purchased.
Jungwirth is highly appreciated as employer in the region and have established themselves as supplier for structural and civil engineering projects since 1926. At the Grünbach site 60 employees are working in the carrousel plant as well as in the production of structural precast elements and in administration. Precast floor slabs as well as double walls and insulated double walls, respectively, are manufactured in the circulation system. The insulated double walls are manufactured with wall thicknesses of up to 50 cm and an insulation layer of 16 cm. The precast elements are delivered to the Linz area but also as far as Vienna. At a second smaller site in Rappottenstein with a workforce of ten additional people, Jungwirth is manufacturing other concrete products, such as manhole elements, pipes and masonry blocks.
Ebawe carrousel plant
The extension of the existing Ebawe carrousel plant includes the installation of a shuttering robot and a storage robot, an automated concrete spreader, new side shifters and a second curing chamber. This new curing chamber was attached to the existing pallet stacker, which had already been designed for a possible extension of this chamber in 2004/2005 and is now able to serve twice the capacity.
Ebos master control system
In addition, the carrousel plant was provided with the Ebos master control system made by Progress Software Development GmbH, the software development company of the Progress Group. Ebos serves as a comprehensive solution for work preparation, production and process analysis, addressing all aspects of the manufacturing process, from the start to the finish.
BlueMesh M-System mesh welding machine
The company also invested in an automated mesh-welding machine of the BlueMesh M-System series and a VGA lattice girder-welding machine in order to get an excellent reinforcement solution, too. The mesh-welding machine is served with reinforcing bars by an MSR multi-rotor straightening and cutting machine and allows for the production of mesh in the size of 4 x 10 m, using wire diameters of 5-6-7-8-10-12-14-16 in longitudinal and traverse direction in a flexible design. Bending of longitudinal and transverse bars for precast floor slabs is also possible as well as stirrups for wall elements.
All three machines come from Progress Maschinen & Automation AG. „In the past, the bars had to be cut into a compartment, for being carried to the circulation by means of a paternoster, and had to be inserted and tied manually. The lattice girders were likewise cut to length from a 14m girder and positioned manually,“ recalls master builder Werner Jungwirth (Baumeister Ing.), managing director of Jungwirth. „In the meantime, production, transportation and installation of the mesh and lattice girders are running fully automatically up to the pallet without any manual operation“ The BlueMesh M-System mesh welding machine enables Jungwirth to achieve a highly flexible, just-in-time production of reinforcement wire mesh from the coil directly.
The strengths of this machine lie in the versatility and the high efficiency and cost-effectiveness due the low power consumption achieved by inverter welding power sources. A production process without waste, without cutting mesh to size and without any laying works is indispensable. This provides for an optimized production flow. Lower storage costs and easier material handling significantly contribute to a more cost-effective production process.
VGA Versa lattice girder welding machine
The present reinforcement production is completed by the VGA Versa lattice girder-welding machine. An integration of the VGA Versa into the entire manufacturing line was easily possible. The principle of just-in-time production allows for manufacturing of each lattice girder individually and accurately fitting, thus eliminating storage costs and cutting waste completely. The lattice girder-welding machine is also producing from coil. Different wire diameters are available for upper chords, diagonals and bottom chords. The VGA Versa can manufacture girder heights from 70 to 400 mm in steps of 5 mm, with fully automated changeover together with wire change in a few seconds.
The production of standard and tailor-made wire mesh, stirrup mesh and lattice girders is not only designed for the own needs of Jungwirth but can also serve the external market. An extension of the mesh-welding machine is to enable the company to add further products, such as reinforcement cages with a length of up to 10 m, in the future.
They also invested in new software: The new Stabos software developed by Progress Software Development GmbH is being implemented at present. Quality, professionalism and adherence to schedules, along with customer retention, have top priority for Jungwirth. So, it was a logical step to integrate a software tool into the production process for the collection and evaluation of machine and production data. Stabos provides worldwide access to data by a cloud solution. Using four highly specialized modules, the software program provides for thorough production analysis in the fields of production statistics (big data), predictive maintenance, key performance indicators (KPIs) and failure analysis.
Due to central data gathering, the production module enables the evaluation of the productivity, improving the quality accordingly. Maintenance planning is significantly facilitated, too: Thanks to a much easier overview of several machines, it is possible to plan maintenance efficiently. For this purpose, the system makes proposals independently. The key performance indicators (KPIs) allow for the determination of the performance of a machine using simple figures. The following indicators can be defined, for example:
daily operating times of the machine;
monthly or weekly operating times of machines for individual days;
comparison of operating times and failure times of machines and
evaluation of downtimes, idle times, etc.
Downtimes can be easily recorded with the aid of the extensive failure archive, for reacting to recurring failures in a timely manner. Jungwirth draws a positive conclusion: „Regarding the extension of our production, we paid particular attention to the fact that the new components could be well integrated into the existing plant. The Progress Group provided the best solution in this respect.“