Otto Dilg GmbH Feinmechanik

OTTO DILG GmbH supplying brushing machines to Airbus Bremen

01/2005

In December 2004, Otto Dilg GmbH, Neufahrn, received the order from Airbus Bremen to deliver two brushing machines, types OTTOMAX120 and OTTOMAT 6-S, each of which includes four brushing stations with two variable processing levels. Use of the systems, which are specific to Dilg, means that Airbus can now process a substantially larger range of milled aluminum circuit boards. In addition to lower investment and operating costs, another point in favor of awarding the contract to Otto Dilg GmbH was, above all, the greater flexibility of the brushing machines and the successful use of identical machines (since 2003) from Dilg within the group at EADS Augsburg.
The contracted brushing machines are a Dilg Company special design, which, unlike other machines on the market, has two processing levels, allowing production that is substantially more even and of higher quality. The brushing machines allow simultaneous two-sided processing of different laminates, from a length of 96 mm (OTTOMAX from 180 mm) and a thickness of 0.2 mm , up to a width of 1500 mm and a thickness of 20 mm (such as pressure plates, printed circuit boards, ceramic substrates, aluminum circuit boards, parts made by chemical blanking, etc). Airbus is using the Dilg brushing machines for cleaning and burring milled aluminum circuit boards. According to the Airbus specification, the machines were set up for a special edge configuration and additionally allow degreasing, forward and reverse brushing, and high power drying within the processing, among other features. The electronic controller is programmed via touchscreen, allowing fully automatically operation and connection to the main controller of complex production lines.

The customized productions for Airbus are based on the Dilg brushing machine program, which has proven itself for many years, and which achieves outstanding results in deburring and cleaning the widest range of materials. Above all, this can be credited to the precision bearing arrangement, the extremely precise transport and correspondingly designed drives, in combination with specially developed brush cylinders.
Fabian von Gleich, Project Director at Airbus Bremen, says: "Dilg was already able to put our high demands into action successfully at EADS Augsburg with its customized brushing machines. By using identical machines in the demanding manufacturing environment at Airbus, we expect to achieve clear process optimization and an increase in production quality. Based on our experience at EADS Augsburg, we also expect to realize a noticeable reduction in production costs."
"Airbus Bremen is another first-class reference for our company," reports Mr. Rüdiger Dilg, Executive Director at Otto Dilg GmbH. "We are happy to have now received a new commission within the EADS Group. This testifies to the excellent price-performance ratio, the customer-oriented product policy at Dilg and the high quality demands we place on our 'Made in Germany' products".
The delivery also includes the installation and commissioning of the brushing machines, which will go into operation at Airbus Bremen in September 2005.

Thicknesses of up to 20mm

Productronic 11/2003

Dilg made a big step forward - big pertaining to the dimensions of up to 1.5m working width and big pertaining to the maximum thickness of 20mm. The new product practically combines two brushing machines in one.

One could remark that there are already brushing machines with four brushing stges. So what does "two brushing machines in one" mean? Often, we are blind to the most obvious solution. We are not talking about the four brushing stages but about two variable working levels.
Due to the extensive experience in building brushing machines that Otto Dilg Feinmechanik GmbH could gain in the past, it was possible to tackle the problem of thick panels. For smaller brushing machines for thinner materials, such as the ones used in the manufacturing of circuit boards, the brush is being adjusted. To ensure a secure footing in the brushing station, these models transport the panels over additional barrels and bend the material a little at the brushing station. For thicker workpieces, these systems quickly get close to their limits. It is often still possible to pass the panel through the machine, but the quality of the brushing suffers. Current systems are not capable of brushing material ranging from 6mm to 20mm.
Otto Dilg uses the following trick. One transport layer (for example the lower one) remains in its standard position. The second transport layer (the upper one) can be trimmed in a way that makes the brushes and all the axles, even the counter barrel to some extent, completely adjustable. For extremely thick pieces, both levels (upper and lower transport layer) can be adjusted to the thickness of the workpiece. The advantage is that passing thick pieces through the machine is no problem while the brushing quality remains excellent. The setup ensures absolutely flat guidance through the machine. The fine tuning, and with it the adjustment of the pressure of the brushing barrel, is done using a wattmetric display.
Complete Brushing Machines
But Dilg is not only known in the field of large installations. Tabletop brushing machines have been one of Dilg's bestsellers for years. From the area of small brushing machines, these systems have matured towards complete solutions. We manufacture doublesided brushing machines with integrated high-pressure cleansing and dryer, called Ottomat. The working width ranges from 400mm to 600mm. A touch screen controls the machine.
Filtering Units

The problem of liquid waste during the brushing of circuit boards is well known. Copper particles get into the waste water and have to be filtered out. Obviously, progress has been made in this area as well. Reducing costs is a top priority, now more than ever. Reusing the process water saves 96% of the water. The sewage runs from the brushing chamber into a tank, pulled by gravity.
This filtering system works without auxiliary processes such as diatomite. Additional candle filters make perfect filtering possible.

New Brushing Machine for large multilayers

Leiterplatten ZEV 10/2003

The new brushing machine, recently announced by Otto Dilg GmbH, is suitable for thicknesses of up to 20mm because of its working width of 1.5m. The system works with two variable processing levels. Due to the extensive experience in building brushing machines that Otto Dilg Feinmechanik GmbH could gain in the past, it was possible to tackle the problem of thick panels. For smaller brushing machines for thinner materials, such as the ones used in the manufacturing of circuit boards, the brush is being adjusted. To ensure a secure footing in the brushing station, these models transport the panels over additional barrels and bend the material a little at the brushing station. For thicker workpieces, these systems quickly get close to their limits. It is often still possible to pass the panel through the machine, but the quality of the brushing suffers. Current systems are not capable of brushing material ranging from 6mm to 20mm.

Dilg, however, uses the following trick: One transport layer (for example the lower one) remains in its standard position. The feat is that the second transport layer (the upper one) is completely adjustable. That means that all the brushes, all barrels and to some extent the counterbarell can be adjusted separately. For extremely thick pieces, both levels (upper and lower transport layer) can be adjusted to the thickness of the workpiece. The advantage is that passing thick pieces through the machine is no problem while the brushing quality remains excellent. The setup ensures absolutely flat guidance through the machine. The fine tuning, and with it the adjustment of the pressure of the brushing barrel, is done using a wattmetric display. The system can not only be applied to the field of manufacturing of circuit boards, but also to the aerospace industries and mechanic processing in the metal industries. Here, aluminum sheets with a thickness of up to 20mm are being brushed again after the lasercutting step, to remove the laser burr. Compact systems are mainly used for manufacturing circuit boards.
But Dilg is not only known in the field of large installations. Tabletop brushing machines have been one of Dilg's bestsellers for years. From the area of small brushing machines, these systems have matured towards complete solutions. We manufacture doublesided brushing machines with integrated high-pressure cleansing and dryer, called Ottomat. The working width ranges from 400mm to 600mm. A touch screen controls the machine.
The problem of liquid waste during the brushing of circuit boards is well known. Copper particles get into the waste water and have to be filtered out. Obviously, progress has been made in this area as well. Reducing costs is a top priority, now more than ever. Reusing the process water saves 96% of the water. The sewage runs from the brushing chamber into a tank, pulled by gravity.
This filtering system works without auxiliary processes such as diatomite. Additional candle filters make perfect filtering possible.

Manufacturing circuit boards without a brushing machine? Impossible!

11/2002

Surface processing is vital throughout the industry, especially when manufacturing circuit boards. Most procedures require burrless edges and surfaces that show no trait of oxidization. Enter brushing machines, that are a viable option for processing workpieces. Some aspects, however, should not be neglected:
In spite of the introduction of "high speed drilling" with very high rotational speed, completely burrless drilling seems hardly possible. Therefore, removing the burrs while keeping the exact geometric position of the holes is of paramount importance. The properties of the brushing roller determine the size of the removable burrs (<25µm). Lamella rollers with or without impregnation are the most commonly used type of roller. Settings like contact pressure, frequency and amplitude of oscillation, and rate of rotation also heavily influence the results of the process. The cutting speed, a product of rate of rotation and circumference of the roller, should never exceed 12m/s. A higher cutting speed combined with an unbalanced roller could result in excessive forces on the bearing.
The brushing rollers are made of a composite of spacially structured fibers and abrasive material, held together by heat resistant synthetic resin. This 3-dimensional structure inhibits condensing and thus aids self-cleaning.

3-dimensional structure of the fibers; Al2O3, Al2O3high Performance, SiC

Burr before and after

Fine-grained lamella rollers are generally used to clean and deoxidize the circuit boards before applying the solder resist or nickel-gold coating. Slight untercutting of the conducting paths requires effective deburring. Accurate roughening of the boards (2.5-3.5µm) enlarges their surface area and improves adhesive strength between the board and the resists.
The feed rate should lie between 1 and 5m/min. Permanent moistening of the rollers is necessary to support self-cleaning. This effectively inhibits lubricating effects which can cause complications later during processing. Optional oscillation ensures best results for a homogenous surface. In most cases the, the oscillation stroke lies between 3 and 10mm at a oscillation frequency of 120 to 240 double strokes per minute.

closed loop (permanent lubrication)

A good way to evaluate the performance of brushing machines is the cleansing of pressed sheet metal, which is very important for multilayer manufacturing, where it ensures the optimal distribution of temperature and pressure in the package. Inhomogeneous temperatures can lead to trapped air and variations in thickness that are outside of the required limits, with undesireable consequences like warped layers and inadequate lamination. Pressed sheet metal also counteracts imprinting of the impurities of one layer to another. Spraying the pinholes with wax keeps the sheet metal from sticking together after pressing.
The most commonly used pressed sheet metal has a thickness of 1.5 to 2.0mm, a tolerance of 0.05mm, a tensile strength of 1500 to 1700N/mm² and a hardness of 45 to 50HRC. Since pressing the sheets under high temperatures causes resin to flow out, they will have to be cleaned and brushed afterwards. The process results in an even surface roughness (Rz=1.5; Ra=0.2) and plane parallelism of 0.03mm. A perfect example is the processing of pressed sheet metal at "Multek", where a Dilg brushing machine cleans sheet metal three shifts a day, six days a week. The machine, built for a tough environment, is equiped with permanent lubrication for the needle bearings ("closed loop"), ensuring ideal heat removal and high reliability.

Dilg brushing machine cleaning sheet metal at "multek"

Brushing is an inevitable process for the production of circuit boards and therefore a foundadtion for following steps. Modifications for special cases and enhancments add to the brushing techiques. A process that is manageable and works! "Never touch a running system!"

Visitors from Kyrgyzstan

11/2002

Interested visitors from Asia were given the opportunity to experience a company characteristic for the german corporate middle class.

Neufahrn (ft) - For a trade delegation from the federal republic of Kyrgystan, a visit to Neufahrn was part if their one-week trip through Germany, arranged by the German Department of Trade and Industry. Their destination was Otto Dilg Gmbh mechanical and precicion engineering. High-ranking representatives of the Republic of Kyrgystan were watching the skilled employees of the model plant Otto Dilg work, to gain insight into the structures of German middle class companies. For Walter Mendisch, chairman of the BVMW (a association of the corporate middle class), the purpose of the event was to give the Kyrgyz representatives a close impression of a German company. "Our goal was to present an average company close-up, and to give an understanding of the personality of an enterprise and it's tasks, problems and challenges.", he said. After the tour through the halls of the company, Rüdiger Dilg and Walter Mendisch answered questions from an interested deputy prime minister Dshoormart Kaipowitsh Otorbajev and other members of the group. Fiscal policy, human resources and the economic development of the German corporate middle class were focal points of the discussion. "We used the event to establish a dialog with the highest authorities of the Republic of Kyrgystan, and be intend to build upon that." said Rüdiger Dilg, commending the exchange with the CIS representatives. Walter Mendisch too sees the event as a success: "We succeeded in initiating cooperation with new territories. Especially in economically harsh times it is important for the businesses to look beyond tomorrow."

Brushing techniques and more

Productronic 3/2001

The immediate proximity to Munich International Airport represents Otto Dilg Precision Engineering in Neufahrn, close to Freising, not only in a figurative way. Both profit from the updraft, each in its own way. Just like the airplanes at the airport, the Neufahrn business seems to thrust forward and take off to reach new goals. Emerging from a mixture of innovation and investment, the small but powerful company is striving for ambitious projects.

Picture 1: The new emblem of the Otto Dilg GmbH

Matching like two gears in an engine, the new concept, which combines precision and mechanical engineering under one umbrella, accelerates the company forward. (Picture 1) The precision engineering subdivision focuses primarily on manufacturing CNC-drilled and milled parts for the automobile and electronics industry. Also, the array of products includes the complex insides of high performance printers. Especially in these areas delivery reliability and quality are paramount, and Dilg meets these strict requirements again and again.

Picture 2: Processing unit Hermle

These challenging tasks necessiatate the employment of top quality machinery and qualified personnel. For example, on an area of over 18000 square feet, the precision mechanics department produces accurate parts that pass even the most rigid tests. (Picture 2).

Custom and off-the-shelf brushing machines

Picture 3: Brushing machine of the BM line

The mechanical engineering department shines especially bright in the area of brushing machines and filter systems, which are used in the cleaning of circuit boards, ceramics substrates, pressed sheet metal for multilayer, etc. Cleaning glass, ceramics, carrier plates and parts of clockwork casings make high demands on a system like that.
About 80% of the brushing machines are tailor-made to meet customers special needs (Picture 3). The 20% share of standard machines offers a wide variety of different designs and performances. A long development process and a lot of experience in the field guarantee the reliability of these off-the-shelf machines.
The development of a compact filtering unit (Picture 4) protects the environment. It separates solids from the waste water of brushing machines. Of course, the system is compatible with any other machine.

Picture 4: Universal filering unit

The internal design bureau is concerned with more in the area of mechanical engineering. Using modern CAD systems, the employees turn customer requests into detailed drawings. The scope of the problems ranges from "vehicle ramps" and "solar cell framing devices" to "clenching machines for roller chains". The high flexibility of the company permits handling projects in very short amounts of time.
Last but not least, the success in mechanical engineering is hignly deoendend on service. Effective first-hand service, that is, directly from the manufacturer, is an important step towards customer satisfaction. Therefore, customers at Dilg are being treated individually, quickly and reliably.

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