Innovation is our heritage

TungsramComponent Manufacturing

2018

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

Tungsram GroupSheet metal and plastic manufacturing (Zalaegerszeg & Nagykanizsa plants)

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Toolmaking(progressive and serial tools)

Deep-drawing

Pressing & bending

Bihler (multi-slide) technology

Degreasing, Ni plating

Technologies

Plastic moulding

Powder coating

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Prima Power E6 Turret Punch Press

Prima Power E6 Compact Express

Amanda Fiber Laser with MP-Flex loading equimpent

Sheet metal forming – cutting I.

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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)

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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)

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Transfer presses 35, 50 tons 54

Stand-alone manual presses (1 – 63 tons) 10

Trowalizing and degreasing equipment 15

Nickel plating line (barrell) 1

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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

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Products and applications

IndustrialComponents

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

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Design:Progressive tooling

Transfer tooling

Bihler tooling

Special tooling

Manufacturing:300+ tools annually

15+ tool experts

40+ technicians

High precision testlab

Upgraded machinery

Tooling

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Plastic Operation Shopfloor

Fanuc Arc Mate 100iC

Linear and 6-axis robots

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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

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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

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3D coordinate measuring / 3 D Sampling

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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

Tungsram GroupElectromechanical assembly (Nagykanizsa plant)

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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

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Electromechanical assembly production line types

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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

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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

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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

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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

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Electromechanical assembly – quality system overview

Tungsram GroupMachining manufacturing (Hajdúböszörmény plant)

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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

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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/

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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

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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

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Professionals In

Laser & High speed welding

Wire drawing

Chemical treatmentHigh Temperature treatment

Process Monitoring system

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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

Tungsram GroupAssembly and welding operation (Kisvárda plant)

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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

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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

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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

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New business development

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Professionals In

Class formingAutomated

production line

Liquid Penetration testResistance welding

Vacuum technology

AWI welding

Grind blasting

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Certificates

ISO 9001:2008 ISO/TS 16949:2009 ISO 14001:2004

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