Energy efficiency driving innovation-Schuler presents new press generation for lamination production

The need for greater energy efficiency and the search for alternative energy sources and drives are currently among the key innovation drivers in industry. The European countries have created the political framework for this drive with such measures as the obligation to reduce energy consumption by 20 percent by 2020. As a consequence of the so-called eco-design guideline, the EU has issued a series of decrees with binding regulations for specific product groups. As of June 2011, for example, manufacturers of motors are only allowed to offer highly efficient asynchronous AC motors in the performance range 0.75 kW to 375 kW. These regulations create direct impact on the production of electric motor laminations. With its new generation of high-speed presses, Schuler now offers machines for the production of laminations which are perfectly geared to these requirements. The new Smartline presses promise maximum productivity and part quality with greatly enlarged die areas and much lower die wear.

According to Hans Dieter Jung, Divisional Manager of the Drives&Generators market segment of Schuler Presses, manufacturers currently face three major challenges: 鈥淲ith regard to the material to be processed, it is obvious that the share of thinner sheets will increase, as this reduces magnetic loss among other things,�explains Jung. 鈥淚n turn, this greatly helps motor manufacturers meet statutory regulations regarding the energy efficiency of their products. The requirements concerning press bed size will continue to grow in future as modern electric motors are based on increasingly complex geometries. And finally, cost pressure will remain high as international competition becomes even fiercer. As machine manufacturers, we need to face these changes and deliver compelling solutions which help our customers compete successfully on the market,�says Jung.

Smartline �efficient lamination production
Schuler鈥檚 answer to the changing requirements in lamination production is called Smartline. The Goeppingen-based machine and equipment manufacturer will be unveiling its latest generation of high-speed presses in July. 鈥淲e focused on two key aspects during the development phase, which basically apply to all machine manufacturers: part quality and productivity,�states Jung. 鈥淲hat makes the new presses special is that they succeed in perfectly combining both aspects.�This is illustrated by a look at the performance specifications which Schuler promises for its Smartline range. The new line is expected to achieve 10 to 30 percent increases in output �while at the same time offering much larger die-areas with bed lengths of up to 3,300 millimeters. Only such large die-areas make it possible to use correspondingly large-scale progressive dies, which in turn enable the production of electrical motor laminations with much more complex geometries.

Size and speed are just part of the story though, as Hans Dieter Jung explains: 鈥淭he real intelligence of the Smartline �and thus the key to raising efficiency �is the combination of its mechanical and control systems. This also meets a key demand expressed by users, as we found a way to significantly reduce wear and tear on the die.�

Intelligent control system reduces die wear and raises productivity
The service life of a die has a direct impact on profitability. A particular benefit of the new press generation is its patented depth penetration control. This regulates the penetration depth of the upper die with a precision of 1/100 millimeters. The new feature enables the mechanical interlocking of extremely thin sheet metal, as well as being more gentle to the die. As usual, the highly rigid multi-piece press frame in cast iron and tie-rods design, and the trusted play-free column guidance of the slide ensure maximum precision. Users can also raise production speeds with the aid of a interlock control which is integrated into the press control system. This is made possible by a new drive concept for the rotation of punches and matrices.

Schuler presents the Smartline at the Blechexpo fair. The machine can also be seen in operation at the company鈥檚 facility in Goeppingen from July onwards.