Knucle Joint Press

The enTire world of meTal forming

Components for sheet metal forming.

3TAble of conTenTS / ThE ENTiRE WoRld oF mETAl FoRmiNG

TaBle of ConTenTS. The enTire world of meTal forming.

WElComE To ThE STAmPiNG PlANT. WElComE To SChulER.

01 | BlANkiNG liNESindividual solutions for your production.

02 | hydRAuliC SiNGlE PRESSES Flexible presses for suppliers to the automobile industry, the household appliance industry and for multiple metalforming applications.

03 | mEChANiCAl SiNGlE PRESSES Fast, flexible and cost-effective. C-frame presses, blanking presses, knuckle-joint presses, transfer & prog-die presses and servo presses.

04 | AuTomATioN oF SiNGlE PRESSES Coil lines, roll feed units, tri-axis transfer systems and destackers.

05 | PRESS liNES hydraulic, hybrid, mechanical or servo press lines are fully automated system solutions.

06 | AuTomATioN oF PRESS liNESSchuler press lines are equipped with the appropriate mechanization concept for the range of parts, productivity and space requirements.

04

06

14

22

42

52

62

07 | TRyouT SySTEmS Cost-effective die startup with hydraulic and mechanical tryout presses, tryout centers, die turnover devices and simulators.

08 | liGhTWEiGhT TEChNoloGiES lines for press hardening (hot stamping), for cold and aluminum forming. For forming fiber-reinforced plastics and for hydroforming.

09 | PRoCESS TEChNoloGy From simulation to series production.

10 | SySTEmS lARGE PiPE mANuFACTuRiNGSpiral pipe welding lines and system solutions for longitudinally welded pipes.

11 | loCATioNS ANd SChulER SERviCETechnical customer service, components and accessories, project business, special services and used machines on your doorstep, worldwide.

70

78

88

92

98

Subject to technical modifications and amendments to content.

4welCome To The STamping planT.welCome To SChuler.

Transfer press with Servodirect technology.

TABlE oF CoNTENTS

5As a world market leader in the technology of metal forming, Schuler offers presses, automation solutions, dies, process technology and service for the entire metal working industry and lightweight automotive construction. its customers include automobile manufacturers and components suppliers as well as companies in the forging, domestic appliances, packaging, energy and electrical industries. Schuler is a leader in coin minting technology and produces system solutions for the aerospace, railway and large pipe industries. 5,500 people work for the company worldwide. The Schuler Group is present in 40 countries and is majority-owned by the Austrian ANdRiTz-GRouP.

We support you in all phases of a project, in planning new stamping plants through to integrating forming lines into existing structures. in close cooperation with your planning departments, technical purchasing, stamping plant and maintenance, we handle the installation, commissioning and production startup of lines and automation components. in this process, you also benefit from the extensive know-how of our project teams installations all over the world. We are also in daily contact with users of mechanical and hydraulic press technology regarding modernization, rebuilding, relocation and performance enhancements available for existing forming lines. Together we can find solutions that improve the cost-effectiveness of the stamping plant.

This book provides you with an overview of our range of products and services. We are just right for the job wherever the highest parts quality, maximum plant availability and reliable press engineering is required day-in, day-out. From blanking and the forming process through stacking the finished components our lines offer the right answer to future requirements including increased use of high and extra high-strength steels or integration of additional process steps in the forming process.

Put us to the test.

Welcome To Schuler / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about our selections? Further information is available on the internet at www.schulergroup.com. you can also follow us on Facebook at www.facebook.com/schulergroup or on youtube at http://bit.ly/1gQpNd8. There you will find interesting news and worthwhile information.

Schuler online

TABlE oF CoNTENTS

601TABlE oF CoNTENTS

7AT A GlANCE

Blanking lineS

Blanking lines from Schuler offer the complete process sequence from the coil through the blank stack from a single source. you work with the latest safety and control concepts. Their modular structure permits solutions that are individually tailored to the user. All the components of the line have been tested in practical operations, are precisely adapted to one another and guarantee the highest levels of availability and reliability. Expansions for processing aluminum and high-strength steels can be easily retrofitted. And it does not matter where the Schuler line will be used our services are available worldwide.

BlANkiNG liNE WiTh PRESS

BlANkiNG liNE WiTh CRoSS-CuT ShEAR

BlANkiNG liNE WiTh lASER CEll

10

11

12

blAnkinG lineS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about our blanking lines? you can find our complete product range at www.schulergroup.com/automotive. There, you will find extensive information about our system solutions for large-scale mass production.

Schuler online

TABlE oF CoNTENTS

8mAximum producTiviTy WiTh ServodirecT preSSeS in addition to the use of conventional presses (mechanical or hydraulic), lines for manufacturing shaped blanks are preferably equipped with servo presses nowadays. Servodirect technology from Schuler enables movement sequences of the press to be adapted individually to the different blanking dies. This increases productivity and the service lives of dies significantly. Also, lines with this technology are configured for processing an extremely wide range of materials such as aluminum or high-strength steels. material with a sensitive surface can also be processed carefully, using a press blanking line with the highest productivity.

All upstream and downstream automation components, such as the roll feed unit driven directly by servomotors or the flexible Stop2drop stacker, support the impressive press performance and ensure powerful dynamic properties in blanking. A high level of automation ensures quick production changes and a smooth production process.

Blanking line with servo press.

BlANkiNG liNES

individual SoluTionS, flexiBle appliCaTionS

TABlE oF CoNTENTS

9Blanking line with cross-cut shear. Blanking line with laser cell.


blAnkinG WiTh croSS-cuT SheAr The SoluTion for STrAiGhTforWArd blAnk ShApeSSchuler offers blanking lines equipped with cross-cut shears for manufacturing blanks with a rectangular, parallelogram or curved shape. if the manufacturing process is restricted to straightforward blank shapes, then cross-cut shears represent the ideal solution both with regard to purchase costs and their productivity. optionally, the shears can be equipped with an automatic die change.

lASer cuTTinG: flexible producTion, compAcT line deSiGnBlanking lines with lasers are particularly suitable for production sequences with frequent product changes as well, because no tooling is used for laser cutting.

This means there is no need, whatsoever, to invest in dies, die maintenance and die warehousing. The compact design of the line means it can be used even when space is limited and overhead heights are low. With their innovative dynamicFlow technology, they offer the most flexible possible production conditions with comparatively low investment costs. The laser cutting line processes an extremely wide range of materials such as aluminum or high-strength steels, and guarantees high productivity even with skin panels that have sensitive surfaces.

TABlE oF CoNTENTS

10

BlANkiNG liNES

Blanking line wiTh preSS

ideal for producing shaped blanks high output performance high level of automation

Reducing die wear with Servodirect technology Proven technology

AdvAnTAGeS

Blank shapes when using a press with die (max. stroke rate 105 spm).

feed length [mm] 300 500 750 1,000 1,500 2,000 2,500 3,000 3,500 4,000

Servo press basic version [strokes / min] 75 71 64 59 51 42 35 30 28 28

Servo press with more powerful motor [strokes / min] 91 79 70 64 51 42 35 30 28 28

ouTpuT rATe of blAnkinG line WiTh Servo preSS

TABlE oF CoNTENTS

11

BlANkiNG liNES

Blanking line wiTh CroSS-CuT Shear

ideal for producing blanks with a rectangular, parallelo-gram or curved shape

Attractive price / performance ratio

high output performance high level of automation Proven technology

AdvAnTAGeS

Blank shapes when using a cross-cut shear (max. stroke rate 120 spm).


feed length [mm] 300 500 750 1,000 1,500 2,000 2,500 3,000 3,500 4,000

cross-cut shear [strokes / min] 100 80 66 57 47 41 35 30 28 28

ouTpuT rATe of blAnkinG line WiTh 4-column croSS-cuT SheAr

TABlE oF CoNTENTS

12

BlANkiNG liNES

Blanking line wiTh laSer Cell

Suitable for all blank shapes No costs for dies and die warehousing Fast product change, delivering a high level of availability Adaptation of blank contours after production startup Simultaneous production of different blank shapes

Reduced material costs high energy efficiency Reduced investment volume Space-saving line design

AdvAnTAGeS

Blank shapes when using laser cutting heads.

ouTpuT rATe of A blAnkinG line WiTh lASer The productivity of a laser line must always be seen in the context of sheet metal thickness, blank contour and laser power. We would be happy to calculate the possible productivity for you on the basis of your product data.

TABlE oF CoNTENTS

13

The requiremenTS: delivery of a blanking line for producing shaped blanks with the shortest downtimes during a coil change. Cutting steel, aluminum and

high-strength steels up to 1200newtons / square millimeter

Coil width: 2,150 millimeters Coil thickness: 0.5 to 2.5 millimeters Coil weight: 35 tonnes

The SoluTion:Fully automated blanking line with blanking press in Servodirect technology. Coil loading cart for two coils moving decoiler for 35 tons Threading unit with dirt and

clean rolls Cropping station Coil washing machine

BlANkiNG liNE WiTh SERvodiRECT TEChNoloGy

in praCTiCeCuSTomER: AuTomoTivE SuPPliER, PEoPlE'S REPuBliC oF ChiNA


leveling machine with crowning function with 2 cassettes (17 rolls)

loop equipment Roll feed unit with weld detection Blanking press with 8,000 kilonewtons in Servodirect technology

Stacker in Fly2drop and Stop2drop stacker technology (energy-efficient vacuum generation by blower)

1

2 14

6 15 10

3 4 5 7 8 9 11 12 13

1. Decoiler2. Coil infeed3. Crop shear4. Coil washing machine5. Leveling machine6. Loop pit

7. Roll feed unit8. Telescopic roller train with

left-over coil feed9. Blanking press with

ServoDirect technology10. Cutting die

11. Telescopic conveyor12. Vacuum blower for stacking

aluminum blanks13. Blank stacker14. Stack cart15. Hydraulic unit

TABlE oF CoNTENTS

14

02TABlE oF CoNTENTS

15

AT A GlANCE

hydrauliC individual preSSeS

you've got to be flexible. We've got the machines to help. hydraulic press systems from Schuler are extraordinarily versatile and make it possible for you to achieve efficient series production of a wide range of components from the blank through the finished part. At the same time, innovative hydraulic solutions ensure high output levels, production reliability and the best quality. Whether in classic metal forming, die tryout, die hardening, tubular hydroforming, precision blanking or processing fiber-reinforced plastics: hydraulic presses from Schuler can cope with any challenge round the clock, seven days a week.

hydRAuliC iNdividuAl PRESSES

PRESSES FoR ThE NoN-AuTomoTivE iNduSTRy

hydRAuliC TRANSFER PRESSES

16

19

21

hydrAulic SinGle preSSeS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about our hydraulic presses? you can find our complete selection at www.schulergroup.com/hydraulic_press. in addition, you can download the hydraulic press systems. For the best component quality in the stamping plant brochure as a PdF file.

Schuler online

TABlE oF CoNTENTS

16

economicAl, flexible And for reliAble producTionBecause of their versatility, hydraulic presses offer a wide range of applications in the stamping plant. They can be used as a single press, automated press line, transfer press or, with slight modifications, as a tryout press. in combination with a coil line, destacker or tri-axis transfer, this creates turnkey system solutions for economical parts production. These have a modular structure and offer users a wide range of expansion options.

Equipped with a hydraulic bed cushion, impact shock dampening, slide parallelism control and cylinder mode switching, hydraulic presses provide all the prerequisites for efficient production in the component supplier's stamping plant. A data analysis system assists the press operator in straightforward fault diagnosis of the entire system, at the same time as increasing productivity and optimizing the process.

hydraulic presses offer flexible applications.

They can be used as a single press, in press lines or as a transfer press

Production alternative for a wide range of parts Reduction in unit costs by dynamic cylinder mode switching Simple operation by slide comfort control

high process quality through impact shock dampening and a hydraulic bed cushion

Parallelism control increases parts quality and reduces die wear

Precise eight-way slide guidance

AdvAnTAGeS


flexiBle appliCaTion wiTh high produCTion reliaBiliTy

TABlE oF CoNTENTS

17

on request, hydraulic presses are available with alternative bed sizes and press forces up to 100,000 kN.

press force [kn] 1,600 2,500 3,150 4,000 5,000 6,300 8,000 10,000 12,500 16,000 daylight [mm]

bed length [mm] bed width Standard option

1,0001,3001,6002,000

1,3001,6002,000

1,3001,6002,000

1,3001,6002,000

700 1,000

1,300 1,6002,0002,500

1,6002,0002,500

1,6002,0002,5003,000

1,6002,0002,5003,000

1,6002,0002,5003,000

1,6002,0002,5003,000

1,6002,0002,5003,000

2,0002,5003,000

2,5003,000

2,5003,000 850 1,300

1,600 2,500 2,5003,000

2,5003,000

2,5003,000

2,5003,000

2,5003,000

2,5003,000

2,5003,000 1,100 1,600

model overvieW hydrAulic preSSeS 1,600 To 16,000 kiloneWTonS


hydRAuliC PRESS WiTh A PRESS FoRCE oF 4000 kiloNEWToNS

4

10

9

2

8

3

7

5

16

1. Press cylinder

2. Adjustable eight-way precision slide guidance with solid guide

3. Hydraulic drawing cushion

4. Hydraulically operated slide locking in upper end position

as per UVV (safety codes and regulations)

5. AC drive motors designed to suit application

6. High-performance axial piston pumps with electronic

pump control

7. Torsion-resistant press frame

8. Slide / piston connection

9. Slide / limitation / impact shock dampening

10. Impact shock dampening cylinder

TABlE oF CoNTENTS

18

The requiremenTS: delivery of a production line for finish-processing of preformed side sill plates and roof bows.

Perform pick-up Component transfer through the press hole punching and forming of specified contours

The SoluTion:hydraulic blanking and coining press with tri-axis gripper transfer, blanking and forming dies.

Press force: 2,500 kilonewtons Bed size: 2,500 1,300 millimeters Slide parallelism control with screw adjustment Roll-formed component pick-up by robot Part transfer into the press and through the die stations Semi-automatic die change in 15 minutes maximum output rate: 12 strokes / minute

hydraulic press for producing side sill plates and roof bows.

maximum output rate of the line: 12strokes / minute.

Semi-automatic die change in 15 minutes.

hydRAuliC dRAWiNG PRESS FoR mANuFACTuRiNG SidE Sill PlATES

in praCTiCeCuSTomER: AuTomoTivE ComPoNENTS SuPPliER, CzECh REPuBliC

TABlE oF CoNTENTS

19

hydrAulic preSSeS for The non-AuTomoTive induSTryhydraulic presses represent an efficient alternative for a wide range of production tasks in the domestic appliance industry as well as for manufacturers of components made from stainless steel. Both single presses and automated production systems increase users' competitiveness. The lines are characterized by high reliability, availability, fast die changes as well as straightforward adaptation to modified production conditions.

Pre-engineered press configurations in conjunction with a wide variety of modular automation options and die change techniques permit customer-specific manufacturing solutions. The lines are also noted for their high degree of user-friendliness.

Reliable equipment with high levels of uptime maximum flexibility optimum line configuration using proven components

maintenance-friendly because of easy accessibility of all components

high part quality due to sturdy design Process analyses with integrated data analysis system

AdvAnTAGeS

hydraulic presses for producing stainless steel sinks.


preSSeS for The non-auTomoTive induSTry

hydrAulic SinGle preSSeS / ThE ENTiRE WoRld oF mETAl FoRmiNGTABlE oF CoNTENTS

20

The requiremenTS: high requirements apply to fully automated forming of heat exchanger plates: high stamping forces, many different plate geometries, close tolerances in stamping depth, production process reliability and high equipment availability.

The SoluTion:The fully automated production system has at its heart the hydraulic coining press with a multi-cylinder system in short-stroke technology. The system permits flexible adaptation of press force ranges to the different geometries and process technology sequences.

The producTion SySTem: Blanking system with coil line lifting bar transfer system for transporting parts in the press

loading and unloading feeder Foil winding units Fully automated die change systems master controller Presses for edge trimming and hole-punching for fluid outlets

hydraulic coining press. Press force: 25,000 kN.

Fully automatic production system for manufacturing heat exchanger plates.

heat exchangers of various sizes.

hydRAuliC PRESS FoR mANuFACTuRiNG hEAT ExChANGER PlATES

in praCTiCeCuSTomER: mANuFACTuRER oF hEAT ExChANGER PlATES, uSA

Flexible adjustment of the pressure circuits, adapted to various plate shapes

optimal press force distribution and material flow control thanks to pre-selection of individual pressure circuits and adjustment of individual cylinder pressures

Bowing or shimming of the dies no longer required deflection between bed and slide reduced to a minimum

AdvAnTAGeS

TABlE oF CoNTENTS

21

efficiency, STep by STephydraulic transfer presses permit part production on multi-station transfer dies. high throughput rates can be achieved due to hydraulic solutions such as the Schuler ring valve technology and dynamic cylinder mode switching. in single-slide or multi-slide design (with options for one or more bed and / or slide cushions),

Easy to adapt to different dies Freely programmable slide motion curves Programmable pressure dwell in BdC high level of availability

Production of deep components by counter drawing Nominal capacity available over the entire stroke Simple die startup

AdvAnTAGeS

hydraulic transfer press. Press force: 25,000 kN. Feeder loading station with blank singling.


hydrauliC TranSfer preSSeS


the capacity range for these presses is 5,000 to 30,000kilonewtons. The active electrohydraulic slide parallelism control and hydraulic impact shock dampening ensure superior part quality and reliability in the forming process. other auxiliary functions can be directly integrated into the die.

TABlE oF CoNTENTS

22

03TABlE oF CoNTENTS

23

AT A GlANCE

meChaniCal individual preSSeS

Blanking and forming systems from Schuler are used successfully in a very wide range of industries. Sheet metal parts produced flexibly and economically with the best quality, and overcome challenges such as large part quantities, complicated part geometries and processing high-strength materials. The breadth of our product range for economical series production of high-quality components is matched only by the requirements of the various industries. Whether C-frame presses, automatic blanking presses, knuckle-joint presses, servo presses or conventional mechanical transfer / prog-die presses together, we can find the right solution for your success.

C-FRAmE PRESSES

AuTomATiC BlANkiNG PRESSES

kNuCklE-joiNT PRESSES

PRESSES WiTh SERvodiRECT TEChNoloGy

PRESSES WiTh TWiNSERvo TEChNoloGy

TRANSFER PRESSES

mulTiPlE-SlidE TRANSFER PRESSES

24

25

28

30

38

40

41

mechAnicAl SinGle preSSeS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about mechanical single presses? you can find our complete selection at www.schulergroup.com/stamping_cutting. in addition, you can download the At home in Every industry. Blanking and Forming Systems from Schuler. brochure as a PdF file.

Schuler online

TABlE oF CoNTENTS

24

for univerSAl ApplicATionC-frame presses provide small and medium-size companies high product quality at low per unit cost. innovative solutions for equipment and controls ensure an integrated manufacturing process. The machines are configured for manual loading (CB series) and either manual loading or automatic mode (C series).

modulAr flexible erGonomicThe newly developed C-FLEXline (CFl) series is based on a combination of experience gained from users and more than 70 years of experience in building C-frame presses. The modular structure makes it possible to adapt to changing production conditions at any time from straightforward manual loading to fully automatic production. The presses are converted quickly and ergonomically, while two different control concepts allow the presses to be adapted to individual customer requirements.

C-FLEXline 630 kN comfort with foot pedal.

mEChANiCAl iNdividuAl PRESSES

C-frame preSSeS

model cb-250 cb-400 c-400 cfl-630 cfl-1000 cfl-1600 c-2500

press force [kn] 250 400 630 1,000 1,600 2,500

drive capacity [kW] 1.5 2.2 4 7.5 18.5 18.5

Stroke rate [spm / ] 150 60 140 30 120 30 90 20 70 19 57

Adjustable slide stroke [mm] 5 75 5 100 8 120 10 130 12 180 19 250

Slide adjustment [mm] 50 70 100 100 110 130

bed dimensions [mm] 465 360 650 480 820 590 950 660 1,250 750 1,400 860

Slide dimensions [mm] 220 160 370 300 470 410 540 510 850 630 1,000 700

Shut height* [mm] 270 240 320 370 440 470

Throat [mm] 185 220 280 330 370 430

Weight with normal equipment [kg] 2,000 3,000 5,000 7,000 14,000 28,000

* maximum stroke down, slide adjustment up, without clamping plate.

model overvieW of c-frAme preSSeS

TABlE oF CoNTENTS

25

Wide rAnGe of pArTS hiGh ouTpuTBlanking presses (mC series) are standard machines with extensive basic equipment for blanking classic sheet metal components from the coil. in the range from 1,250 to 5,000 kilonewtons, they represent an optimally-priced solution for manufacturing components with high output rate.

Automatic blanking presses: The optimum solution for straightforward components.


auTomaTiC Blanking preSSeS


little bowing due to rigid welded construction long slideways ideally absorb off-center forces Two transverse shafts compensate for rotational

forces without additional masses low-noise drive with helical gearing

optional servo drive permits optimized speed profiles for higher output with the same component quality and longer die service lives

Quick conversion to new die hydraulic overload protection protects the machine

and the die

AdvAnTAGeS

moTion chArAcTeriSTicS

Time [s]

Sinusoidal profile Modified sequence (servo drive)

Stroke [mm]

max

.

0

The blanking presses are also available up to 2,000 kilonewtons with servo drive as well (mSC series). Eight predefined slide speed profiles enable optimum adaptation to the components to be produced. in combination with an integrated high-performance transfer system, it is also possible to manufacture stampings with complex geometry directly from the die.

TABlE oF CoNTENTS

26

model mc-1250 mSc-1250

mc-2000 mSc-2000

mc-3000 mc-4000 mc-5000

press force [kn] 1,250 2,000 3,000 4,000 5,000

bed length [mm] bed width

1,400 1,000

1,800 1,100

2,200 1,300

3,000 1,300 1,400

Shut height [mm] 450 550 650 750 800

Slide adjustment [mm] 150 150 150 200 250

Adjustable slide stroke [mm] 20 180 20 220 40 315 40 315 40 315

Stroke rate mc [spm] 30 150 30 130 25 100 20 80 20 70

Stroke rate mSc [spm] 130 100

model overvieW of blAnkinG preSSeS (mc) And blAnkinG preSSeS WiTh Servo drive (mSc)

2

3

8

1

9

7

4

5

6

1. Flywheel with pneumatic clutch

2. Torsion-resistant press frame

3. Press drive by helical gearing

4. Bolt fittings for high pull-back forces

5. Lubricated, re-adjustable eight-way

precision guiding

6. Press bed openings provided for

scrap removal

7. Hydraulic overload protection

8. Slide counterbalance

9. Intermediate gear for diametrically

opposed running of eccentric gears

BlANkiNG PRESS

TABlE oF CoNTENTS

27

model mcf-630 mcf-800 mcf-1000 mcf-1250 mcf-1600 mcf-2000

press force [kn] 630 800 1,000 1,250 1,600 2,000


1,000 700 700

1,300 800 800

1,600 1,000 1,000

Shut height [mm] 350 350 400 400 500 500


Adjustable slide stroke [mm] 12 80 12 100 10 100 10 120 10 120 10 130

Stroke rate [spm] 30 300 30 300 30 280 30 280 30 260 30 260

model overvieW of hiGh-Speed blAnkinG preSSeS (mcf)

hiGh-Speed blAnkinG preSSThe two-rod high-speed blanking press (mCF series) is designed for producing components with output rates of up to 300 strokes / minute. The slide guidance system with preloaded, play-free roller bearing units also guarantees the necessary precision in the process: the best prerequisite for series production of small components with tight die clearances. in these lines and processes, perfect synchronization between automation and the blanking press is of great importance. users can fully tap the output potential of the new press generation in practical operation.

The AdvAnTAGeS: Fast and reliable press type output rate up to 300 strokes / minute Stress-relief annealed frame long die service lives longitudinal shaft machines with rotary mechanical

counterbalance linear roller bearings Planetary gear unit ensures high available power,

even at low speeds Fully automatic stroke and slide adjustment reduces

die change times infinitely variable overload protection for die

and machine

mCF twin-rod high-speed blanking press.

mechAnicAl SinGle preSSeS / ThE ENTiRE WoRld oF mETAl FoRmiNGTABlE oF CoNTENTS

28

preciSe in operATionThe very rigid press concept and the slide movement that is characteristic of knuckle-joint presses guarantee that ready-to-install precision parts can be manufactured economically. Each machine permits efficient blanking, drawing, embossing, punching and calibrating in one operating sequence, while the various stations can also

knuckle-joint press with servo drive. Press force: 8,000 kN. Control panel of the overall machine.


knuCkle-joinT preSSeS

optimized slide motion by modified knuckle-joint drive and maximum production flexibility with user-programmable stroke heights and motion sequences in knuckle-joint presses with servo drive

drawing, bending, cleaning, blanking and calibrating operations in one press cycle

high system rigidity for close component tolerances and reduced cutting impact

Excellently suited for processing high-strength steels Reliable repeat accuracies, even with fluctuating

material thicknesses and strengths Shorter die startup times by precision setup using

hand wheel

AdvAnTAGeS

be combined with one another. The optional use of Servodirect technology also ensures extra flexibility and productivity. The new PSk and PSk PluS series are the perfect solution for components with increased requirements for precision and smooth cutting proportion.

TABlE oF CoNTENTS

29


press force [kn] 2,000 2,500 3,150 4,000 5,000 6,300 8,000 10,000 15,000


1,500 1,000 1,000

2,000 1,000 1,000 1,100 1,100

2,500 1,000 1,000 1,100 1,100 1,200 1,400

3,000 1,100 1,100 1,200 1,400 1,500 1,500 1,500

3,660 1,200 1,400 1,500 1,500 1,500

Shut height [mm]

Stroke down 400 500 600 700 700 800 800 800 800

Adjustment up 500 600 700 800 800 900 900 1,100 1,100

Slide adjustment [mm] 150 150 150 150 150 200 200 200 200

Slide stroke [mm]

with stroke adjustment 40 160 40 160 60 200 60 200 60 200 80 250 80 250

with fixed stroke 160 160 200 200 250 250 250 300 300

Stroke rate [spm / ]

with stroke adjustment 20 140 20 140 20 120 20 120 20 90 20 90 20 80

with fixed stroke 20 110 20 110 20 95 20 95 20 75 20 75 20 70 20 65 20 50

model overvieW of knuckle-joinT preSSeS (Tmk)

press force [kn] 2,500 4,000 6,300 8,000 10,000 15,000


2,000 1,000

2,500 1,000

3,500 1,300 1,300 1,300 1,300

Stroke rate [spm / ] 3 160 3 120 3 80 3 70 3 60 3 60

model pSk / pSk Plus2-250

pSk / pSk Plus2-400

pSk / pSk Plus2-630

pSk / pSk Plus2-800

pSk / pSk Plus2-1000

pSk / pSk Plus2-1500

press force [kn] 2,500 4,000 6,300 8,000 10,000 15,000

Stroke height in full stroke [mm] 160 200 300 300 300 300

Stroke height in oscillating mode [mm] 40120 50150 75225 75225 75225 75225

Stroke rate* [spm/ ] 3160 3140 3100 380 370 360


2,000 1,000 1,100

2,500 1,000 1,100 1,300 1,300

3,000 1,100 1,300 1,300 1,300 1,300

3,500 1,300 1,300 1,300 1,300

Shut height [mm] 600 700 800 800 900 900


model overvieW of knuckle-joinT preSSeS WiTh Servo drive (mSk)

model overvieW of knuckle-joinT preSSeS WiTh Servo drive for preciSion blAnkinG And forminG proceSSeS (pSk)

All information for systems with two-conrod design. Stroke rate depending on programmed stroke height and kinematics.

TABlE oF CoNTENTS

30

SucceSS cAn be proGrAmmedPresses with Servodirect technology open completely new perspectives: maximum flexibility in production, economical production of complex parts geometries and a high level of productivity with optimum parts quality. in combination with highly dynamic Schuler roll feed units, coil lines, destackers or tri-axis transfer systems, fully

operating panel of a servo press. Production with optimally matched system components.


preSSeS wiTh ServodireCT TeChnology

automatic forming systems are created for a broad range of parts. The presses are driven directly by torque motors which permit highly dynamic forming processes thanks to their high torque. The lack of a flywheel and clutch / brake combination makes the presses flexible, energy efficient and cuts down the maintenance required.

TABlE oF CoNTENTS

31


proGrAmmAble Slide moTion curveSThe use of highly dynamic torque motors permits straightforward and rapid programming of different movement profiles in one press cycle. This means the slide kinematics can be quickly and easily adapted to the process parameters of the die and the automation system, and optimized for a high stroke rate.

oScillATinG STroke modeoscillating stroke mode permits user-programmable slide stroke heights. The reversing movement of the torque motor means that the eccentric drive of the slide has an oscillating motion and alternates between forward in one stroke and backward in the next stroke. This significantly improves cycle count and energy efficiency.

individual programming of the slide motion reduces the cycle time while keeping the forming speed constant.

Servodirect technology allows the slide motion to be programmed individually.

Time [s]Reduction in cycle time

Motion profile of conventionally driven eccentric press Motion profile of the servo press with optimized performance Operation in oscillating stroke

Stroke [mm]

max

.

0 Time [s]

Oscillating mode, small stroke Oscillating mode with rest position Pass-through mode

Stroke [mm]

max

.

0

FlExiBiliTy ANd EFFiCiENCy

Significant increase in productivity compared to conventionally driven mechanical presses

maximum production flexibility due to user-programmable stroke heights and motion sequences

increased parts quality and die lives due to motion sequences optimally adapted to the particular forming requirements

Greatest availability for production mode Best suited for processing high-strength steels

Short delivery times and optimized spare part management due to standardized modules

Shorter die tryout times because of setup and tryout functions with hand wheel

lower energy costs due to efficient drive solution Easier maintenance compared to conventionally

driven mechanical presses, because there are fewer mechanical components.

AdvAnTAGeS

TABlE oF CoNTENTS

32

Servo press in monoblock design. Press force: 6,300 kN.

Servo press in monoblock design. Press force: 2,500 kN.

Servo presses in monoblock design. Press force: 4,000 kN each.

enerGy mAnAGemenTEnergy accumulators can be used as an option in order to reduce the connected load. This means energy is returned to the energy accumulator during the press cycle in the generative braking phase. This stored energy is available during the subsequent motor acceleration phase, without imposing any additional load on the electrical system.

reliAble componenTSThe monoblock press body is implemented as a stress-free annealed welded structure. The eccentric gears have a double herringbone profile to provide axial guidance and to reduce noise. The slide roller guide is preloaded to eliminate play. This results in components that guarantee high availability of the machine.

TryouTStarting up new dies demands the greatest flexibility. The setup speed can be varied by a hand wheel. The slide can be stopped in any position and the direction of movement can be reversed if required. The quick-lift function makes it possible to move the slide to the maximum top reversing point at any moment during the setup procedure.

model overvieW of Servo preSSeS in monoblock deSiGn

All information for systems with two-point connecting rod design. Subject to technical modification.*Stroke rate depending on programmed stroke height and kinematics.

modell mSd 250 mSd 400 mSd 630 mSd 800

press force [kn] 2,500 4,000 6,300 8,000


2,000 1,100

2,500 1,100

3,050 1,400

4,000 1,800 1,800

Shut height [mm] 550 600 700 1,000 1,000

Slide stroke [mm] 32 160 40 200 60 300 80 400 80 400

Slide adjustment [mm] 150 200 250 300 300

Stroke rate [rpm]* 3 160 3 140 3 90 3 60 3 60

TABlE oF CoNTENTS

33


2

6 7

8 9

1

3 4 5

1. Coil feed line2. Decoiler3. Leveling machine4. Loop pit

5. Roll feed unit 6. Servo press in monoblock design 7. Electronic, modular tri-axis transfer

8. Operator panel9. Energy accumulator

SERvo PRESS iN moNoBloCk dESiGN WiTh AuTomATioN

leGend

TABlE oF CoNTENTS

34

hiGheST line AvAilAbiliTyThe "kurvengenerator" (curve generator) software developed by Schuler allows optimum tuning of slide motion properties and automation parameters for the highest process reliability. The design of all components has been optimized using FEm calculation methods. The press bodies are built as welded structures and annealed to reduce stress.

reduced STArTup And SeTup TimeSWide range of tryout functions for the production press using hand wheel function: die closing movement with variable setup speed intermittent movement with reversing movement

when required Spotting function with selectable die force Quick-lift function for rapid die opening

different die change systems such as tandem change cart or an extendable bed plate achieve short changeover times.

Servo press in tie rod design. Press force: 11,000 kN.

model TSd 630TSc 630

TSd 800TSc 800

TSd 1000TSc 1000

TSd 1100TSc 1100

TSd 1250TSc 1250

TSd 1600TSc 1600

TSd 2000TSc 2000

TSd 2500TSc 2500

TSd 3200TSc 3200

press force [kn] 6,300 8,000 10,000 11,000 12,500 16,000 20,000 25,000 32,000


4,000 1,600 1,800

4,600 1,800 / 2,200* 1,800

5,000 2,200*

5,100 2,200 1,800 / 2,200* 1,800

6,000 2,500*

6,100 1,800 / 2,200* 1,800 / 2,500* 2,500* 2,500* 2,500*

7,000 2,500* 2,500* 2,500*

Shut height [mm] 900 1,100 / 1,100 1,100 1,200 1,100 / 1,200 1,100 / 1,300 1,400 1,400 1,400

Slide stroke [mm] 100 350 120 450 / 120 500 120 450 150 600 120 450 / 150 600 150 450 / 200 600 200 700 230 700 230 700

Slide adjustment[mm] 300 300 / 300 300 300 300 / 300 300 / 300 300 300 300

Stroke rate** [rpm] TSdTSc

3 70 3 60 / 3 503 50

3 50 3 453 36

3 45 / 3 403 38 / 3 34

3 40 / 3 363 32 3 34 3 30 3 30

model overvieW of Servo preSSeS WiTh Tie rod deSiGn

All information for systems with two-point connecting rod design. Subject to technical modification. *Four-point connecting rod design. **Stroke rate depending on programmed stroke height and kinematics.

TABlE oF CoNTENTS

35


2 3 4 5 6 7

1

8 9 10

11

13 12

1. Material feed (operation either with coil feed line or destacker)

2. Decoiler3. Leveling machine4. Destacker, two destacker carts including

scissor-lift table and double-blank depositing station

5. Roll feed unit6. Coil or blank lubricating unit7. Transfer and centering station8. Servo press in tie rod design9. Electronic, modular tri-axis transfer

10. Combined sequential or transfer die11. Exit conveyor12. Hydraulic, modular drawing cushion13. Scrap disposal

SERvo PRESS iN TiE Rod dESiGN WiTh AuTomATioN

leGend

TABlE oF CoNTENTS

36

SERvo PRESSES

in praCTiCeBlANkiNG TRiAlS ANd PRoCESS iNTEGRATioN

Cylinder head gasket.Seat shell. Component with welded nut.

inTeGrATion of folloW-on proceSSeSFrequently, component production involves several production steps which performed one after another take up time and productivity. highly dynamic servomotors from Schuler

allow completely new working methods. Processes such as welding or laser cutting can be integrated directly into the press cycle in a reliable process and with high output rates because of the opportunities for user-programmable time / distance

sequences, as well as by providing rest times. The results are economical production of complex parts geometries and highest output rates with maximum quality. For extra efficiency.

formed part mode component-specific press force [kn]

depth of draw [mm]

max. stroke rateconventional

max. stroke rateServo

increase

flange Progressive 1,200 30 30 56 + 87 %

Gas generator holder Progressive 1,300 60 25 40 + 60 %

holder Progressive 2,000 40 30 60 + 100 %

cage Progressive 2,400 50 30 50 + 67 %

cross plate Progressive 4,000 90 23 33 + 43 %

cover Progressive 6,900 40 15 34 + 126 %

center console Transfer 6,000 190 12 17 + 42 %

insert cup Transfer 6,600 130 8 15 + 88 %

Support Transfer 7,190 67 14 30 + 114 %

Tank filler neck Transfer 9,650 145 14 18 + 29 %

Seat shell Transfer 12,600 130 16 24 + 50 %

Side panel Transfer 14,750 80 19 29 + 53 %

TABlE oF CoNTENTS

37


The requiremenTS: delivery of a servo press for producing a wide range of parts.

The SoluTion:Servo press in monoblock design with a maximum press force of 4000 kilonewtons. Automated with coil line and feed unit.

monoblock design Bed surface: 2,500 1,100 millimeters Slide stroke 300 millimeters maximum stroke rate in continuous operation:

80strokes / minute

SERvo PRESSES

in praCTiCeCuSTomER: AuTomoTivE ComPoNENTS SuPPliER, GERmANy ANd AuSTRiA

Servo press in monoblock design. Press force: 4,000 kN. Servo press in tie rod design with 16,000 kN press force, coil feed line and destacker combination.

The requiremenTS: delivery of a servo transfer press with complete automation for manufacturing structural components in progressive or transfer mode.

The SoluTion:Servo press in tie rod design with a press force of 16,000kilonewtons and Schuler automation components.

Coil line / destacker combination Roll feed unit Electronic, modular tri-axis transfer Conveyor belt Bed surface: 6,000 2,500 millimeters Slide stroke: 600 millimeters Tie rod design

TABlE oF CoNTENTS

38


preSSeS wiTh TwinServo TeChnology

AdvAnced ThinkinG in Servo TechnoloGyFollowing the market launch of Servodirect technology, the next milestone in a success story was set with TwinServo technology. The new press generation is driven by decentralized TwinServo technology, which offers users additional interesting possibilities in sheet metal forming. The performance capabilities of this innovative press technology are impressively demonstrated by Schuler at its umformCenter Erfurt on a new transfer press. The new press system produces at a press force of 16,000 kilonewtons and is fully automated with components from Schuler.

press force [kn] 10,000 16,000 20,000 25,000 30,000 35,000

bed length [mm] bed width standard and option*

5,000 2,200 2,200* 2,500* / 2,200* 3,000 / 2,500*

6,000 2,500 2,500* / 2,200* 3,000 / 2,500* 3,000* / 2,500* 3,000*

7,000 3,000 / 2,500* 3,000 / 2,500* 3,000*

8,000 3,000 / 2,500* 3,000

Slide stroke [mm] 600 600 600 750 750 750


press force millimeters before bdT [mm] 6 6 6 6 6 6

number of connection points 4 4 4 4 4 4

Stroke rate at max. stroke** and constant speed [spm] / rated capacity [kj] 40 / 400 35 / 500 40 / 900 30 / 1,200 25 / 1,500 25 / 1,500

oscillating stroke rate 1 / 3 stroke**[spm] / rated capacity [kj] 50 / 250 50 / 250 60 / 400 40 / 650 35 / 700 30 / 900

model overvieW of TWinServo preSSeS

* option. ** deviations possible depending on the motion curve and force profile.

TwinServo transfer press at the Schuler umformCenter Erfurt.

TABlE oF CoNTENTS

39


die change by moving bolster.

Schuler umformcenTer erfurT: The first transfer press with TwinServo technology was installed at the umformCenter Erfurt.

Coil line with decoiler and leveling machine.

Transfer press with TwinServo technology. Press force: 16,000 kN.

AuTomATEd TRANSFER PRESS WiTh TWiNSERvo TEChNoloGy

in praCTiCeSChulER FoRmiNG CENTER ERFuRT

The SoluTion:press decentralized TwinServo drive Press force: 16,000 kilonewtons main motors: 2 AC servo torque motors 503 kilowatts

Four contact points Bed dimensions (l W): 5000 2200millimeters

Slide stroke: 600 millimeters Slide adjustment: 300 0.1millimeter

Stroke rate: Controllable 3 30 / minute, in oscillating mode without transfer 3 40 / minute

coil feed line Coil line with decoiler, leveling machine, coil-end welding device, PowerFeed roll feed unit and spraying system, can be used with aluminum

destacker Schuler destacker with removal

feeder and shuttle device in the press

Transfer Electronic tri-axis rhombus

transfer from Schuler

Additional equipment Two moving bolsters and parts outfeed belt

dimensions Total length of the machine: 25meters

Press height over floor: 6.50 meters

Required foundation depth: 5.30meters

TABlE oF CoNTENTS

40

mechanical multi-station press.

individuAlly AdjuSTAble forminG STATionSmulti-station presses differ from transfer presses mainly in the ability to adjust individual forming stations. Another difference in multi-station presses is the externally mounted blanking slide for integrated blank production. multi-station presses are built both as single-slide and multi-slide machines with a press force range from 2500kilonewtons to 60,000 kilonewtons. Either mechanical or electronic rail transfer systems are used for parts transport. The advantages are high output and high availability, individual station adjustment in each station and, if necessary, the externally mounted blanking slide for integrated blank production.


TranSfer preSSeS

mulTi-STATion preSS WiTh exTernAlly mounTed blAnkinG Slide

1

2

3

4

6

5

7

1. Crown with press drive

2 Press upright

3. Drawing slide

4. Transfer system

5. Die change cart

6. Blanking slide

7. Drawing cushion

TABlE oF CoNTENTS

41


mulTifuncTionAl mASS producTionmulti-slide transfer presses deliver impressive practical performance as a functional unit comprising press, transfer and material feed. The configuration is based on the parts spectrum, die size and forming process. Single-slide, double-slide or triple-slide machines are used, depending on the parts spectrum, which also influences the size and number of dies. Parts are transported by a rail transfer system which can be equipped either with cam-controlled or electronic drive.


mulTiple-Slide TranSfer preSSeS

mulTi-Slide TrAnSfer preSS

5

4

6

7

1

10 9 8

2 3 1. Destacker

2. Transfer press

3. Tie rod

4. Crown

5. Upright

6. Slide

7. Finished part unloading belt

8. Moving bolster

9. Damping element

10. Drawing cushion

multi-slide transfer press.

TABlE oF CoNTENTS

42

04TABlE oF CoNTENTS

43

AT A GlANCE

auTomaTion of Single preSSeS

our automation ideally combines the press, automation devices and die, offering impressive precision and process reliability. With automation components from Schuler, you benefit from a greater output rate even when processing high-strength steels or aluminum.

dESTACkER

Coil FEEd liNES

Roll FEEd uNiT

TRi-AxiS TRANSFER

44

45

48

50

AuTomATion of SinGle preSSeS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about automating single presses? you can find our complete selection at www.schulergroup.com / automation. in addition, you can download the Performance Along the line Automation from Schuler brochure as a PdF file.

Schuler online

TABlE oF CoNTENTS

44

AuTomATioN oF SiNGlE PRESSES

deSTaCker

in order to automate transfer presses, Schuler not only offers tried-and-tested destackers but also a special solution. This consists of a mobile combination of coil line in short design with a destacker. For the press owner, this solution opens a wide range of options regarding material and flexibility for efficient part production. it represents a flexible solution for blank and coil processing on a single line. The control is compatible with both the press and transfer, and meets all production requirements.

destacker with transfer system for blank destacking. integrated system solution. destacker and coil line on a servo press. Press force: 16,000 kN.

TABlE oF CoNTENTS

45


Coil feed line in short design.

coil feed lineS in ShorT deSiGnour coil feed lines in short design have been specially developed for the requirements of customers in the components industry. They offer process reliability while meeting the highest material requirements. The lines are optimally suited for producing structural components and processing high-strength materials even in the higher coil thickness range. They are the ideal solution when space is at a premium. our product range includes coil feed lines in various high-performance basic versions, and is adapted to all press types. The modular concept permits flexible configuration of the lines. With our extensive package of options, you can react to new requirements at any time while keeping control over your investments.


Coil feed lineS

coil width [mm] up to 1850

coil thickness [mm] up to 12

coil weight [t] up to 27

reference dATA of The bASic verSionS

TABlE oF CoNTENTS

46

TechnicAl dATA of The poWer line

bASic verSionS of coil feed lineS in lonG deSiGn

coil data for light weight class

poWer line l-bS 0650 l-bS 0800 l-bS 1050 l-bS 1300 l-bS 1600

coil weight max. [t] 5.5 12 12 14.5 17

coil width min. [mm] 110 [40] 110 [80]

coil width max. [mm] 650 800 1,050 1,300 1,600

coil thickness min. [mm] 0.5

coil thickness max. [mm] 4

leveling rolls [mm] 53

loop radius [mm] 1,000

coil feed lineS in lonG deSiGncompact line product lineThe Compact line from Schuler has been specially developed for small coil widths and tonnages. it covers coil widths up to 800 mm and tonnages up to 7.4 tons for requirements with a straightforward level of automation.

power line product lineAs an expansion of the Compact line product line, Power line coil feed lines are available for large coil widths and tonnages. These Schuler coil feed lines do full justice to the requirements of the automotive and components industry for material feed with the option of a high level of automation for high-speed, prog-die and transfer presses. Coil widths up to 1850 millimeters and coil weights up to 27tons make it possible to prepare coil material for structural and skin panels as well as blanks.

compAcT line l-bS 0450 l-bS 0650 m-bS 0800

coil weight max. [t] 3 5.5 7.4

coil width min. [mm] 110 [40] 110 [40] 110

coil width max. [mm] 450 650 800

coil thickness min. [mm] 0.5 0.5 0.5

coil thickness max. [mm] 4 4 6

leveling rolls [mm] 70 70 70

loop radius [mm] 1,000 1,000 1,300

TechnicAl dATA of The compAcT line

Schuler Power line.

TABlE oF CoNTENTS

47


flexibility: Systems and components available on short notice Scalable weight classes > light > medium > heavy Wide range of options can be retrofitted Can be configured for manufacturing structural

and skin panels implementation of customer-specific requirements Rapid retrofitting Flexible attachment to existing price systems

variable level of automation: manual or motor-driven adjustment of the setup axes visualization

Attractive price / performance ratio: Significant cost advantage by modular line configuration

and preconfigured components Energy-efficient by optimum drive configuration very straightforward maintenance

user-friendly machine operation: intuitive operating concept online diagnosis

AdvAnTAGeS

coil data for heavy weight class

poWer line h-bS 0650 h-bS 0800 h-bS 1050 h-bS 1300 h-bS 1600

coil weight max. [t] 10 15 15 17 23

coil width min. [mm] 120 205

coil width max. [mm] 650 800 1,050 1,300 1,600


coil thickness max. [mm] 8 6



coil data for medium weight class

poWer line m-bS 0650 m-bS 0800 m-bS 1050 m-bS 1300 m-bS 1600 m-bS 1850

coil weight max. [t] 13.5 11.5 12.5 13.5 16 22

coil width min. [mm] 110 120 160 205

coil width max. [mm] 650 800 1,050 1,300 1,600 1.850


coil thickness max. [mm] 6 4 4.5



TABlE oF CoNTENTS

48

Power Feed.

poWer feed roll feed uniTThe Power Feed roll feed unit shortens the automation time, especially with highly dynamic presses. Servodirect drives provide greater dynamics and system accuracy, as do the low-play and maintenance-free planetary gear units. in the long term too, this makes it possible to achieve a system accuracy of 0.05 millimeters. Furthermore, there is an optimally configured roll coating which transfers the high acceleration values to the material. The Schuler Power Feed is divided into different weight classes depending on the mass to be moved: Weight class l (light) with movable mass up to 100 kilograms, m (medium) with movable mass up to 180 kilograms or h (heavy) with movable mass up to 300 kilograms.


roll feed uniT

feed performAnce diAGrAm, poWer feed (exAmple)

Feed time 240,0 180,0 120,0 60,0

Stroke rate [spm]

Feed length [mm]

Feed time [s]

0 100 200 300 400 500 600

0,40

0,35

0,30

0,25

0,20

0,15

0,10

0,05

0,00

400

350

300

250

200

150

100

50

0

TABlE oF CoNTENTS

49


Connection to all press types ideally usable within highly dynamic processes Servodirect drive System accuracy of 0.05 millimeters

Scalable in weight class and performance Available on short notice low maintenance requirement Can be retrofitted at any time

AdvAnTAGeS

poWer feed m-bp 0300 m-bp 0450 m-bp 0650 m-bp 0800 m-bp 1050 m-bp 1300 m-bp 1600 m-bp 1850

coil width min. [mm] 40 40 40 40 40 80 80 80

coil width max. [mm] 300 450 650 800 1,050 1,300 1,600 1,850

coil thickness min. [mm] 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

coil thickness max. [mm] 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6,0

coil cross section max. [mm] 1,350 2,025 2,600 2,800 3,150 3,900 4,800 7,200

loop radius [mm] 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300

poWer feed h-bp 0650 h-bp 0800 h-bp 1050 h-bp 1300 h-bp 1600

coil width min. [mm] 40 40 40 80 80

coil width max. [mm] 650 800 1,050 1,300 1,600

coil thickness min. [mm] 0.5 0.5 0.5 0.5 0.5

coil thickness max. [mm] 8.0 8.0 8.0 8.0 8.0

coil cross section max. [mm] 3,250 4,000 5,250 6,500 6,400

loop radius [mm] 1,600 1,600 1,600 1,600 1,600

modEl vARiANTS

coil dATA

poWer feed l-bp 0300 l-bp 0450 l-bp 0650 l-bp 0800 l-bp 1050 l-bp 1300 l-bp 1600

coil width min. [mm] 40 40 40 40 40 80 80

coil width max. [mm] 300 450 650 800 1,050 1,300 1,600

coil thickness min. [mm] 0.5 0.5 0.5 0.5 0.5 0.5 0.5

coil thickness max. [mm] 4.0 4.0 4.0 4.0 4.0 4.0 4.0

coil cross section max. [mm] 750 1,125 1,300 1,600 2,100 2,600 3,200

loop radius [mm] 1,000 1,000 1,000 1,000 1,000 1,000 1,000

TABlE oF CoNTENTS

50

Schuler Pro Trans transfer.

The new modular transfer generation is a high-performance addition to sheet metal forming presses. designed with three sizes, the transfer system covers a wide range of applications. in all transfer solutions, active vibration damping Avd also guarantees reliable parts transport with the highest level of dynamic properties and at full load.


Tri-axiS TranSfer SySTemS

Can be retrofitted regardless of the press optimally adaptable to different applications Simple and cost-effective performance increase high output performance high rigidity in the overall system

low tendency for vibration Short changeover times large clearances for attaching components for material feed and material unloading

left-over strip processing regardless of material

AdvAnTAGeS

pro TrAnSWith its three motor versions l (light), m (medium) and h (heavy), Schuler Pro Trans covers low, medium and high part weights and stroke rates. The heavy version has twice the performance capability of the light version, while the medium variant is situated in between. All the transfers owe their significantly improved output performance to having motor systems with direct advance drive, featuring highly dynamic servo drives. overall, the Schuler Pro Trans has a modular principle: The three defined standard models AT1, AT2 and AT3 can quickly and easily be adapted to changed requirements. Schuler offers a wide selection of options for this.

poWer TrAnSSchuler offers a high-end transfer solution for high-performance presses in the form of Schuler Power Trans and the S (Speed) motor system, the use of which permits productivity to be increased even further and by a significant amount. For example, the output rate with Power Trans is up to 30 % higher than with Pro Trans motor systems. This additional performance is achieved in particular by using newly developed carbon rails with aluminum profile functions combined with the Servodirect drive. The rails are very light and rigid, which means the vibration levels are extremely low. As a result, they are ideal for use in highly dynamic production processes.

TABlE oF CoNTENTS

51


Attachment variants of the transfer drive housings of the Schuler transfer system on the press upright.

inTrA TrAnSThe Schuler intra Trans can be equipped with all motor variants from l (light) to S (Speed), which means it is suitable for use in presses ranging from conventional to high-performance. in intra Trans, the transfer rails do not operate through the press window, but are installed between the press uprights. Parts feed in the working direction is performed by movable slides mounted on the transfer rails, with servo drives integrated in the rail. Each carriage of the intra Trans can be moved individually so the central joining of parts or even different distances between stations are possible. using this compact transfer makes it possible to manufacture larger parts with the same transfer press. The new transfer solution is also a genuine alternative to progressive die manufacturing. Conventional transfers require a larger press for the same maximum part size but the compact design of the intra Trans means it needs only the same space as the progressive die. The transfer exploits its full benefit: less material is consumed, because the parts are transported by the slides and not by the coil material itself. Additional material is required in combined sequential production, and the material has to be cut off the finished pressed part as scrap. intra Trans is ideal for retrofitting to existing combined sequential presses as a means of reducing unit costs. Access to the die and the die change are possible without restrictions as before, and as far as the operator is concerned there is no difference from the Schuler transfers in the Pro Trans and Power Trans series.

Size Support width [mm] press window / drive unit width [mm]

AT1 3,000 up to 1,600

AT2 6,000 up to 2,500

AT3 10,000 up to 5500

overvieW of The SizeS

modulAr SySTemAll models in the Pro Trans, Power Trans & intra Trans series have gripper rail drive units that can be attached in the press (1), between the press uprights (2) or on the outside of the press uprights (3). Furthermore, they can be installed above (hanging) or below (standing) the transport level, resulting in the highest level of flexibility both in project planning and for retrofitting to existing presses.

Gripper rail drive units

Gripper rail drive units

Slide

Moving bolster

3 32 2

3 32 1 1 2

TABlE oF CoNTENTS

52

05TABlE oF CoNTENTS

53

AT A GlANCE

preSS lineS

The future starts with Schuler: with high-quality implementation and the technology of tomorrow, we are taking measures today to ensure the greatest possible productivity in mass production for the automotive industry. our results satisfy the most exacting requirements and win over our customers worldwide. Flexibility and quality are what we stand for. our innovations are unusual and practical. we create change for the market, time and time again. Groundbreaking new developments such as Servodirect technology, press automation with the crossbar feeder or crossbar robot ensure the best component quality, high availability and output.

hydRAuliC PRESS liNES

hyBRid PRESS liNES

mEChANiCAl hiGh-SPEEd PRESS liNES

SERvo PRESS liNES

54

56

57

59

preSS lineS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about our automotive press technology? you can find our complete selection at www.schulergroup.com/automotive. in addition, the highlight on the page provides direct information about the important aspect of high-Speed in the Stamping Plant.

Schuler online

TABlE oF CoNTENTS

54

reliAble, flexible And economicAlhydraulic press lines are mainly used to manufacture a wide variety of parts in small to medium batch sizes. depending on the forming operations, the lines consist of four to six single presses. The production process is fully automated from the blank to the finished component. depending on requirements, automation is provided by

Flexibility in the forming process Ease of maintenance and installation thanks to block hydraulics

dynamic cylinder mode switching and ring valve technology increase production rates

Automation for tooling and dies to ensure fast changeovers

Precise slide guiding and rigid press frame uniform control concept user-friendly operation and efficient fault diagnostics Fast startup of new die sets

AdvAnTAGeS

PRESS liNES

hydrauliC preSS lineS

conventional robots or crossbar robots developed by Schuler. The control and graphic display for hydraulic press lines offer the operator uniform, user-friendly operation, efficient fault diagnostics and the management of all process and die data for all presses and automation systems.

Fully automated hydraulic press line. loading station with robot automation.

TABlE oF CoNTENTS

55


The requiremenTS: When the Euro-6 exhaust standard comes into force on january 1, 2014, permitted nitrous oxide emissions from trucks with a weight of more than 3.5 tons will be reduced by 80%. our customer took this opportunity to thoroughly revise all of their models. in the future, important components of the new trucks will be produced on a high-performance hydraulic press line from Schuler. high productivity combined with high flexibility proved to be convincing arguments.

hydRAuliC PRESS liNES

in praCTiCeCuSTomER: TRuCk mANuFACTuRER, FRANCE

Existing and newly-developed dies will be used. Automation with crossbar robot, one destacker and two outfeed belts.

The SoluTion: hydraulic lead press with 20,000 kilonewtons press force Three hydraulic follow-up presses, each with 10,000kilonewtons press force

destacker Press automation with crossbar robots unloading with crossbar robot Two outfeed belts

TABlE oF CoNTENTS

56

leAd preSS hydrAulic folloW-up preSSeS mechAnicAlhybrid press lines consist of a hydraulic lead press and mechanical follow-up presses. They are a cost-effective alternative when single-action and double-action dies will be used on the same line. modern hydraulic slide drives put the output rate of hybrid lines in the region of mechanical press lines. The slide cycle of hydraulic lead presses is user-programmable, and the nominal press force of the press is fully available at any time throughout the press stroke.

hybrid press line with hydraulic lead press and mechanical follow-up presses.

one forming system for single and double-action dies Flexible production alternative

Suitable for complex drawn parts because of the hydraulic lead press

Quick and easy startup of new die sets

AdvAnTAGeS

PRESS liNES

hyBrid preSS lineS

TABlE oF CoNTENTS

57


croSSbAr feeder improveS ouTpuT performAnceTo increase the cost-effectiveness of mechanical press lines, Schuler developed the crossbar feeder. in press lines with crossbar feeder automation, the components are transported directly from press to press without intermediate stations. if required, the components can also be repositioned before placement into the die. As compared to mechanical press lines with robot or feeder automation, it is possible to achieve production rates as high as 15 strokes / minute.

in mechanical press lines with crossbar feeder automation, both the loading of press 1 as well as unloading the finished parts can be performed with the crossbar feeder.

output rate up to 15 strokes / minute Crossbar feeder with seven degrees of freedom No intermediate stations required

one set of tooling for each press opening Short distances between presses Rapid die and tooling changes

AdvAnTAGeS

mechanical high-speed press line with crossbar feeder automation.

PRESS liNES

meChaniCal high-Speed preSS lineS

TABlE oF CoNTENTS

58

The requiremenTS: delivery of a fully-automated mechanical high-speed press line.

mEChANiCAl hiGh-SPEEd PRESS liNES

in praCTiCeCuSTomER: AuTomoBilE mANuFACTuRER, PEoPlE'S REPuBliC oF ChiNA

mechanical high-speed press line. End-of-line-System.

The SoluTion:Schuler high-speed press line.

destacker loading press 1 with crossbar feeder Fast die change Crossbar feeder press automation End-of-line-System with crossbar feeder and robot Control station

TABlE oF CoNTENTS

59


PRESS liNES

Servo preSS lineS

quick, compAcT And flexibleEquipped with a Schuler destacker, crossbar feeder and End-of-line-System, servo press lines offer the greatest possible flexibility, high output rates with a wide range of parts as well as short die and tooling change times. using innovative drive technology, the slide movements of all presses can be individually adapted for each component, the forming process, the die and the parts transport. in identical processes, this leads to higher output rates for single, double or four-fold parts in steel, aluminum and components made from higher-strength materials. The combination of high output, short change times and high flexibility contributes to reduction of part unit costs and improvement to the productivity of press shops.

Six-stage servo press line with crossbar feeder automation.

output rate up to 23 strokes / minute high level of flexibility Reduction in part unit costs Slide movement freely programmable optimum adaptation to various forming processes Automation with destacker and crossbar feeder Compact design of the press line

Fully automatic die and tooling change in three minutes one set of tooling per press opening die tryout possible with hand wheel function user-friendly user interfaces Ergonomic parts outfeed Easy-to-maintain technology, because the flywheel,

clutch and brake are dispensed with

AdvAnTAGeS

TABlE oF CoNTENTS

60

The requiremenTS: delivery of three servo press lines for large-scale mass production of a wide range of parts in three plants. output performance: 17 strokes / minute.

The SoluTion:Fully automated servo press line with six die stations.

destacker with lubricating unit and optical centering station loading press 1 with crossbar feeder Crossbar feeder press automation End-of-line-System with robot and crossbar feeder Control station hand wheel function for die startup Crossbar feeder simulator die change in three minutes

Servo press line with six die stations. destacker. Control station.

SERvo PRESS liNES

in praCTiCeCuSTomER: AuTomoBilE mANuFACTuRER, GERmANy

TABlE oF CoNTENTS

61


Press line with Servodirect technology.

TABlE oF CoNTENTS

62

06TABlE oF CoNTENTS

63

AT A GlANCE

auTomaTion of preSS lineS

From the single press to the complete press line: As a system supplier, we automate your forming systems intelligently and practically. We boost the performance of your production efficiently and economically. Whether it comes to a broad portfolio of parts, high productivity or the need for a compact space, automation solutions from Schuler guarantee high efficiency and reliable production processes. When it comes to modernizing existing lines, we offer tried-and-tested practical solutions for efficient production of components in the highest quality. Automation solutions from Schuler deliver convincing performance in all aspects of forming technology.

dESTACkER FoR PRESS liNES

BlANk WAShERS ANd luBRiCATioN uNiTS

RoBoTS

CRoSSBAR RoBoT

CRoSSBAR FEEdER

PART RACkiNG SySTEmS

64

65

66

67

68

69

AuTomATion of preSS lineS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about our stamping plant? you can find our high-Speed in the Stamping Plant focus at www.schulergroup.com/automation. in addition, you can download the Performance along the line Automation from Schuler brochure as a PdF.

Schuler online

TABlE oF CoNTENTS

64

modular designed destacker concepts for mechanical and hydraulic press lines are designed to suit downstream forming systems. Schuler offers a selection of models adapted to the required part size and contour, the type of material, the blank weight and the loading speed. From the simplest loader with one robot without centering station for small parts and simple operations, up to destackers with two destacking stations, optical or mechanical centering station, blank washers and lubrication units for large and / or heavy blanks we have it all. The blank destacking is performed by the robot or feeder. To help make full use of the capacities of large press lines, two or even four blanks can be processed at the same time. For press lines with crossbar automation, loading the first die station can be performed by a crossbar robot or crossbar feeder. in addition to handling conventional steel sheet, these destackers can also process blanks in aluminum, steel-aluminum mix, and higher-strength steels.

Crossbar robot automation.

one or two destacking stations for separating blanks with a double blank monitor

optical or mechanical centering station Wash unit

lubricating unit loading unit with robot, crossbar robot

or crossbar feeder

The blAnk componenTS

AuTomATioN oF PRESS liNES

deSTaCkerS for preSS lineS

TABlE oF CoNTENTS

65


Superior, consistent surface quality of the components Best possible part quality, even with high drawing forces increased productivity levels

Cost-savings for entire process longer intervals between die cleaning

AdvAnTAGeS


Blank waSherS and luBriCaTing uniTS

blAnk WASher And lubricATinG uniT Superior quality for outer skins and structural parts requires blank washing prior to processing to remove any dirt and deposits, and a final application of a defined amount of oil. The effect of systematic washing and a consistent application of oil prevents downtime for the entire process.

in addition, blank washers also provide significant reductions in downstream reworking and costs when it comes to body-in-white assembly and painting. Blank washers are an integral part of modern destackers and can, if required, be retrofitted to existing lines.

depending on requirements, the blank washers are designed to suit variable blank lengths and widths. A defined amount of oil provides optimum preparation of the blank for subsequent forming processes. Flexibly programmable spraying heads in the lubrication unit ensure superior part quality for forming involving high drawing forces.

Blank washer, lubrication unit and loading robot in front of a hydraulic press line for manufacturing aluminum components.

Blank washers provide a high and consistent component quality.

destacker with optical centering station, loading robot and blank washer.

TABlE oF CoNTENTS

66


roBoTS

in addition to advanced automation solutions, such as crossbar technology, there is still a place for conventional solutions with robots. Robots are flexible since only one robot is required per press opening. Automatic changeover of robot tooling is easy.

Press line with robot automation. loading robots position the blanks accurately in the die of the first press.

TABlE oF CoNTENTS

67


The crossbar robot combines proven robot technology with the advantages of crossbar technology. This application uses a conventional industrial robot. The robot is then expanded by one feed axis and the crossbar beam provides a second axis. The horizontal motion takes place along the x-axis that is mounted on the press uprights. Programming is done at the operator's panel for the robot. The crossbar robot can be delivered with new lines or integrated into existing press lines.

The crossbar robot combines the advantages of robot technology and crossbar technology.


CroSSBar roBoT

direct parts transport from die to die Press spacings from 5 to 10 meters No intermediate station Flexible parts orientation from die to die No turning of components from die to die user-programmable change in parts orientation Simple programming Adapter permits takeover of the crossbar feeder tooling

Complete solution including destacker and End-of-line Can also be used as destacker and unloader Flex, double and four-fold parts production possible Suitable for steel and aluminum one set of tooling per opening Rapid automatic tooling change Ease of maintenance due to free access to the

press opening

AdvAnTAGeS

Axr90

max. loading crossbar robot [kg] (part and tooling) 90

max. throughput rate with press [strokes / min] 12 15

Turning horizontally 10

Swiveling at right angles to the transport direction 25

Swiveling in the transport direction 25

croSSbAr roboT

TABlE oF CoNTENTS

68

Seven degrees of freedom output rate up to 23 strokes / minute No intermediate stations required optionally available with feed-direction rail for large distances between presses

one set of tooling per press opening variable press spacings Free access to the press opening Compact construction possible Fast die changes

AdvAnTAGeS


CroSSBar feeder

The crossbar feeder is the automation technology for high-speed mechanical and servo press lines. it increases the line and process efficiency of mechanical press lines. The crossbar feeder offers seven degrees of freedom, three rotating and four linear axes, increasing the

Crossbar feeder within the press line. Three rotating and four linear axes.

productivity of the stamping plant. The components are transported from die to die without intermediate stations and can also be repositioned. The short, compact design makes the feeder extremely rigid.

TABlE oF CoNTENTS

69


Part racking systems are reliable and fast, while ensuring maximum part quality. A special suction-cup technology protects the highly sensitive surfaces of outer skin panels for downstream processing and preparation for subsequent body-in-white assembly.

AuTomATic pArT rAckinG SySTem for Servo preSS lineSThe newly-developed, automatic, flexible part racking system from Schuler operates with hanging robots, which can also be moved on a track. The position of the finished parts is detected visually by a camera system.

Then the correction data is transferred to the robots. The robots pick up the finished parts in the correct orientation and stack them in parts containers. The automatic racking system allows single, double and four-fold parts to be stacked with a stroke rate up to 17 strokes / minute. up to four robots are used with single parts, while there are up to eight used with double and four-fold parts. The robots operate in pairs and alternately stack the parts in the same container in order to ensure a high output rate. The part racking system may also be equipped with an automatic quality control function.


parT raCking SySTemS

Stacking of single, double and four-fold parts Four-fold racking performance up to 68 parts / minute

Compact, short design Automatic quality control can be integrated

AdvAnTAGeS

Press line with Servodirect technology and automatic part racking system.

TABlE oF CoNTENTS

70

07TABlE oF CoNTENTS

71

AT A GlANCE

TryouT SySTemS

Tryout systems offer the highest level of flexibility for die making and stamping plants. depending on the requirements, they contain various hydraulic or mechanical press types, die turnover devices and turntables. The time-consuming job of manually reworking the dies is carried out outside the tryout presses. The individual components of the tryout system are connected by moving bolsters on a rail system.

hydRAuliC diE-SPoTTiNG ANd TRyouT PRESSES

hydRAuliC mulTiCuRvE PRESSES

TRyouT CENTERS

TRyouT PRESSES WiTh SERvodiRECT TEChNoloGy

diE TuRNovER dEviCES ANd SimulAToRS

72

73

74

76

77

TryouT SySTemS / ThE ENTiRE WoRld oF mETAl FoRmiNG

Would you like to find out more about our tryout systems? you can find our complete offer at www.schulergroup.com/hydraulic_press. There you can find a complete overview of all our system solutions.

Schuler online

TABlE oF CoNTENTS

72

die TryouT before The producTion STArTupTo keep the startup costs of new die sets low, it is important to prepare them optimally for series production. hydraulic tryout presses ensure short startup phases under near-to-production conditions. They are suitable for use in die tryout and startup prior to production getting underway. The line operator has the full press force available at any time, and can lower the upper die sensitively onto the lower die if required. in terms of sizes, performance data and equipment details, die-spotting and tryout presses are designed to meet the requirements of die tryout and pilot-series production.

Tryout center with hydraulic tryout presses.

TRyouT SySTEmS

hydrauliC die-SpoTTing and TryouT preSSeS

Programmable speeds and forces Slide return possible at any point Precise slide movements using a joystick maximum force available over the entire stroke Simple adjustment for varying die heights

For double-action presses: operation possible in single-action or double-action modes

Rigidity like production presses Bed cushion technology like in production lines ensures optimum startup results

AdvAnTAGeS

TABlE oF CoNTENTS

73


preciSe SimulATion of forminG proceSSeS hydraulic multicurve presses are used for starting up die sets in the die shop, in tryout centers and in the stamping plant. Equipped with a hydraulic accumulator drive, they simulate the slide motion characteristics of various hydraulic and mechanical production presses. To properly represent the forming processes of mechanical production lines, the hydraulic multicurve press achieves working speeds up to 500 millimeters / second. various user-programmable slide motion curves are available to the user at any time, with any desired adjustable stroke rate. The four-point drawing cushion in the press bed is identical to that in the production press and ensures optimum startup results.

multicurve presses with moving bolster and die turnover device.

TRyouT SySTEmS

hydrauliC mulTiCurve preSSeS

Precise simulation of the slide movement curves of all press types

drawing speeds up to 500 millimeters / second user-friendly management of the programmable

motion curves

Reduction in startup times on production lines Bed cushion identical to that on the production press

AdvAnTAGeS

TABlE oF CoNTENTS

74

flexible SySTem SoluTion in The die Shop Tryout centers with a number of different press types offer an extremely high degree of flexibility in the die shop. depending on the design, these centers may include mechanical and hydraulic die-spotting and tryout presses, die turnover devices and turntables. The time-intensive manual die rework mainly takes place outside of the tryout presses. The various pieces of equipment within the tryout center are connected by moving bolsters on a rail system. The dies can be moved into the optimum position for the required work.

Tryout center with die-spotting and tryout press.

TRyouT SySTEmS

TryouT CenTerS

high level of flexibility die startup on moving bolsters outside the presses Turning the upper dies with die turnover devices for ergonomic reworking from above

use of simple die-spotting presses for die-spotting work optimum utilization of the equipment

AdvAnTAGeS

TABlE oF CoNTENTS

75


The requiremenTS: Tryout center for die startup of series production dies.

The SoluTion:Tryout center with a total of twelve hydraulic tryout presses.

Bed and slide dimensions: 4,500 2,500 millimeters Each press with moving bolster to the front, hydraulic

drawing cushion, hydraulic slide cushion and hydraulic impact shock dampening

hydRAuliC diE-SPoTTiNG ANd TRyouT PRESSES iN ThE diE ShoP

in praCTiCeCuSTomER: AuTomoBilE mANuFACTuRER, GERmANy

Tryout center with hydraulic tryout presses. The slide can be moved sensitively up and down using a joystick.

A hydraulic multicurve press, press force: 25,000kilonewtons With multicurve accumulator technology drawing cushion in eight-point design

Three hydraulic multicurve presses, press force: 21,000kilonewtons each With multicurve accumulator technology drawing cushion in eight-point design

Four hydraulic tryout presses, press force: 16,000kilonewtons each

Four hydraulic tryout presses, press force: 12,000kilonewtons each

TABlE oF CoNTENTS

76

increASinG The AvAilAbiliTy of producTion preSSeS Tryout presses with Servodirect technology are configured as a duplicate of mechanical production lines. The bowing and deflection properties of the line are consistently simulated for the slide drive, connection point arrangement, spacings between uprights and bed cushions. This means the availability of production operation can be increased even further. The hand wheel function in particular offers the press operator new possibilities when starting up new dies. The servo drive allows optimum simulation of the movement properties of an extremely wide range of presses.

Tryout presses increase availability in the press shop.

TRyouT SySTEmS

TryouT preSSeS wiTh ServodireCT TeChnology

Simulation of the production conditions of mechanical presses

increased availability in production

Reduced parts costs per stroke Slide tilting is identical to production presses Takeover of die data

AdvAnTAGeS

TABlE oF CoNTENTS

77

TRyouT SySTEmS

die Turnover deviCeS and SimulaTorS


die Turnover device erGonomicAl die reWork For ergonomic rework of upper dies in the tryout phase, it is preferable to turn them to an ergonomically favorable position. die turnover devices are used for safe opening and turning, and can be connected to the tryout presses using moving bolsters. die turnover devices simplify die handling, so that the dies are subsequently available to the production presses more quickly.

The AdvAnTAGeS Simple opening and turning of the dies Ergonomic rework of the turned dies integration into tryout centers using rail systems

and moving bolsters

SimulATorS preciSe SeTup of AuTomATion equipmenT At the interface between the die shop and stamping plant, tryout presses and simulators both play a role in preparing dies and automation devices for series production while the production continues without interruption. The component transport is simulated

Documents

Knucle Joint Press