Category: X2000NC

An Ohio Company and Schmale’s X2000

An Ohio Company and Schmale's X2000

An Ohio based company faced a severe problem with their production. It was complex with multiple machines, multiple steps, and lots of manpower needed. The production process was loud, messy, and inefficient. The company faced a decision: to continue their current production style or revolutionize and upgrade?

They contacted Daniel Schmale in 2017 to see what Schmale Machinery could do for them. Daniel flew out from Atlanta, GA to their location in Ohio. There, he met with the team responsible for the production. He brought with him examples of parts that the X2000 series can produce. The team excitedly listened to what Daniel showed and told them. Of course, the experienced technicians knew their own process well. They knew what to look for. Most stunning to them were the speed and versatility of the Schmale machines. “That’s slick!” was one exclamation from a technician. The finance department and CEO saw a fast machine, almost no operators and clean production. The CEO looked over to his technicians and said “That’s engineer porn!” The CFO asked how much less the worker’s comp would be since the safety measures are far ahead of the ones in place.

The technologies the X2000 can produce are almost endless. The machine can be used to have a very efficient mass production of complex parts. What does that mean? Many different materials can be used such as metal wire, strip metal (sheet metal), metal tube, plastic, and magazine different materials. One can use a broad spectrum of these materials from 1/16th to 1-inch wire. From these materials, there is a range of what one can use. A small X2000 with a short six-foot wall with some slides that can just bend wire is a simple thing. But add onto it to with additional walls, slides and presses to flatten, press, bend, punch and more. The utilization of the machine is very broad and you open the same machine up to a whole new spectrum of parts.

Each station is mobile within the X2000. A station contains a press or slide that bend, flatten, or weld the parts. Presses and slides within the unit can be moved to produce an endless stream of different parts. The X2000 can handle up to fifteen different stations to create the most intricate parts.

With Schmale machines, an additional part can be produced on the same machine. The slides and presses can be rearranged to make all kinds of parts. There is literally no end in sight. For example, a wire part and a strip metal part can be produced on either end and meet in the middle to be welded together.

The X2000 is compatible with a wide range of items. It can be compatible with a company’s own tools. If a customer wants to use his tool set, then Schmale will make it happen. With some companies, they do not want to show their tool sets to anyone and they don’t have to. Schmale will make it compatible without seeing the tool sets, so the company does not need to share their proprietary information. Also, there are many third-party items that the customer may have. A decoiler, for example, can be kept by the customer and integrated into the X2000. The same is true with welding units and other units that can be integrated. It goes so far as Schmale does not buy the unit, the customer does and then the unit is integrated into the machine. Schmale machines are also compatible with Bihler machines, a German company that produces smaller wire bending machines.

The company was astonished at all the X2000 could do and what it could offer. They thought it over and considered what needed to change within their company before they could agree. Daniel was there to answer all of their questions and concerns. The sale wasn’t made that day, but Daniel would be back again a few months later.

The company had a long talk within their team about what to do. Their production was average and they needed a way to increase it. Schmale Machinery offered what they needed, and more, in a revolutionary way. They could downsize their machines to an all-in-one option. The production would be more efficient, they would have increased output, a higher quality product, increased versatility with the X2000 if they wanted to change parts produced, and the possibility of decreased cost per piece produced.

In time, the Ohio company chose Schmale and invested in their own X2000 series machine. They avoided costly second production, time consuming production with multiple machines, and inefficient production. Schmale’s excellent customer service sent out a technician to assist the company with their production and training. The operation was simpler than they thought since the X2000 runs similar to a traditional mechanic machine, except with servo-electric drives. The training lasted one week and customer service was always on stand-by to assist, if needed.

After a couple of months, the customer began work on his own tool sets for the Schmale machine. Before long, the technicians had a dozen tool sets migrated. A road building section was that Schmale provides 3D-data of their machines, so customers can start from there.

read more

History of the X2000 – Revolutionizing Production

History of the X2000 - Revolutionizing Production

Schmale History

Albrecht Schmale started as a simple mechanic and was tasked with repairing machines for a company in his village in Germany. He knew the machines could be improved, but his company refused. However, companies in surrounding villages heard of his ideas and asked Albrecht to improve their machines. He continued improving the machines for cash payments in his basement until one company demanded an invoice.

In December 1965, he established the machine building company. In time, Albrecht had to make a decision to either stay with his career as a mechanic or work full-time improving and making machines for others. A friend that had been with him since the beginning told him he had to follow his passion. But it wasn’t such a simple task in Germany since one must have a degree that matches the position. Albrecht was a mechanic, not an engineer. After some back and forth with the government, he was allowed to continue as a machine consulting firm that could discreetly build machines.

Since the beginning, Schmale’s customers have seen the advanced technology and automation that make it renowned. Every Schmale machine achieves the level of automation that customers did not know, or do not know, today. The German government also recognized this and granted Albrecht an honorary engineering degree based on the machines he built.

The X2000

Schmale saw a need for higher automation in the part production industry. The X2000 was introduced in 1984 and up to that point, wire production was one step at a time. One machine handled either punching, flattening, threading, or bending. Then the part had to be moved to another machine for the next step. Each machine could only handle one step at a time. While others tried to connect existing machinery to eliminate human operators, Schmale developed a new concept that made all operations synchronous, at the same time in the same rhythm.

Schmale saw a need to have a machine that combined all of these steps with a transfer system between the steps. The X2000 was developed to have all of the operation steps connected without human interference. Schmale emphasized on the availability of a huge variety of options such as bending, coining, punching, swaging, threading, collar forming, end forming, and a variety of force one can utilize.

All of Schmale’s competitors max out on a bending slide at 6 or 8 tons. Schmale maxes out at 24 tons. For pressing slides, the competitors max out at 40 tons, Schmale maxes out at 700 tons. So, to give all the options to the customers, the technologies and forces available were key then and are now.

The X2000 can be used to have a very efficient mass production of complex parts. What does that mean? Many different materials can be used such as metal wire, strip metal (sheet metal), metal tube, plastic, and magazine different materials. One can use a broad spectrum of these materials from 1/16th to 1-inch wire. From these materials, there is a range of what one can use. A small X2000 with a short six-foot wall with some slides that can just bend wire is a simple thing. But add onto it with additional walls, slides and presses to flatten, press, bend, punch and more. The utilization of the machine is very broad and it opens the same machine up to a whole new spectrum of parts.

Each station is mobile within the X2000. A station contains a press or slide that bend, flatten, or weld the parts. Presses and slides within the unit can be moved to produce an endless stream of different parts. The X2000 can handle up to fifteen different stations to create the most intricate parts.

With Schmale machines, an additional part can be produced on the same machine. The slides and presses can be rearranged to make all kinds of parts. There is literally no end in sight. For example, a wire part and a strip metal part can be produced on either end and meet in the middle to be welded together.         

Compatibility

The X2000 is compatible with a wide range of items. It can be compatible with a customer’s own tools. If a customer wants to use his tool set, then Schmale will make it happen. With some companies, they do not want to show their tool sets to anyone and they don’t have to. Schmale will make it compatible without seeing the tool sets, so the company does not need to share their proprietary information. Also, there are many third-party items that the customer may have. A decoiler, for example, can be kept by the customer and integrated into the X2000. The same is true with welding units and other units that can be integrated. It goes so far as Schmale does not buy the unit, the customer does and then the unit is integrated into the machine. Schmale machines are also compatible with Bihler machines, a German company that produces smaller wire bending machines.

Schmale machines are usually compatible with the customer’s IT. Customers want to pull data from the Schmale machines, such as speed, so they are tied to the customer’s servers and machine monitoring systems. All of the machines have ethernet connections to be plugged into the customers IT infrastructure.  

Schmale machines are compatible to most of the operators’ way of thinking. Mechanic machines think in a 360-degree circle and Schmale machines think in that same degree. So, the operator does not need to learn a programming language. It is the same 360-degree cycle that the fifty-year-old mechanic machines run on with the addition of a touchscreen, state of the art drives and safety systems.

Servo-electric drives

The X2000 uses servo-electric drives. Servo electric motors utilize a device called a frequency converter and they control the speed the motor is running within a few RPM and they control the position, amongst others. The frequency converter checks on the values a thousand times a second. They have extreme precision and provide that to the machines. As a result, the servo-electric motor can bend wire and precisely go to the command positions.  

Customer Service

Schmale customer service offers all that is needed and wanted. They offer the simple spare parts and servicing on-site. They offer consultations on production problems such as production order and production needs. They offer designs and provide the drawing to the customer. That is important for a customer that already has a Schmale machine and wants to produce a new part, but doesn’t have a design department. Schmale is there to make that design for the customer. That makes it cheap and easy for the customer. They can not only order the design and consultation, but also the actual parts and tools needed to make that design happen. Schmale can also mount the tools and run the machine to ensure it produces the part including a 10,000-part run off at the customer’s plant. They can also ensure training and supervision of the machine. A technician will be on site for a week to supervise the machine and train the operators.

In the rare case a machine breaks down, Schmale has a warehouse in Atlanta, GA with shelves upon shelves of spare parts, and a warehouse in Germany with even more parts. A technician will go out to the company to fix the machine and all machines have remote access to help determine the problem.

Schmale Machinery is renowned for their innovation and revolutionary machines. Call 678-365-1015, email daniel.schmale@schmale-machinery.com, or visit our website to schedule an appointment at your company today!

read more

X2000NC – The Dream Machine

The X2000NC machine series offers not only speed and efficiency, but also the ability to adjust, change, and adapt. The machines are made of modular components and can grow or shrink with your business.

The X2000NC series is perfect for any company with changing or static needs. The six foot sections that make up the wall can be added or taken away depending on production needs. The modular pieces go where you need them to.

The X2000NC can be switched and changed if new parts or components are needed. No longer will you need multiple machines to create the parts. Let the X2000NC be your all-in-one!

Possibilities are endless with the X2000NC series. Call today to build your dream machine!

 

read more

Get In Touch

  • 1640 Cobb International Boulevard, Suite 3, Kennesaw, GA 30152

  • +1-678-365-1015

  • daniel.schmale@schmale-machinery.com

Newsletter