Isgec Solution g

for

Hot Forming Line

Hot Forming Line Composition : g p

1. De-Stacking and Marking Station (Cell # 1)

2. Furnace Loading and Unloading (Cell # 2)

3. Press Loading (Cell # 3)

4. Hydraulic Press (Isgec)

5 End of Line (EOL) Station with Racking (Cell # 4)5. End of Line (EOL) Station with Racking (Cell # 4)

Hot Forming Line Layout

Oven 4 Stacks of 4 Ovens(4 load and unload locations, highest at 12’)

PaP

Load/Unload Load/Unload

ConPo

alletized P

arts 1

Press Cycle Time

= 8 sec

ntainer1Pick from

1or 2 C

entering

table

Containe

r2

1

PalletizP

arts

Load/Unload

zed 2

Load/Unload

After Pick-up Stamp part with date and time stamp

Hot Forming Line details : gCycle time of Press : 8 sec. without Hold (Dwell) time

Press sequence : Fast Closing

Fast Initial Pressingg

Final Pressing

Hold (Dwell)

Fast Return

Blank Material : Steel coated Hot Stamp Material

Single blank dimensions

- Width (Flow direction) : 1220 mm (48”)

- Length : 1830 mm (72”)

Twin blank dimensions

- Width (Flow direction) : 1220 mm (48”)

- Length : 1830 mm (72”)

Blank thickness : 0.635-2.54 mm (0.025”-0.10”)

Single Blank weight : 20 kg Maximum

Twin Blank weight : 10+10 kg Maximum

De-Stacking and Marking Station (Cell # 1) : g g ( )

Consist up of :

1 no. Robot for De-Stackingg2 nos. Moving Carts on Rails / Tables (both options available)Magnets to avoid Double blank pick up1 no. Conveyor with Centering station (Vision system)Cart Transfer speed : 0 25 m/s with PositionalCart Transfer speed : 0.25 m/s with Positional accuracy of +/- 3 mm

Options :

Marking MachineAutomatic Positioning system for Magnets

Furnace Loading and Unloading (Cell # 2) : g g ( )

Consist up of :

4 nos. Electric Heated Furnace suitable for Batch System with 4 Cubicles each one (t t l 16 ll )(total 16 cells)Suitable for heating blanks upto 920 Deg.C and Blank Size 2200 mm x 2200 mm x 3 mm(86.6” x 86.6” x 0.11”)Maximum load per cycle per chamber : 35 KgOpening and Closing by Pneumatic cylinders automatically operatedp g g y y y p2 nos. Robots for Loading and Unloading blanks

Options :Fifth Chamber

Temperature Profile of Furnace

Temperature Profile of Typical Chamber

Blank is 1.2 mmHeats up to 950 Deg. CApprox. 200 sec.

Chamber Uniformity

Better than +/- 10 Deg. C

Floor Mounted Heating Elements, Bottom Access

Heating Elements

Common wired elements to rear

Multi Chamber, Atmosphere,Development Unit

Proto Unit,3 chamber, Atmosphere Side

Atmosphere Flow Stand, Control Panels

7 Chamber System, 2 Piece Sections

Fork Load Chambers

Chamber Interior

Removable RoofMultiple Zones-Frt-RearAtmosphere CapabilityPiers selected based onPiers selected based on automationModular Design for maintenance

Press Loading (Cell # 3) : g ( )

Consist up of :

1 no Robot for Loading blanks inside the Press1 no. Robot for Loading blanks inside the PressPyrometer inside press measure blank temperatureInteract with Press for checking blank temperatureIf blank temperature low, Robot pick the blank and put it in garbage container

Robots :

MAIN TECHNICAL FEATURES AXIS / PART DATARobot model COMAU SMART NJ 100-3.2Structure Articulated ParallelogramA tit 6Axes quantity 6Maximum Static Load on Wrist 100 kg(220.46 lb)Additional Maximum Load on Axis #3

50 kg (110.23 lb)

Total Maximum Load 150 kg (330.69 lb)T A i 4 638 NTorque on Axis 4

56

638 Nm638 Nm280 Nm

Axes Stroke (Speed) 1+723

± 180° (120°/s)-49° to +95 °(108 °/s)222° t 68° (120 °/ )3

456

-222° to -68° (120 °/s)± 200° (190 °/s)± 120° (190 °/s)± 200° (250 to 275 °/s)

Repeatability ± 0,20 mmMaximum Reach Horizontal 3209 mm (10.53 ft)

Weight Robot 1250 kg (2755.77 lb)Programming language COMAU PDL2Control unit weight C5G 125 Kgg(C5G base only)

g

Smart IP :

A powerful software with a “user-friendly” interface and “Windows-like” icons. It reduces the robot start-on-production time and manages the line production parameters, calculating the cycle-time of the robots and synchronizing them with the press line during loading/unloading and transfer of the parts. Immediate productivity display

Total parameterization of the performances.

Hydraulic Press (Isgec) : y ( g )

Major Technical parameters of the Press :

Capacity : 12000 kN (1330 US Ton)Daylight : 2000 mm (78 7”)Daylight : 2000 mm (78.7 )Stroke : 1500 mm (59”)Slide/Bolster Size : 3000 mm x 2200 mm (118.1” x 86.6”)Fast Approach : 800 mm/s Pressing @ 6000 kN : 250 mm/s

Pressing travel : 250 mm (9.84”)Pressing @ 12000 kN : 75 mm/s

Pressing travel : 10 mm (0.39”)Fast Return : 800 mm/sNo. of Moving Bolster : 2 nos.No. of Moving Bolster : 2 nos. Direction of Moving Bolster : Center to Left &

Center to Right

Hydraulic Press (Isgec) : y ( g )

Major Bought-outs used in the Press :

Main Pumps : Parker / Rexroth

Major Hydraulic Valves : Parker / Rexroth / Oilgear

Pressing & Safety Module : Rexroth

Seals & Packing : Merkel -Simrit / Parker / Buchak Shamban

Pipe & Pipe Fittings : Parker / Legris / Hyloc

Main Motor : Siemens / ABBMain Motor : Siemens / ABB

PLC & HMI : Allen Bradley / Siemens

Lubrication System : Woerner / Voegel

End of Line (EOL) Station with Racking (Cell # 4) : ( ) g ( )

Consist up of :

1 no Robot for Unloading of blank from the Press and place it in container1 no. Robot for Unloading of blank from the Press and place it in container.2 nos. Racking Containers2 nos. Automatic roll doors

Isgec Reference Installations : g

12000 kN (1330 US Tons) Hydraulic Hot Forming Press installed at MARTINREA FABCO, Detroit, USA (Formerly Thyssen Krupp Fabco)

Isgec Reference Installations : g

25000 kN (2780 US Ton) Hydraulic Hot Forming Press installed at AXLE INDIA LIMITED, India

Isgec Reference Installations : g20000 kN (2220 US Ton) Hydraulic Hot Forming Press installed at BHARAT FORGE LIMITED, India

• First machine supplied in 1991• Repeat order received in 1999• Repeat order received in 1999• Used for Calibration & Padding Application• In 24 x 7 continuous operation with CLAMA robot

Comau Robotics Reference Installations :

Hot Forming Press Line installed in Cassino Italy

Comau Robotics Reference Installations :

Hot Forming Press installed in Clinton, TN

Project Organisation :j g

Responsible for Project

Supplier of Hydraulic Press Supplier of

Robotic Automation

Responsible for Project

Supplier of Furnace

(After Sales Support)(Line Integration, Prove Out & Component Trial)

Isgec Customers :g

Comau Robotics Customers :

Thank You