When it comes to communication and understanding, there is hardly anyone who can ignore the products of the Rohde & Schwarz technology group. In addition to many other high-performance electronic products, the Bavarian company manufactures components, devices and systems for measurement, radio and transmission technology. The mechanical and electronic production plant in Teisnach ensures precision to the nearest μm. Here, competent specialists, high-tech machines and reliable partners work hand in hand. For years, the high-performance cooling lubricants from the manufacturer, Oemeta, have ensured smooth machining, precise results and long service lives.
What the electronics experts of the long-established and innovative Rohde & Schwarz Group develop in Munich and assemble in Memmingen is first manufactured in Teisnach. As a system supplier and centre of excellence for mechanical and electronic manufacturing, the largest plant in the network specialises in the production and assembly of electromechanical assemblies and systems. From individual parts for measuring instruments, to aerospace and medical technology systems and products, electromechanical assemblies, TV and radio transmitters, body scanners, customised communication systems and micromechanical precision parts which are all produced with decades of in-house competence. Printed circuit boards, housings, hollow conductors and antennas complete the product range.
High machining volume for demanding products.
The Rohde & Schwarz plant in Teisnach employs around 2,000 people in 74,000 square metres of floor space. This is where the metal-cutting production is located with more than 80 machine tools, including well-known brands such as Heller, Hermle and Kern Microtechnik, process about 800 tonnes of aluminium annually into high-performance products. "Aluminium makes up about 80 per cent of the material mix, which also includes copper, bronze, brass and, of course, steel", reports Martin Ebner, a technologist in metal-cutting production. "Simply for weight reasons, our often portable products should be as light as possible“. For outdoor and marine use, they also have to be weather- and corrosion-resistant.
In high-frequency (HF) technology these are, for example, waveguides or signal generators. HF technology, in particular, places special demands on precision. Here, compliance with tolerances of +/- 2 µm is required, and production in air-conditioned rooms ensures the required results. This is where the 3 and 5-axis machining centres are in their element as they mill, turn, drill, ream and cut threads, whatever the cutting edge has to offer. The machining volume is often large for the workpieces, which are clamped as blocks, and often leave the machine as a filigree grid structure. At Rohde & Schwarz Teisnach, housings, half-shells, shafts or frames and connectors for the demanding products are created on mass. The batch sizes are usually between one and 100.
Approval takes place after an extensive test phase.
The North German lubricant manufacturer, Oemeta Chemische Werke GmbH, has long been responsible for the supply of suitable cooling lubricants. The family-run company with over 100 years of tradition is characterised by close customer proximity and specialist products. From the summer of 2014, extensive tests were carried out before the suitably selected cooling lubricant was rolled-out into production in autumn, 2015.
The popular boron and formaldehyde-free cooling lubricant, NOVAMET 910, is used. It is characterised by extraordinarily high performance in a wide range of applications and materials, as well as low consumption rate. Oemeta promises high stability and long tool life. "We have been able to halve some of the coolant maintenance intervals on the systems with this and feed the cleaned coolant back into the process," Ebner emphasises. "We are very satisfied with this“.
Special challenges due to water and subsequent process.
This was not the case before Oemeta. This is because the situation at the site is special, and the processes that follow machining place high demands on the coolant. For example, the water in the Bavarian Forest is very soft, which results in high foam formation. "With the previous product, we had to use a lot of anti-foam," Ebner recalls. "With NOVAMET, we now don't need that at all. Also, with the previous product, the odour was unplesant and, there was some skin irritation. Overall, the performance was not satisfactory. And we know that the consumption was also excessively high before we switched to Oemeta“, says Ebner.
"In addition, the surface quality and the subsequent coating result improved with our NOVAMET 910“, reports Hubertus Hatzl, South-East Area Sales Manager at Oemeta, who has been serving Rohde & Schwarz for years.
Switch to Oemeta Coolant improves results.
NOVAMET 910 is a water-miscible, broadly applicable cooling lubricant for machining, that is free of boron and formaldehyde. It is characterised by high performance in a wide range of applications and materials, as well as low consumption, the manufacturer promises. The material compatibility is equally good with aluminium and stainless steel, as well as with non-ferrous metals. “Exactly what we need“, says Ebner. It also always shows good results in the various machining operations. The input concentration at the Teisnach plant is between seven and nine per cent. The individually filled machines are replenished via a central supply system.
The improvements were not only striking in the machining processes. In addition to the better residue behaviour and significantly longer service life, with simultaneously extended cleaning intervals, the odour almost completely disappeared. The excellent skin compatibility of NOVAMET, with a pH value of 9.4 at five percent, also improved occupational safety. And Ebner doesn't want to miss anything out: "Our machines and the workpieces are much cleaner than before“. "This is due to the high washing and rinsing capacity of NOVAMET 910“, explains Hubertus Hatzl. All these improvements have led to a solid relationship of trust between Rohde & Schwarz, Teisnach and Oemeta, and are a successful example of a good partnership - just as the philosophies of both companies proclaim.
Improvements in all areas strengthen partnership.
Therefore, products manufactured with precision at the Rohde & Schwarz plant in Teisnach such as; transmitter systems, digital radio, DAB radio or critical infrastructure, for use in air traffic control, can continue to contribute to secure communications. For example, to bring passenger aircrafts safely to earth - "roger and over".
Company info Rohde & Schwarz GmbH & Co. KG
Rohde & Schwarz - one technology group, three divisions, diverse markets.
The Rohde & Schwarz technology group, with its leading solutions in the fields of Test & Measurement, Technology Systems and Networks & Cybersecurity are among the pioneers of a secure and networked world. Founded more than 85 years ago, the Group is a reliable partner for its customers from industry and the public sector around the globe. As of 30 June 2021, the number of employees worldwide was around 13,000. The independent group generated revenues of 2.28 billion euros in the 2020/2021 financial year (July to June). The company is headquartered in Munich.
Rohde & Schwarz Teisnach plant
Great vertical range of manufacture and decades of in-house competence
The Teisnach plant was founded in 1969 and with 2000 employees is dedicated to the complete production of electronic systems, devices, modules and components - from product and software development to after-sales service. As a system supplier and competence centre for mechanical and electronic production, the largest plant in the network specialises in the manufacture and assembly of electromechanical assemblies and systems. From automotive to aerospace technology to medical technology, systems and customised products of all kinds, electromechanical assemblies, TV and radio transmitters, body scanners, customised communication systems and micromechanical precision parts are produced with great vertical integration and decades of in-house competence. Printed circuit boards, housings, waveguides and antennas complete the versatile product range on 74,000 m² of production space.