complete solutions in industries · robotic welding workplace tig two-position positioner 2000 mm...

COMPLETE SOLUTIONSIN INDUSTRIES

2

Table of contents

3 About company

4 History of the company

5 Director’s message

6 Company management

8 Sales

10 Investment

14 Manufacturing

16 Technical capabilities

30 Certificates

3

About company

ATONA s.r.o. company based in Blansko has been active in the market since 2000 and asserting itself in the processing of sheet metal by using of latest technologies, but mainly thanks to the top quality of performed work, flex-ibility and expertise of all its employees.

Our philosophy – to be a flexible partner – has proven itself as a crucial factor to achieve common success and meet customers’ requirements.We mainly focus on a production of sheet metal parts and welded structures ac-cording to the customers’ manufacturing documentation.

Our goal is customer’s satisfaction, which we try to achieve by continuous quality improvement of our services. To meet this goal, we constantly improve our proc-esses and upgrade our production equipment.

About company

4

History of the company

ATONA, s. r. o. has been engaged in sheet metal processing since 2000. The main point of the company’s activity is production of sheet metal parts and welded structures according to customer specific requirements. A flexible approach to our clients‘ requests is a pillar of the company’s philosophy for that matter. This is complemented with maximization of service quality and continuous innovation of production technology. The aim of the philosophy is full customer satisfaction and long-term partnerships.

History endowed ATONA with valuable experience. From production with the first re-furbished laser in a rented hall Paulinka through the necessity of dealing with almost liquidating consequences of floods and moving to our own, for production much more suitable premises, to expanding the spectrum of services offered. These now include everything from bending, punching and welding to all-inclusive locksmith production.

Our production capacity is supported not only by the machinery equipment of the factory but also human resources (more than 120 permanent employees) and certified management systems QMS and EMS. This predisposes us to comply with the requirements of customers from the Czech Republic as well as the European Union and associated countries.

History of the company

5

Director’s message

The company ATONA s.r.o. is active in the market since 2000 and wins rec-ognition in the field of sheet metal processing thanks to application of the most progressive technologies, but mainly thanks to the first-class quality of done work, flexibility, expertise and skills of all employees of our company. Our policy – to become flexible partners – has proved to be the decisive factor for reach of the common success and satisfaction of customer requirements.

Organizational structure of the company ATONA s.r.o. is adapted to respond flex-ibly to the most demanding requirements of our customers with observation of the principles of modern management. Our utmost objective is to manufacture and deliver the requested product within the set deadline, without unnecessary bureaucracy and with respect to a high quality and optimum price. Fulfilment of these objectives is priority for each member of the top management as well as for all employees.

Nowadays the company employs 120 specialists and this trend is of ascending character. From September 2006 we have been manufacturing our products in a new modern manufacturing hall and in 2008 we were awarded the certificates con-forming to the standards of the integrated management system, QMS and EMS.

Let me express many thanks to all of you, to our customers and business part-ners. Thanks to you the company ATONA has chosen the right path.

Ing. František ŠvecGeneral Director of the company ATONA s.r.o.

Director’s message

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Company management

Company management

Currently, Atona has 120 employees.

Managing directorand ISM Representative

Finance Director

Production Director

Quality Manager

Head of Produc-tion Engineering

HR Manager Representative for QMS and EMS

Head of Sales Department

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Sales

Customer distribution by States

Sales

European Union

Czech Republic

Other(Switzerland,

Norway, China)

Currency/year 2013 2014 2015 2016 2017 2018 2019 (2020)

million CZK 114 145 153 173 191 204 193 (210)

million EURO 4,4 5,3 5,6 6,4 7,3 8,0 7,6 (8,3)

0

50

100

150

200

250

10 Significant investments

Significant investments

Year 2020: Completion of construction of a new production hall - with a production area of 1,800 m2, compre-hensive facilities and wheelchair access. Planned completion date: March 2020

3D laser cutting of profiles and tubes Processing of round profiles up to 240 mm diameter Processing square profiles up to 200x200 mm Lengths of semi-finished products and products up to 6.5 m Angular cuts (chamfering) up to and including 45°

Robotic welding workplace TIG two-position positioner 2000 mm long, turning diameter 1000 mm total weight of the positioner 1200 kg repeatable approach accuracy to +/- 0.02 mm permanent load 240 A additional wire 0.8 to 1.6 mm

Equipment for cold joining of sheet metal, so-called “clinching” Joint diameter 6 or 8 mm Jointed sheets 1 to 4 mm

Machine equipment for machining NC lathe with spindle passage 80 mm and turning length 1500 mm, driven tools,

additional axis “C” and “Y” CNC vertical milling machine with table 1000x500 mm and load up to 600 kg, automatic tool

change, spindle 12 000 rpm.

Painting shop for powder coating with an area of approx. 250 m2 and an annual capacity of 40 000 m2 of lacquered surfaces Painting cabin 2,5x2x1,5 m Electrostatic powder coating, gas firing furnace Overhead conveyor system

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Year 2019: Robotic welding workplace Weldments volume up to 1 m3 and weight up to 750 kg 6 axis robot, range 2 m Welding source using the processes Pulse, CMT, LSC, PMC Economical use of welding time to clamp another weldment

Plasma equipment for metal cutting

Year 2018: Overhead crane JASS 2.5 t - welding shop Semi-automatic welding of elements Pro-C 1000 with Powerflex arm

Year 2017: Hydraulic NC horizontal press brake 800 t Mounting tables, height adjustable Assembly equipment HEYMAN

Year 2016: Deburring machine COSTA Upright drilling machine PROMA

Year 2015: CNC controlled punching and forming press for sheet metal processing up to 8 mm thick and 3000 × 1500 mm in size

Hydraulic CNC press brake 220 - 250 t with min. bending length 3200 mm Hydraulic CNC press brake 30 - 60 t with min. bending length 1020 mm Welding workplace: 6 x MIG/MAG, 1 x TIG

Year 2014: TruLaser 5040 Heltos triple-spindle drill HUBTEX forklift PEGAS automatic saw – large Rosller tumbler machine

Year 2013: TruLaser 5030 Fiber 3D measurement equipment MITUTOYO CRYSTA – PLUS M574 Cloos robotic cell


14 Manufacturing

Structure:

Design templates and simple products that make produc-tion easier, more precise, and cheaper.

Creating 3D models according to the customer’s PDF draw-ings and producing elaborated surfaces for sheet metal parts.

ATONA uses the program Solid Edge, which enables parametric modeling, the creation of draw-ings and 3D visualization.

Input formats supported – STEP, IGES, DWG, DXF (complete with PDF).

CNC programming:

Creating cutting drawings and CNC programs for laser and punch machines.

We use the program TruTops for the above operations.

Input formats supported – DWG, DXF.

Technologies:

Preparing technical documents for calculating bids and offers.

Preparing manufacturing proce-dures and instructions.

Operative solutions for techno-logical problems in production

Manufacturing processes and technologies Planar cutting of material with

a laser Planar cutting of material using

punch presses Bending sheet metal on press

brakes Fitting shop Welding Grinding and preparing parts

prior to coating Deburring, tumbling and clean-

ing, labeling Slitting metallurgical material External cooperation

Manufacturing

The production process starts with the customer’s demand, and then the price calculation and the offer are issued according to the technical documentation.

After we receive the order, the technical preparation of the production begins, consisting in processing the technological process and the bill of material, and in the capacity planning and verification of the production date.

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Technical capabilities

We offer comprehensive processing of sheet metal by CNC and NC technol-ogy on Trumpf machine tools. We offer flat cutting and cutting of sheet metal by laser, sheet shearing and punching on a punching machine, sheet forming on hydraulic NC press brakes, metal working, shielded welding MIG/MAG and TIG (WIG) and locksmithing. We are able to manage small-quantity as well as mass production including all subcontracts and surface treatment (powder coating, electrogalvanizing and more).

We also procure transport to any required place on your request.

Planar cutting of material with a laser

Cutting steel, stainless steel and aluminum sheets with a laser is among the fastest and most technologically advanced methods of cutting material. It significantly in-creases the economy of the whole process, because in comparison with slitting materials by machine, it mini-mizes waste and therefore saves production costs.

At ATONA we use the following equipment for laser cut-ting:

Technical capabilities / Planar cutting of material with a laser

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TruLaser 5030 (L41) – FIBER

Productive cutting a thin sheet with a precision of ± 0.1 mm High machine dynamics thanks to linear drives High-pres-sure cutting of stainless steel and aluminum alloys with no burrs or oxidation on the cut edges.

Sheets fabricated from the following material:

MATERIAL MAX. THICKNESS OF SHEET

Carbon steel 15 mm

Stainless steel 10 mm

Aluminum 10 mm

Copper 6 mm

Brass 6 mm

Aluzinc 4 mm

Galvanized steel 4 mm

Technical parameters:

PARAMETER VALUE

Fabricating sheets up to dimensions

3 000 × 1 500 mm

Machine output 5000 W

maximum weight 900 kg

Cutting gases Oxygen, Nitrogen

TruLaser 5040 (L53)

Machine characteristics similar to Laser 5030 (L41). Preci-sion during burning ± 0,1 mm

Sheets fabricated from the following material:

MATERIAL MAX. THICKNESS OF SHEET

Carbon steel 20 mm

Stainless steel 20 mm

Aluminum 15 mm

Galvanized steel 6 mm

Technical parameters:

PARAMETER VALUE

Fabricating sheets up to dimensions

2 000 × 4 000 mm

Cutting gases Oxygen, Nitrogen

Technical capabilities / Planar cutting of material with a laser

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Bending sheet metal on press brakes

Bending is a forming process where the material is per-manently deformed into a different bending angle with less or more rounded edges. We use bending tools – dies, nuts

TruBend 7036 PARAMETER VALUE

Pressing force 360 kN

Bending length 1020 mm

Fabricated thickness of sheet 0,5 mm – 2 mm

Stroke 120 mm

TrumaBend V130 PARAMETER VALUE




Stroke 215 mm

ZOPF T800 PARAMETER VALUE


Fabricated thickness of sheet 1 mm - 25 mm

Stroke 300 mm





Stroke 445 mm





Stroke 445 mm

Maximum surface of the part for bending

1000 × 1500 mm

Maximum weight of the part 40 kg

Technical capabilities / Bending sheet metal on press brakes

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Planar cutting of material using punch presses

Cutting on the punch press is technology designed for perforating and punching out specified holes using spe-cial tools – dies.

Punch press – Trumatic 3000R

Compact machine for thin sheets

PARAMETER VALUE

Forming possibleSheets, Embossed surfaces, Necks, Threads, Bridges

Table of maximum dimensions 1500 × 3000 mm

Maximum thickness of fabricated sheet

3 mm

Machine precision ± 0,1 mm

Maximum weight of the sheet 108 Kg

Maximum punch force 180 kN

Fabricated materialCarbon steel, Stainless steel, Galvanized steel, Aluminum

Punch press – TruPunch 5000 PARAMETER VALUE

Maximum sequence of strokes during cutting

1350 1/min

Maximum cutting force 220 kN

Table of maximum dimensions 1550 x 3050 mm

Maximum thickness of fabricated sheet

1 mm

Machine precision ± 0,1 mm

Technical capabilities / Bending sheet metal on press brakes

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Fitting

In the field of locksmithing and assembly work we haveexperience in assembling and packing various com-ponents and assemblies from all of our materials. We are also equipped with Flowdrill technology for forming holes and threads. We have pneumatic and accumulator riveting machines.

Pressing fasteners into sheet metal

Machines used

Lis HAEGER 618plus He PEMSERTER

Components used

Nut: reliably creates threads outside the material with high resistance against spinning and pulling. Compression nuts may be used for high-strength applications, for press-ing into thin sheets or on the sheet edges.Screws: reliably create threads outside the material with high resistance against spinning and pulling. Compression screws may be used for high-strength applications, for pressing into thin sheets or on the sheet edges.Studs: can be used for thin sheets where it is necessary to create threads. Standoffs do not protrude after pressing from the sheet. Like other fasteners and standoffs, they have a high resistance against spinning and pulling.

Capacitor welding

Welding machine Nelson a KST110/ESP1-S

Semi-automatic welding machine Pro-C 1000 with Powerflex arm

Material:

Copper-plated steel Stainless steel Aluminum

Used for capacitor welding:

Screws M3 – M8 Weld pins with internal threads – diameter from 5 mm

(M3) to 8 mm (M6) Weld pins without threads – diameter from 3 mm to

7.1 mm of Studs Fastons

Technical capabilities / Fitting

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Minor mechanical assembly

Riveting

Material:

Carbon steel Stainless steel Aluminum Brass

Bonding

Able to be glued to finished products:

Rubber components Plastic components

Nejpoužívanější typ lepidla: Loctite

Final assembly

Drilling, threading, countersinking

Heltos triple-spindle drill

Drill press

Magnetic drill

Bit diameters from 1.1 mm to 52 mm


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Welding

Steel welded assemblies weighing up to 1.5 tonsStainless steel welded assemblies up to 100 kgAluminum welded assemblies up to 100 kg

The welding process is certified by the Certification Body TÜV SÜD Czech s.r.o.

Hand welding

Welding method MIG, MAG Welding method WIG Welded material: Carbon steel,

Stainless steel, Aluminum

Robotic welding

CLOOS robotic cell

Welding method MIG, MAG Welding: by pulse, short-circuiting Two-axis positioner Multi-axis robotic arm with weld-

ing head Welded material: Carbon steel,

Stainless steel, Aluminum, Maximum dimensions of welded

piece: 800 × 800 × 800 mm

Spot welding machine

Pei Point spot welder

Welded material: Carbon steel, Stainless steel

Maximum thickness of two welded parts: 8 mm (1 sheet max. 4 mm)


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Grinding and preparing parts prior to coating

Finishing method of machining surfaces with a tool whose edges are formed by grains of hard materials interconnected with a good binder.

Increases precision and surface quality Light grinding under paint Fabricated material: Carbon steel, Stainless steel,

Aluminum

Technical capabilities / Grinding

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Deburring, grinding, cleaning and marking

We mainly use for deburring COSTA and FLADDER machines, for tumbling ROSLER machines. Separate processing of stainless steel is a matter of course.

Deburring machine

Deburring machine – Fladder AUT

Cutting away burrs after punching and laser cutting Material:

Carbon steel Stainless steel Galvanized steel Aluminum

Tumbling machine

Rosller tumbler equipment

Used for deburring and rounding edges, smoothing and polishing surfaces, degreasing and cleaning, removing scale or rust.

Material:

Stainless steel Aluminum Carbon steel

Technical capabilities / Deburring, grinding, cleaning and marking

25

PEGAS automatic saw – small

Maximum cross-sectional dimen-sions of the semifinished product:

235 × 300 mm

PEGAS automatic saw – large

Maximum cross-sectional dimen-sions of the semifinished product:

360 × 600 mm

Manual plasma

Used for rough slitting material Used for cutting shapes into hol-

low sections

Maximum thickness of the material:

10 mm

Slitting metallurgical material

All of the following machines are used on this material:

Carbon steel Stainless steel Aluminum

Technical capabilities / Slitting metallurgical material

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External cooperation

We are able to provide the following additional operations performed at the ATONA plant for external cooperation.

Chip-forming machining

Milling Lathing CNC milling CNC lathing Grinding

Blasting: Mechanically removing paint, impurities

Blasting with corundum and glass beads:

Using a very fine abrasive Corundum – surface cleaning and

uniformity Glass beads – surface polishing

Material: Stainless steel Other nonferrous metals Carbon steel

Special processes

Hot-dip galvanizing Creating uniform and high-quality

coatings In accordance with DIN EN ISO 1461 Coating layer – 50 – 190 microns

Anodizing Chemical and thermal surface

treatment of aluminum

Laser engravingPickling stainless steelWaterjet cuttingSandblasting and tumbling parts

Metal finishes with powdered plastics in accordance with ČSN EN ISO 12944

Chemical stripping in accordance with ČSN EN ISO 12944

Coating Plastic finish Maximum dimensions

– 600 × 500 × 200 mm

Painting Manual and automatic coating

with powder paints in booths In accordance with ISO 2409

Electroplating Zinc and nickel coating iron parts Maximum dimensions –

1800 × 900 × 250 mm Blackening steel partsPotisk kovu

Technical capabilities / External cooperation

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Inspection

Verifying the compliance of the requirements with the actu-ally achieved state is the basis of the production quality con-trol for us. The frequency and scope of the inspections is de-termined not only by the customer’s requirement, but also by our internal regulations complying with QMS certification.

Input, output and production checks

Parts are checked using:

standard instruments gauges Mitutoyo CRYSTA-PLUS M574 3D

measuring device Mahr PS1 roughness gauge Multimar Mahr length gauge

Metrology

Instruments and gauges are docu-mented and externally calibrated.

Internal checks are performed on working gauges.

Mitutoyo CRYSTA-PLUS M574 measuring equipment

Maximum height of the workpiece: 590 mm

Maximum weight: 180 kg Measuring range: X axis – 500 mm,

Y axis – 700 mm, Z axis – 400 mm Resolution: 0.0005 mm

Optical Comparator Keyence IM 6226

Is used for contactless measurement of contour parts during production with an accuracy of 0.001 mm.

Measuring range: X axis – 200 mm, Y axis – 100 mm

Maximum weight: 60 mm Maximum weight: 2 kg

Technical capabilities / Inspection

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Shipping and material receipt

The workplace is equipped with additional handling de-vices (4-tonne fork-lift truck, 10-tonne bridge crane) for unloading and loading products. At the workplace, pack-ing is performed according to our own packing plans, but we can also satisfy special packing and shipping require-ments of customers.

5t and 10t handling bridge cranes

Technical capabilities / Shipping and material receipt, 5 t and 10 t handling bridge cranes

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Certificates

Certificates

Prague

BrnoBlansko Olomouc

ATONA s.r.o.Poříčí 2428/44, 678 01 BlanskoID: 26226413, Tax ID: CZ 26226413Bank: UniCredit BankCZK: 2106251288 / 2700 EUR: 2106251296 / 2700 IBAN: CZ9727000000002106251296SWIFT: BACXCZPP

The company is entered in the Commercial Register of the Regional Court in Brno, Section C, File 38346.

Telephone reception: +420 516 498 771, +420 516 498 774Mobile gateways: +420 737 227 114, +420 737 227 115Fax: +420 516 498 770E-mail: [email protected]

complete solutions in industries · robotic welding workplace tig two-position positioner 2000 mm...

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