2010-12-28 15:31:51PRINT
Three new Schuler stamping lines for Ford in Brazil and Mexico
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With the further development of its Crossbar Feeder, Schuler has reached new performance levels for fast press lines and large parts.
The Schuler Group is installing three major new stamping lines at Ford Motor Company facilities in Brazil and Mexico to support the company’s efforts to standardize production operations throughout the Americas. The new stamping lines will produce large car-body panels, including side-panel frames, tailgates and doors.
Schuler recently completed the installation of a stamping-press line at a Ford facility in Cuautitlan, Mexico, and will complete two similar lines at Ford plants in Camaçari and São Bernardo, Brazil, within the next year.
To meet Ford''''s standardization objectives, Schuler''''s stamping lines in Mexico and Brazil will be largely identical. Each press line will include a lead-off press with 2,500 metric tons of force. The lines in Cuautitlan and São Bernardo will have four follow-on presses with a total press-line force of 7,100 metric tons, while the Camaçari line will have three follow-on lines with 6,100 metric tons of force.
Schuler’s new generation of crossbar feeders will transport parts within the press lines. Together with blankloaders at the beginning of the lines and end-of-line automation for unloading parts, the high-performance capability of the press lines features output capabilities of 15 strokes per minute. If the lines use dies which can form four parts per stroke, they can produce up to 60 parts per minute.
Schuler’s advanced simulation technology ensures optimum system performance. With digital simulation all aspects of the process, including part transport as well as tool-and-die engineering capabilities can be integrated. Whether a line can achieve its performance specifications and maintain consistent part quality ultimately depends on many factors, such as the construction of press dies. Schuler’s digital process simulation, for example, enables the user to adapt die designs to a desired number of strokes as well as avoid restrictions for fast part transfers.
Global OEM manufacturing strategies also call for global teamwork with suppliers. Schuler not only offers a global manufacturing network, but also provides key-account engineers who know production conditions and requirements at various production locations around the world. “Die technology used in one region, for example, might require special draw cushions for ultra-large dies,” said Thomas Schmider, Schuler’s Nafta OEM key account manager. “The new equipment we''''re installing in South America, for example, takes into account these special draw cushions.”
In order to standardize manufacturing processes throughout an automaker’s regional or global network, a machine supplier must have a high degree of know-how and global expertise. “We believe there will be strong demand for our large-press-line expertise in coming years,” said Uwe Kreth, Schuler''''s engineering group leader for large presses. “Car manufacturers are standardizing their global manufacturing networks, which in turn allows them to raise output levels and reduce part costs. Schuler''''s experience in press-line planning and design, coupled with our global network of manufacturing and service facilities, means we always are capable of finding the right solutions for a customer''''s metalforming processes – whether in the Americas, Asia or Europe.”
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