The requirements for manufacturers of complex sheet metal parts are clearly defined: top quality and the ability to produce a wide range of parts are high on the list of customer priorities. When it comes to investing in new machinery, therefore, manufacturers are interested above all in output, process reliability and flexibility. Schuler''''''''s new automatic blanking and forming presses with servo drives have been designed specifically to meet these requirements. Saxonia-Franke in Göppingen, Germany, was amongst the first companies to invest in the new technology.
Saxonia-Franke has been using one of the new-generation automatic blanking and forming presses since spring 2007. The Göppingen-based company is growing rapidly and expanded its machine base with the addition of the 4,000 kN Schuler press with a significantly higher press force than the 3,150 kN of its existing eccentric presses. The investment has paid off for the company, says Production Manager for Metal Goods, Jürgen Birkhold: Thanks to the servo drive, we can now adapt the movement curves exactly to the die, forming process and automation equipment. In this way, we have been able to raise output compared with our conventional mechanical eccentric presses by up to 40 percent. In some cases by even more.
Saxonia-Franke manufactures fastening and safety elements on the new machine, mainly for the automotive, electrical and construction industries. The press offers extra benefits especially for flat parts. Due to the freely adjustable stroke height in oscillating stroke operation, flat parts can be produced with significantly shorter cycle times.
Schuler''''''''s automatic blanking and forming presses with servo drives also hold a few surprises when it comes to energy consumption. The high power connection values of servo drives are only relative. The additional acceleration power is recaptured and stored during the generator’s braking sequence. This energy can then be used for the next acceleration cycle. With the aid of this energy management system, power consumption can be significantly reduced and peak needs smoothened.
Short ways from tryout to serial production
At Saxonia-Franke it really is a short step from tryout to serial production. On the one hand, the company uses almost exclusively its own, self-developed and constructed progressive dies - the specialists are therefore always on site. On the other hand, the servo technology of the new presses provides optimum tryout conditions for new dies. With the aid of a hand-wheel, the slide can be moved up and down in degrees, tenths of degrees or continuously, and thus exactly positioned. The slide movement is reversible at any point and the so-called Quick Lift function enables the operator to move the slide to TDC at any time. A huge bonus says Saxonia-Franke employee Markus Rieger: The hand-wheel gives us completely new possibilities for die tryout and faster serial production preparation,he explains. However, this more convenient operation also offers real economic benefits, as Jürgen Birkhold explains: We were surprised how fast we were able to produce top quality goods on the new press – and at high output levels.
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| Maximum flexibility for greater investment security |
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In addition to fast tryout times and high output levels, a further benefit of servo press technology is its flexibility. The ability to freely program the movement curves means that the press can be quickly configured for the production of various parts. The operator is given further support by the machine''''''''s visualization system. This enables him to program the respective curve for a variety of configurations and to store it in the die database. Once it has been stored, the individual curves are
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quickly available in the case of die changes. This significantly reduces changeover times and downtime. In view of the shorter model cycles of manufacturers and fast changing peak loads, the new technology provides investment security for the metalforming company.
The new range comprises automatic blanking and forming presses with servo drives offering press forces of 2,500 to 6,300 kN. Thanks to their modular design based on standard components, the presses can be quickly delivered and easily maintained. The new press range is rounded out by an extensive package of services - from maintenance and servicing to finance models and the return or retrofitting of used machines. |
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