TECTRENDS

April 2008

Information for Forming Technology Professionals special edition: servo Press Technology

NEWSLETTER

SUCCESS IN THE STAMPING PLANT PERSPECTIVES FOR THE FUTURE

SERVO PRESSES CHANGE FUNDAMENTAL CONCEPTS IN THE STAMPING PLANT

ince the introduction of Blanking and Forming Presses by Schuler and Mller Weingarten, servo drive technology has become established in its markets. Evidence for this can be seen in the decision by a customer in the automotive supplier sector to invest in a second servo press as part of its plant capacity expansion program. This particular plant was able to increase production of a wide range of parts by an average of 40 percent with the existing servo press. In total, the Schuler Group has now sold more than 30 servo presses to the automakers and their suppliers and to the household appliance, electronics and furniture sectors. After the success of the PSE model series with capacities of 2.500 to 6.300 kN, the product line was expanded to include lines with capacities of up to 30.000 kN. A milestone in growing the product offering was the development of the first large-scale, high tonnage project involving fully automated press lines and blanking systems using servo presses with direct drives.

expanding part variety leads to customer satisfaction and success

Our customers are extremely satisfied with these new models; this can be demonstrated by the fact that we have received so many orders in such a short time, explained Heinrich Peper, who, as general manager of the ProfiLine and Solid Forming/Forging business units at Schuler Presses, is responsible for servo presses. Until now, customers have mainly used our presses to manufacture small and medium-sized parts. By expanding the product line to include the higher capacities we can now offer solutions that allow production of an even wider range of parts. The Erfurt Forming Center operates an 11.000 kN servo press, and the Schuler Gppingen facility offers a servo press with 2.500 kN capacity to optimize customer dies used in high-volume production for use on servo presses.

Servo presses open up many new possibilities whether blanking and forming cell, transfer or blanking press or in fully automated press lines.

INCREASED THROUGHPUT RATES

PROCESS OPTIMIZATION OF HIGH-VOLUME PRODUCTION DIES FOR SERVO PRESSES
in close cooperation with customers, including both automakers and their suppliers, schuler in Gppingen and the erfurt Forming Center provide die optimization for use on servo presses. This involves high-volume production dies in continuous use on conventional mechanical presses. under actual production conditions these dies are optimized for use on servo presses. The results are unequivocal. in some cases, the production was actually doubled. For testing purposes, schuler has available a 2.500 kN servo press with coil line in Gppingen and an 11.000 kN servo press with coil line and tri-axis transfer in erfurt available for application analysis and optimization.
he optimization process begins with our team performing a thorough analysis of the die, the parts and the complete forming process in order to determine the testing parameters. Only in this way can the full potential for optimization of the servo technology be achieved. The team determines where the limits of the process lie. These include tears that can occur at a drawing speed that is too high, feeding and transfer faults as well as problems in the area of nitrogen springs. We then provide a description of the proposed optimization of existing dies based on two typical components.

The 2.500 kN servo press at the Gppingen facility, equipped with coil line and feed unit, provides the ideal testing conditions for the optimization of progressive dies.

Process optimization: Fastener for gas generator The fastener for gas generators is made from 1 mm thick galvanized sheet material. In volume production at the customers plant, the die is used on a mechanical eccentric press with 1.600 kN capacity and a production rate of 25 spm. This can not be improved upon due to the upper permissible limit of the drawing speed; if the speed were increased, fissures would occur during edge forming of the component. In order to improve both process reliability and part quality, the first step in the testing procedure is to reduce the drawing speed, something that would normally also reduce the throughput rate. Servo technology, however, permits the slide to move at a higher speed outside of this range, thereby recovering any lost time. The second step is then to optimize the slide speed to the feed system. Optimization of the motion curves permitted us to an increase the production rate from 25 to 40 strokes per minute.

Die optimization on the example of the fastener on the 2.500 kN servo press at the Schuler facility in Gppingen.

The manual dial function permits user-friendly and independent adjustments for press and die.

Process optimization: bushing Optimization of a bushing component involved working with H240LA material approximately 2 mm thick. The bushing is currently manufactured by a German automotive supplier company on a mechanical eccentric press at 30 strokes per minute using a progressive die. An analysis of the parameters demonstrated that the forming speed could not be increased due to extremely close tolerances in the flange height as well as intense heat generation in the die. Process optimization was achieved by the ability to freely program the motion of the slide curve while considering other parameters during the full press cycle. Here again, the motion curves were optimized by adapting to the forming and transport process. The result was an increase in the production rate from 30 to 56 spm.

Customer dies can also be optimized using the 11.000 kN capacity blanking and forming cell with tri-axis transfer at the Erfurt Forming Center.

In this diagram the blue curve shows the motion characteristics of the eccentric press while the red line shows the modified curve achieved by the servo press. The die is opened quickly after forming and the return stroke to top dead center (TDC) is reduced to the time required by the feed system. Thus, as in the case of this example, faster opening and closing of the die achieves a significant increase in stroke rate without changing the drawing speed.

140,00

120,00

100,00

Stroke [mm]

80,00

60,00

40,00

20,00

0,5

1 Time [s]

1,5

The motion curve of the servo press (in red) can be optimally adapted to suit both forming and overall processing parameters. Thus, a significantly faster stroke rate can be achieved at the same or even reduced drawing speed.

THE TECHNOLOGY DELIVERS WHAT IT PROMISES

SAXONIA-FRANkE EXPANDS PLANT CAPACITY WITH A SECOND SERVO PRESS
in 2007 saxonia-Franke a successful, flexible company of the supplier industry in Gppingen invested in a schuler servo press. With increased throughput performance of up to 40 percent as compared to conventional eccentric presses, the company succeeded in achieving continuous improvement in productivity and cost-effectiveness over a wide variety of parts. impressed by the superior technology, saxonia-Franke ordered a second identical press one year after start-up of the first press.

mong other areas, Saxonia-Franke has specialized in the development and manufacture of complex fastener and safety elements for the automobile, electronics and construction industries. Because this company is producing parts which require a high degree of precision and quality, in addition to their ability to produce a broader variety of parts, they are able to recover their investment cost quickly. Wolfgang Faul, manufacturing manager of Saxonia-Franke, underscored the critical advantage of Schuler servo technology as follows: Our main criterion for purchase of the first press, in addition to improved throughput performance, was the degree of flexibility provided by the freely programmable slide motion characteristics. The system, under harsh plant conditions, has shown that the technology delivers what it promises. In view of our extreme workload, the performance of the press and the quick delivery promised by Schuler made our decision to invest in a second, identical press very easy.

Press duo increases flexibility

The new blanking and forming cell at SaxoniaFranke is, like its predecessor, a press with a capacity of 4.000 kN. Bed dimensions are 3.05 x 1.40 m (10 x 4.6 ft.). The press is equipped with a coil line and a Schuler feeding system. The press can be quickly reconfigured to suit a wide variety of components by means of the free programmability of the motion curves. The motion curves are stored in a database and can be quickly called up during die change. This shortens set-up, changeover and nonproductive times. Userfriendly control of the press shortens tryout and start-up times up to full volume production of good parts.

With close coordination between die manufacturing and production, Saxonia-Franke has produced a wide variety of sheet metal parts.

New line readily available

The second blanking and forming cell will be started up at Saxonia-Franke in the fall of 2008. One of the main reasons for the short delivery time is the modular construction using standard components and maintaining an inventory of standard press models. The press can be completed using basic units kept in stock. In this regard, Schuler is actively countering the current trend toward longer and longer delivery times. This fulfills customer demands for readily available, high-performance, flexible forming equipment. As explained by Uwe Rosenauer, sales engineer at Schuler Presses, The decisive factor for our customers is flexibility. Every day a variety of different products have to be manufactured on this line. Thus, our customers have to be in a position to manufacture top-quality parts, quickly and in high volumes. In contrast, the proportion of the same parts needed to be delivered over a long period of time is declining. Instead, the market is characterized by shorter production cycles with many different parts. We have designed our servo presses specifically to meet these requirements.

The blanking and forming cell with 4.000 kN capacity has proven its worth under actual plant conditions at Saxonia-Franke.

The user-friendly control systems of the press shorten the time from tryout to volume production of good parts.

PRESS TECHNOLOGY ON THE ROAD

SERVO PRESS OF THE PSE MODEL SERIES ON THE WAY TO THE CUSTOMER
blanking and forming presses with servo drive impress customers not only by means of their flexible technology but also by their short delivery times. Our TecTrends photographer accompanied a servo press of the Pse model series on its way from the assembly bay at schuler Presses in Gppingen to installation at a German automotive supplier. schulers experienced shipping and assembly experts accompany the equipment from disassembly at schuler Presses to the customers plant to ensure flawless delivery and start-up.

SERVO PRESS IN PRODUCTION AT KLEIN FORMING TECHNOLOGY

RELIABLE PART TRANSPORT WITH TRI-AXIS TRANSFER
in January 2008 the new schuler servo press Pse2-630 with tri-axis transfer was started up at Klein Forming Technology in Netphen-Deuz in Germany. The company, a highly specialized supplier to the automobile and household appliance industry, uses advanced forming technology to produce about 34 million components annually. Component transport on the new line is performed by a tri-axis transfer system.

his line, from the PSE model series, has a press capacity of 6.300 kN. As with all Schuler servo presses, the servo direct drive design uses torque motors to control the slide motion. As a rule, in progressive die applications the production rate is determined by the die, but in applications for dies with transfer, the available space for part transport determines stroke length and stroke rate. This is where the flexibility in programming of the motion sequences with servo press technology offers the user key optimization potential. In this way, the servo press at klein Forming Technology is even now providing new possibilities to manufacture finish-formed, high-volume components.
Blanking and Forming Press with servo drive and tri-axis transfer at Klein Forming Technology.

schuler Automation Schuler offers complete automation with either destacker/blank loader or coil line in either long or short-space designs, feeder units and tri-axis transfer systems of the AT model series for its Blanking and Forming Presses. Customers appreciate the AT transfers both for their advanced technology as well as for the modular line concept. All models feature enclosed gripper boxes. These units are attached either between the press uprights or on the outside of the press uprights and can be mounted either suspended above the transport level or floor-mounted under the transport level. The direct drive units are integrated into the rail guiding. Schuler uses high-speed servo drives with low play, low maintenance planetary gearing, play-free shaft couplings, hardened and ground rack-type gearing and pinions featuring long-term lubrication.
Klein Forming Technology manufactures complex sheet-metal parts using a three-shift system.

AT transfers can be selectively designed to the required capacity range and adapted to a wide variety of applications. All three models are available in capacity categories L (light), M (medium) and H (heavy) in order to accommodate low, high and very high part weights and stroking rates. The new direct drive feed itself accounts for a 10 percent increase in throughput performance.

Modular Electronic Tri-axis Transfer.

SERVO PRESS LINES FOR LARGE AUTO BODY PANELS

PRESS LINES WITH SERVO DIRECT DRIVE
After the market introduction of the blanking and forming presses with servo drive, servo drive technology has also made inroads into the mechanical large automotive panel markets. The start-up of servo press lines with blanking systems with servo presses will change the look of stamping plants around the world. used in combination with innovative destacker/ blank loader and crossbar automation concepts, these lines have created flexible press lines with production rates up to 17 strokes per minute, lines that are also well suited for processing of high strength steels.

ervo press lines are characterized by maximum flexibility, high production rates and short changeover times. Not only can the use of this innovative drive technology selectively adapt the slide motion characteristics of the line to suit the forming process, the die and the automation, it also allows synchronization of the line presses to one another. The first of these fully automated servo press lines will start production in 2009.

A critical requirement for high production rates in the stamping plant is perfect synchronization of press and automation. Schuler is setting new standards for the future in this field by continuing development of its crossbar feeders. The new generation of crossbar feeders permits seven-axis variability of motion and impresses users with its compact design. It is the basis for fast, reliable transfer of both singles and doubles from press to press. Only one tool set is required per press opening. The crossbar feeder also handles the loading of Press 1 and end-of-line panel unloading onto a conveyor belt.

Servo press line with destacker/blank loader and crossbar feeder automation.

The Schuler Crossbar Feeder provides fast, reliable part transport in the servo press line.

SERVO PRESSES FOR TODAYS AND TOMORROWS STAMPING PLANT

MODEL OVERVIEW 2.50030.000 kN
servo presses in monoblock design
Capacity [kN] bed length [mm] 2.000 2.500 3.050 3.660 4.000 stroking rate [spm] shut height [mm] slide adjustment [mm] slide stroke [mm] 1110 600 200 60250 1100 600 / 700 200 75300 190 700 250 75300 180 700 / 850 250 75300 1.100 1.100 1.100 1.400 1.100 1.400 1.600 1.400 1.600 1.400 1.600 1.600 160 850 300 80400 2.500 3.150 4.000 bed width [mm] 5.000 6.300

servo presses in tie-rod design

Capacity [kN] bed length [mm] 3.660 4.100 4.600 5.100 6.100 7.200 stroking rate [spm] shut height [mm] slide adjustment [mm] slide stroke [mm] 140 1.000 300 150450 140 1.000 300 150450 140 1.000 300 150450 130 1.200 300 200600 130 1.200 300 200600 1.600 1.600 2.000 1.600 2.200 1.600 2.200 1.600 2.200 1.600 2.200 1.600 2.200 1.600 2.200 1.600 2.200 1.600 2.500 1.600 2.500 1.600 2.500 1.600 2.500 1.600 2.500 1.600 2.500 2.800 2.800 125 1.400 300 200600
2 point

8.000

10.000

12.500

16.000 bed width [mm]

20.000

25.000

30.000

2.800

2.800 2.800 2.800 125 1.400 300 200600

4 point

Publisher
schuler AG Bahnhofstrae 41 73033 Gppingen | Germany Phone +49 7161 66-0 Fax +49 7161 66-233 info@schulergroup.com www.schulergroup.com board of Management Jrgen Tonn (Chairman) Dr. Wolfgang Baur Joachim Beyer Dr. Markus Ernst editor Andreas Trost (Marketing Director)