Innovations for the energy of tomorrow: solutions for the energy industry
The energy sector is currently undergoing a dynamic transformation that offers new opportunities for innovation and growth. The increasing global demand for electricity, particularly in the field of renewable energies, is continuously driving demand for components for energy generation and opening up exciting prospects for manufacturing companies. At the same time, they are faced with global competition, rising prices, new trade barriers and geopolitical tensions. This is the ideal time for them to implement more efficient solutions and optimize production.
Initial Situation
Quality and precision for production in the energy industry
DMG MORI is an experienced partner to the industry. We offer manufacturing companies a wide range of solutions to help them efficiently produce high quality components for power generation. With our range of state-of-the-art machine tools as well as customized automation, digitization and consulting solutions, we are the ideal partner for the energy industry.
High quality requirements with strong cost pressure
Manufacturing companies in the energy sector operate in an extremely dynamic environment. The market situation is characterized on the one hand by the strong growth in electricity demand and renewable energies, and on the other by intense global competition. The high cost pressure is forcing companies to reduce manufacturing costs without compromising on quality.
At the same time, the complexity of component production is constantly increasing. Components for modern energy technology systems are becoming ever larger and their machining requires maximum precision. This leads to an increased need for advanced machining technologies and specialized machine concepts that are capable of manufacturing these demanding geometries efficiently and without errors. However, the increased complexity also requires constant adaptation of the manufacturing processes. In addition, the variety of materials has increased further. The use of aluminum, titanium alloys and carbon fiber-reinforced plastics, for example for wind turbine components, presents manufacturing companies with new challenges.
High demands on production
Manufacturing in the energy sector is subject to the strictest quality requirements in order to ensure the longevity, safety, and efficiency of the end products. Energy systems must be constructed and operated in such a way that technical safety is guaranteed. The law also implicitly includes quality standards for the components used. Key criteria are therefore maximum precision and surface quality, because minimal tolerances and perfect surfaces are crucial for performance and service life, especially for critical components such as gear components or turbine blades.
Another important factor in manufacturing is flexibility: Flexible manufacturing allows companies to respond to fluctuating demand and adapt to increasing requirements (e.g., due to new regulations). Companies often have to switch quickly between different component sizes and types in order to respond to market changes or meet individual customer requirements. Flexibility is also an important prerequisite for coping with disruptions such as supply chain problems or resource shortages.
Economic efficiency and process reliability through automation
Efficient production requires continuous optimization of manufacturing processes in order to minimize waste and shorten throughput times. Process reliability is also essential, as unplanned downtimes cause high costs. Machines and processes must therefore offer extremely stable performance.
A high degree of automation helps manufacturing companies here: automation minimizes sources of human error and ensures consistent quality standards throughout the entire production process. Precise and repeatable processes, which are often supported by integrated sensors and real-time monitoring, allow deviations to be detected and corrected at an early stage. This ensures product quality and reduces rejects.
Value Added
Partner for power: solutions for the energy industry
Manufacturing companies are faced with the challenge of producing highly resilient and durable components as efficiently and reliably as possible. This is precisely where DMG MORI's portfolio of solutions comes in, tailored precisely to the specific requirements of the industry. With decades of experience in the machining of complex materials and large components, we have the necessary technological know-how to realize even the most demanding projects. Our broad machine portfolio covers a comprehensive spectrum, from high-precision milling and turning machines to specialized solutions for machining large parts. We also offer comprehensive automation and digitization solutions, ranging from integrated automation systems such as pallet changers and robot cells to digitalized production processes. A global service network guarantees worldwide support and rapid assistance when required. We therefore not only offer individual machines, but also focus on complete production cells and turnkey solutions.
Your advantages as a DMG MORI customer
DMG MORI supports manufacturing companies in the energy industry with a wide range of machine tools, digitization, consulting, and service solutions. We contribute to optimizing production and offer maximum precision in component machining: Our turn & mill machines the number of process steps and enable a significant increase in productivity thanks to fast machining, short setup times, and automated processes.
A DMG MORI machine tool solution that is particularly relevant for the energy industry is our DMU series, which is ideal for high-precision machining of large and complex components. The NLX and NTX series also play an important role, enabling efficient complete machining of components in a single setup, as do the proven CTX TC turn & mill complete machining centers for universal turning. The LASERTEC series is used for special applications such as additive manufacturing for repairing or modifying components, or laser texturing for optimizing surfaces. Our automation solutions such as Robo2Go or Pallet Master increase machine running times and enable unattended production, especially for large batch sizes or recurring components. Our CELOS X platform acts as a digital interface, networking production and centralizing data management, order planning, and machine monitoring. TULIP, a platform for developing no-code applications for process optimization and workflow digitization, makes real-time production data available everywhere.
Our customers also benefit from a wide range of services: Our comprehensive service and support services and our presence in over 40 countries worldwide ensure that companies can always get the most out of their machines.
More quality and precision for HORA Holter Regelarmaturen GmbH thanks to the CTX series from DMG MORI
Since 1967, HORA has been a reliable partner for durable and low-maintenance control valves. The valves are used in the energy industry, gas infrastructure, process engineering, and building services, among other areas. HORA has been relying on 6-sided complete machining to manufacture demanding workpieces since 2008. The company started production with three CTX gamma TC machines from DMG MORI. From 2021 to the present, six CTX beta models have also been installed, five of which equipped with turn & mill capabilities. Thanks to the latest acquisition, the CTX beta 1250 TC, manufacturing productivity has been increased by 50 percent.
More productivity in manufacturing for Richter Feingerätebau GmbH thanks to the DMC 80 U duoBLOCK from DMG MORI
Richter Feingerätebau GmbH is an experienced supplier in the fields of hydraulics, wind power and mold making. The company's 21 qualified employees manufacture highly complex components with manufacturing tolerances in the μ range. Since 1993, Richter Feingerätebau has relied on CNC technology from DMG MORI for machining. After positive experiences with the machining centers and lathes – including a DMC 80 U duoBLOCK – a grinding machine from DMG MORI was also installed in 2022. The remarkable aspect: DMG MORI has fully automated the TAIYO KOKI IGV-3NT so that Richter Feingerätebau can make optimal use of it almost around the clock.
Workpiece examples
Future Orientation
DMG MORI Corporate strategy
Machining Transformation (MX) is DMG MORI's response to the societal needs that change every ten years. With its MX strategy, DMG MORI aims to promote sustainability and counteract the shortage of skilled workers through automation. In addition, top talent is to be promoted through comprehensive training programs in digitization.
Energy
Manufacturing companies in the energy industry operate in a highly dynamic market environment. On the one hand, this is characterized by a steadily growing demand for highly specialized manufacturing components. On the other hand, it is marked by intense global competition and constantly changing regulatory and technological conditions. These companies must cope with increasing technical requirements in terms of precision and efficiency, high cost pressure, and ever shorter innovation cycles.
DMG MORI is an ideal strategic partner for the energy industry in this challenging environment. We offer companies a comprehensive portfolio of high-precision manufacturing, automation, and digitization solutions that enable them to significantly increase the efficiency and quality of their production and remain competitive.