HOT STAMPING WITH PCH FLEX – FLEXIBLE, EFFICIENT, PRODUCTIVE

Schuler is the technological and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and for lightweight automobile construction. Its customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance, packaging, energy and electronics industries. Schuler is a leading supplier of minting presses and implements system solutions for a wide range of different high-tech sectors. The company has a presence in approximately 40 countries with roughly 6 600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

ABOUT THE SCHULER GROUP – WWW.SCHULERGROUP.COM

� Hot Stamping TechCenter for die testing, prototyping, part production and process development

� Advising and training

� Forming Academy

� Professional project management

� Support during production startup

� Production assistance

� Service

SERVICES

SYSTEM COMPETENCE FROM SCHULER FOR HOT STAMPING SYSTEMS

LINES FOR SEMI-FINISHED PRODUCTS AND BLANKS

� Part design � Feasibility studies

� Simulations � Method planning

� Production concept � Line design and system layout

� Blanking lines with dies or laser technology / Schuler Automation

� Lines for tailored blanks / Andritz Soutec

� Laser welding systems for tailored blanks / Andritz Soutec

DEVELOPMENT

→ →

� Blankloader with robot and marking station

� Roller hearth furnace with centering station

� Blankloader with feeder or robot

� Hot stamping press

� End-of-line with feeder or robot

� Part racking systems

HOT STAMPING LINES

� Hot stamping die

→ → → → →

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LINES FOR SEMI-FINISHED PRODUCTS AND BLANKS

With our experience and knowledge in process engineering, press construction, die engineering, and automation and laser technology, we’ve got you covered. A successful start to series production depends on part geometry that is optimized to fit the specific process. As part of a joint simultaneous engineering project, we’ll help you develop viable hot stamping parts that work with your process. We’ll also supply you with the right dies, tailor-made to match your parts.

SYSTEMATIC SUCCESS.YOUR PARTNER FOR THE ENTIRE PROCESS CHAIN.

Schuler accompanies you from the parts development phase to series production – and beyond. As a global market leader in the field of hot stamping, Schuler possesses unique knowledge of the entire process chain, from the blank to the finished part.

Our roots are in plant engineering. We’ll build you presses and feeders that are optimally designed for your specific process. From the coil to the finished and racked product, we handle every single upstream and downstream process step, including the entire hot stamping system.

We equip your employees with everything they need to know about the hot stamping process – by imparting important process know-how, holding instructional sessions, or conducting on-the-job training. Of course, we’re also here to help you start up your system and get your series production up and running, for example, by assisting with process optimization.

Take advantage of our experience, and turn our competence into your own!

The hot stamping method. In hot stamping, high-strength parts are produced from workpieces that are heated, formed on a hydraulic press, and subjected to rapid, controlled cooling in the die. Lasers are then used to trim the finished parts.

The benefits: � Higher strength and lower part weight � High body rigidity � Improved crash characteristics � Stable floor assemblies for electric vehicles � New possibilities for part design � Excellent repeatability with no deflection � Material is more cost-effective than high-strength steel � No press forces necessary

Higher strengths result in optimal body rigidity, and therefore improved crash characteristics – a key feature that is also particularly important for the floor assembly on electric vehicles.

HOT STAMPING WITH PCH FLEX

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FLEXIBLE, RESILIENT, AND EXTREMELY EFFECTIVE. THE STRONGLINE, SPEEDLINE AND PCH-LINE HOT STAMPING PRESSES FROM SCHULER.

The right line concept for everyone. Combining the individ - ual requirements of our customers with our extensive experience in the field of hot stamping is key to the success of the hot stamping line.

Our design engineers have developed three series of presses for this very purpose: StrongLine, SpeedLine and PCH-Line. By selecting from various options and integrating the press in the right line concept, we can flexibly adapt the equipment to different customer requirements.

With their superior quality, reliability and cutting-edge PCH flex technology, our hot stamping presses and line concepts for any application help ensure that your production process remains profitable.

Quality is standard at Schuler. A solidly welded, stress relief annealed press frame designed to resist fatigue is assem-bled with tie rods to ensure minimal deformation and maximum durability of the press. Whether it’s separately filtered hydraulic functions for the dies, slide-tilt monitoring with a shut-off function, or an extremely powerful hydraulic drive – quality down to every last detail is our unwavering standard.

Part of quality is making sure that all basic press functions can be run quickly – with high repeatability and zero errors – even under rougher application conditions. All three lines deliver the high level of quality that Schuler is known for.

As a system supplier, Schuler provides the entire hot stamping line, from the blankloader all the way to the destacking station.

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HOT STAMPING WITH PCH FLEX

GET THINGS UP AND RUNNING, SIMPLY AND RELIABLY.STRONGLINE. The StrongLine delivers solid performance for any customer. It’s perfect for an initial entry into hot stamping technology, when batch sizes are still small or investment options are limited.

StrongLine. This line is defined by its ability to deliver reli - able production with a focus on streamlining investment costs. The StrongLine comes with a press force of 12,000 kN and a bed size of 3.0 m × 2.5 m. With a controlled drive and conventional standard components, this line is a solid intro - duction to production with hot stamping.

The system can be equipped robots or feeders for a produc-tion speed of 4.5 strokes per minute with up to four blanks.

The StrongLine is the ideal system wherever batch sizes are small and investment options are limited.

Roller hearth furnace

Mar

king Hot stamping

press

Blank destacking

Die change

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SpeedLine. Speed, precision and flexibility for conventional hot stamping technology are what sets this line apart. The SpeedLine is available in two different sizes. In order to meet different requirements, it is available as a 12,000 kN press with a clamping surface measuring 3.0 × 2.5 m or a 16,000 kN model with a 3.6 × 2.9 m clamping surface. Combined with superior stroke repeatability, the controlled hydraulic drive and select high-tech components also give customers the ability to implement attractive energy-saving solutions from the Schuler EHF lineup (Efficient Hydraulic Forming).

The SpeedLine is automated with robots or feeders for an output rate of 5.5 strokes per minute with up to four blanks.

FOCUS ON HIGH OUTPUT. SPEEDLINE.

The SpeedLine is fast and accurate, and can handle the toughest demands for hot stamping applications with conventional technology.

The name speaks for itself: The SpeedLine impresses with its output performance.

Roller hearth furnace

Mar

king

Hot stamping pressBlankloader Die

change

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HOT STAMPING WITH PCH FLEX

FOR MAXIMUM PERFORMANCE, QUALITY AND AVAILABILITY. PCH-LINE.The PCH-Line brings together high-tech and innovative hot stamping technology to create a press that sets new standards for productivity and competitiveness.

PCH-Line. In addition to the features of the SpeedLine, the PCH-Line also improves system productivity and, as a result, competitiveness, thanks to PCH flex technology. Not only does the PCH-Line offer the standard multiple-part produc-tion (up to four blanks per stroke) of the SpeedLine, it also includes a hydraulic cushion and accompanying dies. The result is shorter cooling and cycle times, compensation for different material tolerances, and lower and more uniform die wear.

The PCH-Line comes exclusively equipped with highly efficient high-tech components that are compatible with the latest generation of EHF. An efficient user interface and low-emission noise protection cladding featuring Schuler’s Corporate Product Design round out the features of the PCH-Line.

To take full advantage of the benefits of PCH flex technology, the PCH-Line is automated with feeders for production rates of 7.5 strokes / minute with up to four blanks.

Even more productivity and performance: The PCH-Line features the latest PCH flex technology.

STRONGLINE SPEEDLINE PCH-LINE

Press force (kN) 12,000 12,000 12,000

Clamping surface (m) 3.0 × 2.5 3.0 × 2.5 3.0 × 2.5

Designation WH 1200 3.0 × 2.5 WH 1200 3.0 × 2.5 WHC 1200 3.0 × 2.5

Optional press force (kN) – 16,000 16,000

Optional clamping surface (m) – 3.6 × 2.9 3.6 × 2.9

Designation – WH 1600 3.6 × 2.9 WHC 1600 3.6 × 2.9

Approx. output (stroke/min) 4.5 5.5 7.5

PCH flex technology – – included

Efficient Hydraulic Forming (EHF) – optional included

TECHNICAL DATA

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PRODUCTION SYSTEMS FOR HOT STAMPING.RELIABLE PRODUCTION OF HIGH-STRENGTH PARTS.

The future of hot stamping. Lighter, more functional and more cost-efficient. With its PCH technology (Pressure Controlled Hardening), Schuler has developed a revolution-ary new solution for hot stamping. The method allows efficient series production of hot-stamped parts and opens up new possibilities for the customer.

Benefits of the process. Pressure controlled hardening is the only way to control forming and cooling in-process. The result is a noticeably shorter cooling time and signifi-cantly higher output, owing to the much shorter cycle times. Under actual production conditions, cooling times with PCH flex technology are 50% shorter than with conventional technology. If 1-mm thick sheets are used in multiple-part

production, the cycle time can even be cut to 8 seconds. In four-part production, this translates into a production rate of 30 parts / min.

All that, plus noticeably better quality. Conventional processes tend to involve the formation of hot spots. But with PCH technology, parts harden more evenly and obtain the required strength properties. That’s why custom-ers can safely rely on PCH.

Impressively flexible. Patchwork, tailor welded (TWB) and tailor rolled (TRB) blanks are easily handled with PCH technology.

Customers who choose PCH technology enjoy maximum flexibility when it comes to configuring dies and assigning space on the press bed. Because there is no interaction between the individual cavities, new dies can be moved into place in much less time.

The press is compatible with conventional dies while also leaving customers well equipped to handle new future requirements for door frames and sidewalls, for example.

HEAT TRANSFER CURVE

High heat transfer → short cooling time → high outputLow heat transfer → short cooling time → low output

Contact pressure [N/mm2]

Heat transfercoefficient (W/m2K)

0 5 10 15 20 25 30 350

500

1,000

1,500

2,000

2,500

3,000

Conventional process,poor heat transfer

PCH process,rapid heat transfer

www.schulergroup.com/youtube

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HOT STAMPING WITH PCH FLEX

EXPERIENCE INNOVATION LIVE.THE SCHULER HOT STAMPING TECHCENTER GÖPPINGEN.

TechCenter with automated hot stamping line. To flourish, ideas need the concentration of all available strength, as well as freedom and the right environment. That’s why we’ve pooled our entire hot-stamping process and systems know-how in our Hot Stamping TechCenter. Here, we optimize series production applications for the automotive industry with the goal of decreasing cycle times and re-ducing the cost per part.

At the Hot Stamping TechCenter Göppingen, you can experience cutting-edge technology and the latest developments live and in person – even with your own projects.

Fully automated hot stamping line with innovative PCH bed cushion concept.

Phone: +49 7254 988-220 | Fax: +49 7254 988-339 | Email: hstc-goeppingen@schulergroup.com

CONTACT THE HOT STAMPING TECHCENTER GÖPPINGEN DIRECTLY

Come visit us in Göppingen! We’ll show you the latest in systems technology and innovative process solutions. In addition to forming technology, we also focus on upstream and downstream processes to provide you with knowledge-able support along your entire value chain. Take advantage of our experience in improving efficiency and optimizing output to give yourself a clear competitive edge.

Comprehensive technology advice. At the Hot Stamping TechCenter Göppingen, we provide competent first-hand advice about all relevant processes. In addition, our special-ists work to constantly improve both process flexibility and part quality. It’s how we implement forward-thinking solutions for you. And if you’re an existing Schuler customer who is interested in having your own innovations tested and validated on a series-production system, you can try them out at our TechCenter.

The benefits: � Comprehensive process and systems expertise � Constant improvement of systems and process technology � Die tryout and production of prototype parts � Training on the hot-stamping line � Back-up capacity for Schuler customers

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SERIES-PRODUCED SUCCESS.HIGH-PERFORMANCE DIES FOR YOUR SYSTEM.

Whether its part of a turnkey system or your existing line, Schuler supplies the perfect production die for your application.

In hot stamping, optimal contact between the active die parts and the sheet metal, together with an effective cooling system, are critical to achieving the necessary part quality and output. Carefully planned engineering, high-precision manufacturing and experienced tryout personnel are there-fore vital—and are all reasons to choose dies from Schuler.

High-quality multiple-part production. When used in multi-ple-part production, conventional hot stamping presses are pushed to their limits. Varying sheet metal tolerances and uneven die wear lead to longer cooling times and reduced output levels.

With Schuler’s PCH technology, however, multiple-part production is no problem at all. Since the dies and die functions are separated from one another, a high contact pressure is distributed evenly to all parts. The result: incredibly short cooling and cycle times, excellent part quality and superior system availability.

Series-production die. Engineering.

Innovative dies from Schuler ensure rapid part cooling for high productivity.

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HOT STAMPING WITH PCH FLEX

TAKE YOUR EFFICIENCY TO A NEW LEVEL. AUTOMATION SOLUTIONS FOR HOT STAMPING.

The benefits: � Many years of experience in automating hot stamping

systems � Standardized assemblies � Everything from a single source

Marking without sacrificing output. Schuler’s new marking station was specially designed for processing high-strength materials. It allows short cycle times with extremely low noise emissions.

Flexibility meets speed. The triple-axis Twin Feeder developed by Schuler reduces time-on-air to a minimum. It can be operated in transfer or feeder mode for maxi mum flexibility.

Schuler triple-axis Twin Feeder. Schuler marking station.

Customer-specific solutions. Schuler develops flexible customized automation solutions with press shop-proven components for hot stamping: � Flexible blankloader systems (feeder- or robot-based),

or feed of preformed parts � Marking stations � Mechanical / optical centering systems � Robot- or feeder-based press loading � Part cooling � Logistics, e.g., automatic part racking � Automation systems for lasers � Schuler line control (expandable process control, e. g.,

position control or temperature monitoring of the parts before and after the hot stamping process)

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HIGHER FORMING EFFICIENCY. WITH COMPREHENSIVE DATA ANALYSIS AND SELF-OPTIMIZING SYSTEMS.

Perfect setup. Is it really possible to achieve sustainable financial success by maximizing the availability of presses and automation equipment? The deciding factor is the full-scale collection and intelligent use of process data, which gives customers the ability to use their press efficiently and get the most out of their system.

The Schuler Process Monitoring System – a deciding production factor.

Schuler offers tangible answers to these challenges, providing you with the opportunity to set your systems and production facilities up perfectly for the future.

Our expertise and knowledge of markets and processes allow us to supply you with intelligent system solutions for various different sectors and technologies in response to pressing issues in the forming industry.

System master controller

FoL Robot

Qualityinspection

EoL

Marking

Press Feeder 1 Feeder 2

Tool change

TCP/IPProfinet

Other interfaces

Ethercat

Thermalinspection

Chiller Scrap container

Furnace

Data- base

Process

Condition

Power

Video IIOT device

Processdataacquisition

MMS data acquisition – Pilot project at the TechCenter Göppingen.

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The press shop of the future. In concrete terms, this means that the Schuler Process Monitoring System fully integrates all parts of your system. Measurement data for the different parts being produced are thus continuously collected, analyzed and stored in your database. This gives you the ability to call up and analyze any data you need whenever you need it, with no hassle. Of course, the decision about how you’d like to display the data and who should have access with which authorizations is entirely up to you. In this way, we give you the tools to produce more efficiently and, as a result, take your performance to a new level.

Process monitoring

� Cyclical and permanent collection and evalua-tion of machine-protec-tion and process-control parameters

� Response timed exactly to cycle (>=1 ms) where necessary

� Monitoring and visual-ization include: - Press force profile - Vibration profile - etc.

Intelligent diagnostics

� Automatic archiving of quantities, progres-sions, and control states when defined events occur

� Automatic evaluation of these events

� Long-term logging of selected parameters

Condition monitoring

� Monitoring for damage and wear at regular intervals to allow condi-tion-based servicing

� Monitoring for medium- and long-term changes

� Component monitoring using: - Structure-borne noise analysis - Torque curves - etc.

Energy monitoring

� Collection and logging of all measured values relevant for energy efficiency and quality of power supply

� Monitoring includes: - Harmonics - Voltage dips - Power consumption - etc.

PDC/OEE

� Capture of all planned and unplanned downtime and reasons for downtime

� Collection of data for target and actual production

� Logging of OK/NOT-OK parts

� Logging of all error messages

� Interface to higher-level ERP system

Part quality / identification � Collection, documenta-

tion and archiving of all process and measure-ment data necessary for part quality, for every part produced

As a leader in innovation and technology, Schuler has been working for over 175 years to help its customers benefit from progress. Throughout it all, Schuler keeps its focus on the system as a whole – and can therefore use innovative technologies to optimize your workflow.

Process Monitoring System. Our comprehensive Process Monitoring System has a modular design so that it can be flexibly customized to your exact individual needs.

SMARTDIAGNOSTICS

CONDITIONMONITORING

PROCESSMONITORING

POWERMONITORING

BDE / OEEMONITORING

TRACK &TRACE

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Over 900 service employees worldwide provide expert support 24/7 in close cooperation with you – our partners. Our main priority is always to ensure the maximum productivity and safety of your production equipment in order to secure your company’s continued success. With over 175 years of experience and expertise, we can guarantee the best possible support for the operation of your machines – and not only those supplied by Schuler, but by all other manufacturers. Whatever the situation, Schuler Service has the right solution for your specific needs.

Schuler Service offers a tailored portfolio of services covering the entire life cycle of your equipment.

SCHULER SERVICE.STATE-OF-THE-ART SERVICE FOR MORE PERFORMANCE.

www.schulergroup.com/service_en

EXPERT KNOWLEDGE FOR SUCCESS. LEARNING BASIC PRINCIPLES AND TECHNOLOGY FROM THE SCHULER FORMING ACADEMY.

In our introductory training seminars, decision-makers, planners and users learn everything they need to know about efficient hot stamping processes and systems, which provides them with a quick glimpse into the technology involved.

Current training dates and other additional information about the Forming Academy are available at: www.schulegroup.com/formingacademy.

Hands-on hot stamping training at the Hot Stamping TechCenter. Basic hydraulic principles, taught by instructors with real-life experience.

Training as the foundation for safe and efficient series production. At the Hot Stamping TechCenter, we offer training for your employees. In partnership with our experi-enced process experts and training instructors, we provide hands-on training programs for different systems. Partici-pants obtain a basic working knowledge of the design and function of automated hot stamping systems, and learn how to operate them safely. The training focuses on safety, productivity, operation and maintenance, with tips and tricks for process optimization rounding out our offerings.

Over 900 service employees worldwide provide expert support 24/7 in close cooperation with you – our partners. Our main priority is always to ensure the maximum productivity and safety of your production equipment in order to secure your company’s continued success. With over 175 years of experience and expertise, we can guarantee the best possible support for the operation of your machines – and not only those supplied by Schuler, but by all other manufacturers. Whatever the situation, Schuler Service has the right solution for your specific needs.

Schuler Service offers a tailored portfolio of services covering the entire life cycle of your equipment.

SCHULER SERVICE.STATE-OF-THE-ART SERVICE FOR MORE PERFORMANCE.

www.schulergroup.com/service_en

Schuler Pressen GmbHLouis-Schuler-Straße 168753 WaghäuselGermanyPhone Sales + 49 7254 988-563Phone Service + 49 7254 988-379Fax + 49 7254 988-339

hydraulic@schulergroup.comwww.schulergroup.com/hotstamping

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Schuler is the technological and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and for lightweight automobile construction. Its customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance, packaging, energy and electronics industries. Schuler is a leading supplier of minting presses and implements system solutions for a wide range of different high-tech sectors. The company has a presence in approximately 40 countries with roughly 6 600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

ABOUT THE SCHULER GROUP – WWW.SCHULERGROUP.COM

www.schulergroup.com/hot_stamping