Light Source Factory
• Hard Glass Bulbs
Ceramic Components Factory
Machinery Factory• Tungsten Rod production
Light Source Factory
• Injection moulding• Powder painting• Electromechanical assembly
Kisvárda
Hajdúböszörmény
Budapest
(HQ)
Nagykanizsa
Zalaegerszeg
Light Source Factory
• Electromechanical assembly• Precision welding• Repair
Component Factory
• CNC Machining• Welding• Wire manufacturing
Metal Component Factory
• CNC Sheet metal• Metal stamping• Welding• Plating• Toolmaking
4000+ qualified employees
Tungsram Group in Hungary
3
Tungsram GroupMajor capabilities and references
➢ Sheet metal – GE Grid, GE Industrial Solutions, GE Power Conversion, Borg Warner
➢ Machining – GE Power, GE Transporation, GE Grid, Knorr-Bremse
➢ Electromechanical assembly and precision welding – GE Power, GE Aviation
➢ Injection moulding – GE Lighting, Current powered by GE
➢ Wire drawing for medical market – Intuitive Surgical (in progress)
Integrated supplier of complex projects
5
Toolmaking(progressive and serial tools)
Deep-drawing
Pressing & bending
Bihler (multi-slide) technology
Degreasing, Ni plating
Technologies
Plastic moulding
Powder coating
6
Prima Power E6 Turret Punch Press
Prima Power E6 Compact Express
Amanda Fiber Laser with MP-Flex loading equimpent
Sheet metal forming – cutting I.
7
Sheet metal forming – bending
Amanda HG – 1000 KN (Number of machines: 3)Amanda HFE – 500 KN (Number of machines: 2)
Prima Power – 1050 KN (Number of machines: 1)
8
Machines for metal stamping (Nr.)
Excenter presses from 1 to 100 tons 50+
Bihler 35, 50, 80 ton multi-slide machines (some with welding and mangling units)
12
Transfer presses 35, 50 tons 54
Stand-alone manual presses (1 – 63 tons) 10
Trowalizing and degreasing equipment 15
Nickel plating line (barrell) 1
9
Product sizes and tolerances - Stamping
Material thickness – pressing and bending(depends on raw material alloy and technology)
0,1 – 3 mm
Material thickness – deep drawing 0,1- 1,5 mm
Tolerance of cutted parameters (depends on material thickness)
+/-0,02 mm
Tolerance of flatness (depends on component size and geometry)
min. 0,03 mm
Biggest stamped component (always to be confirmed by technology)
120x120x2 mm
Maximum progressive tool size Length: 1 meter
Maximum number of steps in transfer tool 9
Simple Assemblies
Electrical Cabinet plate + PEMW: 300 mm, Th: 1,5 mm Steel
Electrical Cabinet sheet+ PEM W: 500 mm, Th: 1,5 mm Steel
Plate + PEM W: 600 mm, Th: 0,8 mm Steel
Reflector holder + PEML: 800 mm, Th: 1 mm Plated Steel
BT22 box W: 450 mm, Th: 0,7 mm Steel
HolderL: 500 mm, Th: 1,5 mm Steel
Complex Assemblies
Housing assyW: 1200 mm, Th: 0,7 mm Steel
Blade assy W: 1000 mm, Th: 0,8 mm steel
ReflectorW: 400 mm, Th: 0,8 mm Reflective Steel
Reflector housingW: 600 mm, Th: 0,8 mm Plated Steel
Downlighter AssyD: 300 mm, Th: 1,5 mm Alu
Box assyW: 200 mm, Th: 2 mm Steel
14
Design:Progressive tooling
Transfer tooling
Bihler tooling
Special tooling
Manufacturing:300+ tools annually
15+ tool experts
40+ technicians
High precision testlab
Upgraded machinery
Tooling
16
Demag 250T/630-840 Concept top
Demag 420T/810-1450 Concept Top
csiga átmérő szerszám beépítési magasság max. szerszám beépítési magasság min.Löket térfogat
szerszám felfogó lapok mérete mmZáróerő
ccm3 Tonna
screw diamater mold height max. mold height min. dose volume Tool clamping plates sizeclamping
force
d-50 710 mm 330 mm 442(400g) 630x630 250
d-50 820 mm 380 mm 530(480g) 810x710 420
d-60 820 mm 380 mm 760(690g) 810x710 420
250 – 420 t Demag injection molding machine
17
csiga átmérő szerszám beépítési magasság max. szerszám beépítési magasság min.Löket térfogat
szerszám felfogó lapok mérete mmZáróerő
ccm3 Tonna
screw diamater mold height max. mold height min. dose volume Tool clamping plates sizeclamping
force
d-25 410 mm 200 mm 51(45g) 420x370 50
d-30 430 mm 200 mm 114(101g) 420x420 100
50 – 100 t Demag injection molding machine
19
Line 2
Painted parts:• Aluminium alloys• Aluminium sheets• Steel parts
Pretreatment• 7 stage
Colors• 62 different colors
Window size• 1000x500
Speed• 1,3 m/min
Line 1
Painted parts:• Indoor aluminium• Steel
Pretreatment• 4 stage pretreatment
Colors• 62 different color
Window size• 1500x600
Speed• 1,1 m/min
Off-line spray booth
Sample painting
Low qty. painting
Paint Shop
21
Electromechanical assembly areas
Indoor production area:
• 2500+ m2 assembly production area
• 120+ operators
• 2500+ pcs daily LED indoor fixture production capacity
• 3 pcs semi-automatic production lines
• 8 pcs normal production lines
• 4 pcs U shape production lines
• 3 pcs production cells
Outdoor production area:
• 1000+ m2 assembly production area
• 60+ operators
• 1000+ pcs daily LED outdoor fixture production capacity
• 3 pcs semi-automatic – high capacity - production lines
• 2 pcs normal production lines
23
Electromechanical assembly – SMT
Panasonic
NPM
HB Automation
CS-1202N
KY
Zenith
(3D)
Panasonic
SPG
YJLink
ALMC 200KY
8030
Placement Reflow AOISolder
Printer
Laser
MarkerSPI
SMT line layout
24
Electromechanical assembly – SMT
•Minimum PCB size: 50x70
•Maximum PCB size: 510x460(Paste printer maximum)
•Thickness: 0,3-8 mm
•Max warpage: 0,5 mm
•Fiducial mark
Basic PCB dimension
25
Electromechanical assembly - Cable confection
Cable range:
• PVC or silicone seal
• 0,5-1 mm diameter
• 70-2000 mm lenght
• Optional wire crimps, clips
• Pre programmed wire caracterics
Equipments:
• 2 automatic cutters
• 3 semi-automatic cutters
• 6 crimping machines
Wire crimps:
• F, M, MG, FG types
Cips:
• O, OS, S, B types
26
Electromechanical assembly – in house synergies
Tungsram Group has in Nagykanizsa (& Zalaegerszeg)*:
✓ Automatic Storage System
✓ Powder paining line
✓ Tool shop*
✓ Plastic part production
✓ Paper box production
✓ Sheet metal manufacturing plant*
✓ SMT line
✓ Cable confection area
29
Valve BodyGE Lighting50 x 50 x 140
Spare parts
Bearing CapGE TransportationD 420 X 50
Direct material
CMHL Gas BurnerGE Lighting50 x 25 x 45 with D 0,5 holesSpare parts
Indexing CamGE LightingD 600 X 300Spare parts
GripperKnorr – Bremse600 X 600 X 500
Devices
LatchesGE GridD 25 x 110
Direct material
Shaft endLEAXD 75 x 49Direct material
Pulling wedgeKnorr-BremseD 72 x 143Direct material
Liner StopGE Power38 x 42 x 54
Direct material
Main profile of Production
30
Machine typeMax mfg size (mm)
Accuracy (mm) Machines
CNC turning X: 200-760 0,005-0,02 MAZAK QTN 200, EV 630-01, EEN 400, EEN 320, MAZAK INTEGREXZ: 300-1530
CNC grinding X: 80, Z: 400
0,005 STUDER S20-4
CNC milling X: 400-1050 0,005 MAZAK VCN 510C, DMU 60T
Y: 300-500 0,01 DECKEL FP4CC, DECKEL FP4CC, Mikron WE31D, Mikron VC500, PICOMAX
Z: 200-600 0,05 DECKEL FP3CC,, MVI-6, DECKEL FP5NC, FV30/16, FV30/15, FV30/14, FND, FUW250
Traditional 0,01 - 0,1 BFT 90, MIKRON WF3SA, SUI 80, Copymat, 40LN, SWBE, TOS Bua20, KU 250-04
Other CNC technology
X: 280-350 0,005 - 0,05 Agiecut 120, Agiecut Challenge, FIRST FST 250 CZT
Y: 200-360
Z: 200-300
Parts manufacturing capabilities /More than 88 cutting equipment including 30 CNCs/
31
VCN 510 C IIIntegrex 300 ST IVQTN 200 MSY II
Mazak machinesSize Precision Axis Tool storage Free Capacity
[mm] [mm] [pcs] [pcs] [hours/year]
QTN 200 MSY II D380 x 575 0,01 5 12 4 000 hr
Integrex 300 ST IV D760 x 1530 0,01 – 0,02 11 40 2 000 hr
VCN 510 C II 1050 x 510 x 510 0,01 – 0,02 4 30 2 000 hr
High-tech MAZAK machines
32
High pressure Water Jet cutting
General properties X, Y : 3050*2050 mm
One Z-axis carriage with one cutting head
A standard operation system PTV 886
Material palette: ferrous metal, non ferrous metal, glass,
marble, plastics
3D coorninate measuring
WENZEL LH 1210; 1200mm x 2000mm x 1000mm
33
Professionals In
Laser & High speed welding
Wire drawing
Chemical treatmentHigh Temperature treatment
Process Monitoring system
34
From the total Hajdu Plant 89 703 m2
500+ m2 free shop-floor for business development
800 m2 free for additional buildings
New business development
36
Fuel Nozzle Cap
Power Nozzle
Liner Transition Piece
Combustion space of gas turbines
Gas turbines repair and inspection
Incoming inspection• Visual check for cracks, distortions, missing
parts, identification, NDT-penetration inspection, damages
• Measurements: geometrical, thickness of coating
• Cosmetic surface grinding, TBC coating strip• Disassembly segments, mount seals, repair
with AWI• Taking photos, reporting
37
Generator Control Panel – electrical assembling
Operation• Assembling the connections with skilled electricians
• Ability to use electrical documentation
• Using parts from both the can ban and ordered sources
• Adjustments of built-in electrical components
• Identification of all parts
• Checking connection errors
• GCP (Generator Control Panel) to
mobile gas turbines
• Containing 9’000 parts and 1’500
connections
38
Operations
• To get to know the product and process
• Material handling
• Disassembling parts
• Metal part forming
• Sorting parts based on many criteria
• Semi-skilled workers are capable to be trained
Circuit braker repair and assembly
40
Professionals In
Class formingAutomated
production line
Liquid Penetration testResistance welding
Vacuum technology
AWI welding
Grind blasting