forming presses index - electropneumatics presses.pdfforming presses pioneering forming ... pvt....

FormingPresses

Pioneering forming technology

Forming Tomorrow. Today!

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Electropneumatics & Hydraulics (India) Pvt. Ltd.Gat No. 254/255, Kharabe Wadi, Chakan-Talegaon Road, Chakan, Pune 410501, India. Tel.: +91 (0)2135 667500 Fax.: +91 (0)2135 667502 Email: [email protected] www.electropneumatics.com


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Index

General Features

Hydraulic Metal Forming Presses

Servo Mechanical Presses

Hydraulic Moulding Presses

Hydraulic Die Spotting

and Tryout Presses

Hydraulic Powder Compacting

Presses

Multi-Station

and Transfer Presses

Special Purpose Presses

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70T+60T Servo Formability Testing Machinefor material testing and formability analysis

200T Straightening Machine for axles

100T 2-Station High Magnetic Field Hydraulic Press

CNC Chassis Punching Machine Plate Straightening Machine


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Special Purpose Presses

For applications that do not fall under the standard forming press range, Electropneumatics offers customised solutions based on part, process, cycle time and accuracies required. These could be simple presses or complicated equipment. Our expertise, experience and capabilities in providing tailor-made products differentiate us from the rest.

These Special Forming Presses cater to a wider spectrum of industries. Special machine lines are available for wheel rims, leaf springs, etc. These machines are designed and developed for almost all forming applications including assembly, testing, straightening, specialised forming and other tailor-made needs.

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Indigenous, total system solution provider

Innovative, latest technology Economical, high performance Manufacturing reliability Production flexibility Ease of operation and maintenance

The Electropneumatics Advantage

Machine Manufacturing Division [MMD]




Hydraulic Die Spotting and Tryout Presses

Hydraulic Powder Compacting Presses

Multi-Station and Transfer Presses

Hydraulic Honing Machines

Tube and Pipe Benders

Tube Processing Machines

Chassis Manufacturing Equipment

Power and Transmission Line Equipment

Special Purpose Machines

AC Servo Systems

Component Manufacturing Division [CMD]

Hydroformed tube and sheet parts/assemblies

Tubular bent and formed parts/assemblies

Stamped parts/assemblies

Fluid Power Division [FPD]

Hydraulic Cylinders

Hydraulic Power Packs

Pneumatic Cylinders

Pneumatic Valves and Accessories

�O�u�r� �p�r�o�d�u�c�t� �p�o�r�t�f�o�l�i�oIf you are looking for forming presses and press lines that seamlessly combine innovation with expertise, Electropneumatics is your best source.

As a complete systems supplier, we offer an exhaustive range of products including presses and related automation systems. Electropneumatics is a pioneer and leader in the metal forming industry in India with more than 4000 machines serving the automotive, auto component, white goods, heating and air-conditioning, infrastructure, general engineering, defence and other sectors.

In addition, we offer customised solutions, right from design to product realisation, to meet customer's requirements of part, process, productivity and cost effectiveness.

A Single SourceOur forming press systems incorporate the most modern engineering technology and are built to the highest quality standards to withstand the demanding tasks of day-to-day production schedules.

They guarantee long service life and cost effective execution of operations. They are designed to provide the user with maximum flexibility and ease of operation. The mechanical, hydraulic, electrical and electronic systems indigenously developed by us bring about a perfect synergy in the product. We also offer comprehensive service and spare parts for the entire life of the product.

Our presses powered by conventional, servo hydraulics or AC servo electric drives are used to form metal, engineering plastics/composites, metal powders, etc.

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500T Wheel Press for mounting/de-mounting rail coach wheels/gears on axles

60T x 4-Station Hydraulic Press with four independent slides for mass production of brake linings

250T x 3, 12-Station Hydraulic Transfer Press with blank de-stacker and loader, transfer system and unloaderfor forming servo brake shells

2800T 2-Station Hydraulic Press with two slides, that can be run independently or coupled for forming and punching of commercial vehicle chassis long member

Electropneumatics builds high performance Multi-Station Presses for volume production of formed sheet or solid parts. These highly productive machines are characterised by their flexibility and repeatability. Operations can be performed by a single ram or multiple rams with independent controls of speed, force and position.

These multi-station presses can be equipped with automatic electric AC servo transfer systems for feeding of blank/part from start to end. Transfer presses are completely automated to perform all tasks from blank/coil to finished product, without human intervention. Several optional automation solutions are available as per application and requirement.

�F�e�a�t�u�r�e�s

�O�p�t�i�o�n�a�l� �f�e�a�t�u�r�e�s

Press capacities and stations as per application

Sturdy, column construction with pre-stretched tie rods and 8-point adjustable guiding arrangement or multi-pillar construction

Single or multiple slides, which can operate together or independently

Die cushions, ejectors and shock absorbers, as required

High throughput with efficient hydraulics and electronic controls

Electric AC servo drive 3-axes transfer systems

Advanced Electropneumatics’ SMARTCNC controls with programmable motion, speed and pressure profiles for press and also transfer system

Scrap handling system in press bed

Material feed systems- coil feed lines, blank de-stackers, robots, etc.

Part unloading systems- robots, de-stackers, conveyors, etc.

Quick clamping and die change systems

In-built safety protection devices for press and transfer system

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General Features

Shock absorbers

3D modelling and finite element analysis

Adjustable, 8-point slide guiding with wear liners

�P�r�e�s�s� �F�r�a�m�e� �a�n�d� �C�o�n�s�t�r�u�c�t�i�o�nC-frame, ring frame, 4-pillar, 4-column (tie-rod), H-frame(welded) and special frame constructions based on application

In single/double/triple action versions

Up-stroking, down-stroking or horizontal direction of application of force

Sturdy welded structures fabricated from prime steel (IS 2062) ultrasonically tested, thermally stress relieved and machined to meet dimensional tolerances

Tie rods (in 4-column presses) hydraulically pre-stretched up to 150% of the total tonnage

Geometrical accuracies conforming to JIS grades

Bolster deflection within 0.17mm/m when full load is rduniformly distributed over 2/3 of left-right and full

front-back dimension of the bolster

�S�l�i�d�e� �G�u�i�d�i�n�g8-point/4-point adjustable flat guides or bush guides based on construction

Optimum guide length throughout the stroke to take care of normal off-centre load on the slide

Low wear liners for the guides

Proper lubrication of guides by automatic oil-grease lubrication system

Optional slide parallelism/equalising arrangement to balance high off-centre loads and improve tool life

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�E�j�e�c�t�o�r� �(�O�p�t�i�o�n�a�l�)Hydraulic ejectors (central) in bed or slide

Mechanical/hydraulic bar type knockouts in slide

Hydraulic beam type ejectors in bed


Mechanical knockouts

Ejector in bed

Cushion in bed

�C�u�s�h�i�o�n� �(�O�p�t�i�o�n�a�l�)Cushion in bed for single action or blank holder in slide for double action to provide reaction during drawing or forming, and to function as ejector during return stroke

Cushion pads with adequate flat guiding or round-pillar guides suitably lubricated

Standard reactive cushion function

Active cushion and multi-point programmable draw cushion with proportional hydraulics for independent differential pressure profile as a function of the slide-cushion stroke for draw of critical asymmetric components

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300T 2-Station Hydraulic Press with 3-Axes Electric Transfer System

Multi-Station and Transfer Presses

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�C�o�n�t�r�o�l� �S�y�s�t�e�mPress control options of standard electrical contactor logic, PLC for open loop or CNC for closed loop applications of Electropneumatics make (SMARTPLC/SMARTCNC)

User-friendly, menu-driven graphical user interface with LCD colour touch screen

Process and cycle time optimisation

On-line function screens and diagnostics

Suitable safety interlocks and on-line monitoring through controls

Complete programmability of CNC axes in force-speed-position modes with closed loop feedback monitoring

Facility to interface with component automation/transfer systems

Top view of power pack

Operator panel with LCD colour touch display

�H�y�d�r�a�u�l�i�c� �S�y�s�t�e�mDesigned for high efficiency, optimum power consumption, reliability and ease of maintenance

Modular, compact manifold blocks and logic valve concept, optimally designed using 3D CAD

Clean, neat and accessible arrangement of components

Direct bent seamless pipes with minimum welding andproper clamping for vibration resistance and to prevent leakages

Standard solenoid hydraulics and proportional/servo control systems

Dual pressure relief valves for safety, factory set on main pumps and remote adjustable for major slides

Suitable oil filtration systems such as strainers, return line filters and pressure line filters (in proportional/servo systems) with cleanliness level monitoring

Oil cooling by water or air-oil coolers with oil temperature monitoring interlock

Quick connect minimess points for trouble shooting

Pressure sensing of major actuators by digital pressure sensors and pressure gauges

Electropneumatics' hydraulic cylinders with low friction PTFE seals for smooth operation and long life

General Features

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Features

Optional features

Press capacities up to 1000T

Sturdy press frames, specifically designed for long daylights in H-frame, ring frame, 4-pillar and 4-column constructions

Static and floating die methods of pressing

Top, bottom and auxiliary ejection systems, as per requirement

Complete on-line safety and process monitoring system

Available in CNC versions for full programmability of speeds, positions, forces and with closed-loop feedback monitoring

Advanced hydraulic system with necessary monitoring features

Electropneumatics’ intelligent PLC/CNC controls to monitor process parameters and friendly user-interface to display parameter data and graphs

Auto ejection system for specialised needs

Automatic fill height correction

Programmable electric motorised filling and feeding arrangement

Quick die change systems

Pick & place part transfer units

Automatic weighing arrangement

Magnetising/demagnetising unit (for wet presses)

80T 12-Station Ball Press for ceramic media

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Electropneumatics designs and builds tailor-made Powder Compacting Presses for near-net shape forming of parts. Powders of iron, steel, high speed steel, carbides, ceramics, friction material, bronze, copper and their alloys can be formed into complex parts of high strength. Dry Powder Compacting Presses are usually used to form parts of metal, ceramic and abrasive powders while Wet Slurry Compacting Presses compact magnetic material parts. A wide variety of automation and peripheral equipment can be integrated with these machines for high-volume, economic, continuous production.

Sophisticated tool adaptors with multi-cavities, multi-levels, etc. can be designed for production of complex parts to precision. Sintering and sizing presses are also available.

300T H-frame Wet Compacting Pressfor ferrite magnets

200T Dry Compacting Press for multi-level PM parts

Safety light curtains

Loading/Unloading arm on press

�S�a�f�e�t�y� �M�o�n�i�t�o�r�i�n�g� �S�y�s�t�e�m�sSafety is an inherent feature of every Electropneumaticspress. Some of the features are:

Two-hand safety operation with simultaneous control facility in the control panel

Safety light curtains and mechanical guards protected by limit switches (provided on request)

Hydraulic locking of the main slide and blank holder at top dead centre to ensure safety when working in the tooling area (available on request)

Several other hydraulic and electronic safety interlocks to ensure proper sequencing of operations, to prevent build-up of working pressure beyond operation requirement and to ensure operator and tooling safety

Pressure gauges for blank holder, main slide and cushion for continuous display of operating pressures. LEDs to indicate when the individual control valves respond and provide information on possible fault sources in relation to the work cycle

Digital displays (optional), indicators and interlocks for system malfunctioning such as filter clogging, low oil level, high oil temperature, etc. for ease of trouble shooting

�A�u�t�o�m�a�t�i�o�n� Flexibility and efficiency in manufacturing is a basic need of the day. Small and medium batch sizes also have to be run economically. This means frequent changeover, often several times a day. Limiting these changeover times to a few minutes translates into significant cost advantages. Electropneumatics offers press automation solutions for new presses or as retrofit on existing presses.

Quick Die Change (QDC) systems such as swivel die loader arms, die clamps, die lifters in bolster, moving bolsters or die carts, etc.

Handling devices such as component transfer systems, robots and pick & place systems working in conjunction with the presses for loading/unloading and inter-press transfer in press lines

Material feeders such as coil feed lines, blank de-stackers, transfer systems, etc.

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Hydraulic PowderCompacting Presses

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500T 4-Column CNC Powder Compacting Press with AC Servo Feeder, Pick & Place and On-line Weighing


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500T 4-Column Die Spotting and Tryout Press15T 4-Pillar Mould Spotting Press

Increasing number of models in shorter periods, small batches and complex forming processes have led to a demand for spotting and tryout presses that are reliable and efficient. Component and die simulations alone are not sufficient since it cannot accurately replicate the actual forming process and trying out dies on the production line is expensive. Spotting and tryout presses bridge this gap by simulating the actual production conditions of the press, die, material and lubrication, thereby saving time and cost on shutting down the production line for trials.

Electropneumatics’ Spotting and Tryout Presses can be used for die/mould inspection, adjustment and finishing, as well as limited batch/prototype production. These machines reduce start-up times of new dies and offer flexibility to vary draw force and speed, die heights, draw depths, etc. They are ergonomically designed for optimal access to the die. Automation options make proving of dies in small batches economical.

�F�e�a�t�u�r�e�sPress capacities up to 1000T

4-pillar and 4-column constructions with accurate slide guiding arrangement in JIS Grade I or special grades

0Upper 90 swing-out platen/slide for easy access to upper die half

Moving bolster/table to load dies and work on lower die half

Automatic and manual locking devices for operator safety while working on tool

Equaliser and micro-inching facility

High speed slide approach and return functions

Programmable slide speeds, positions and forces to simulate different production/process conditions

Slide parallelism control arrangement

Optional- die cushions, stroke limiters

Large bed sizes available

Electropneumatics’ SMART CNC/PLC control system and LCD touch screen user interface

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800T 4-Column Hydraulic Press with Cushion and Mechanical Knockouts

Hydraulic Die Spotting and Tryout Presses

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Electropneumatics' Hydraulic Metal Forming Presses can be used for a wide range of operations such as deep drawing, stamping, trimming, cold extrusion, coining, hemming, blanking, press fitting, riveting, etc.

Each press is designed to meet individual customer requirements of tonnages, sizes, strokes and speeds. They offer flexibility in process sequence.

We offer single presses with manual loading, automated presses or completely integrated automated press lines.

Our CNC hydraulic presses with proportional/ servo controls give the user a high-level of control over the forming process through on-line diagnostics and control monitoring features.

100T 4-Pillar Hydraulic Press for calibration of wheel rims

300T Anvil/Horn Press

3500T Ring Frame Press for forming, trimming and piercing stainless steel heat exchanger plates

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300T 4-Column Die Spotting and Tryout Press

500T 4-Column Upstroking Hot Moulding Press with heatedplatens for clutch facings

Special 25T APG/Epoxy Moulding Machine for resin castelectrical components

Electropneumatics’ Hydraulic Moulding Presses use the compression or transfer moulding technique. These hydraulic presses are designed to provide accurate control of force, speed and position as well as controlled parallelism of the slide through out the stroke, required for moulding. They have features and controls specially designed to properly execute forming, heating and cooling cycles and accurately level, form and eject parts to achieve Grade I component surfaces.

Typical parts produced on these machines are hoods, fenders, spoilers, vehicle interiors, brake linings, clutch facings, electrical switchgear, tank panels, etc.




Single station or multi-station presses in ring frame, pillar and column constructions

In up-stroking or down-stroking configurations

Large bed presses for moulding thermoset resins (SMC, DMC) and thermoplastic resins (LFT, GMT) into large, flat or moderately curved parts. Comparatively smaller bed, single or multi-station presses for moulding friction material small parts

Ability to dwell for a period of time under pressure and provide constant force over a large area

Thermo-symmetrical or adjustable 8-point slide bearing arrangement to accommodate for expansion/ contraction due to heating and cooling cycles

Multi-platen presses available for multi-part and/or large volume production

Electropneumatics’ SMARTCNC/PLC and user interface for total monitoring and programming of all process parameters- force, speed and position

Depending on the type of product being made

Intelligent slide parallelism and leveling arrangement

Insulators and water-cooled platens

Heater platens with heating controls

Central and side ejectors

Quick die change systems and loader/unloaders

Exhaust systems

400T 4-Pillar 3-Daylight Upstroking Hot Moulding Press with heated platens and loader/unloader for clutch facings

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HydraulicMetal Forming Presses

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150T 4-Column Hemming Press


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� �F�e�a�t�u�r�e�sPress capacities up to 15000T

Available as single, double or triple action presses in C-frame, H-frame, 4-pillar, ring frame, straight-sided, 4-column constructions

Various die cushion options like conventional, active, multi-point, etc., programmable to suit application

Powered by high-performance hydraulic systems

Provided with necessary safety features and on-line monitoring systems

Maximum force available over entire stroke, especially for cold extrusion, deep drawing, etc.

Electropneumatics' user-friendly PLC/CNC controls for process optimisation, sequence setting and advanced diagnostic capabilities

�O�p�t�i�o�n�a�l� �f�e�a�t�u�r�e�sCushions, ejectors, blank holder

Mechanical knockouts, shock absorbers


Coil feed lines, transfer systems

Loaders, unloaders, rotary/linear tables, etc.

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1200T 4-Column Hydraulic Press with Multi-Point ProgrammableCushion and Two Moving Bolsters for drawing SUV roof tops

7000T Special Ring Frame Hydraulic Press for forming stainless steel heat exchanger plates

1000T 4-Column Hydraulic Press with Feeding Arm for trimming and punching rail coach side panels

1500T Tube Hydroforming Press

1000T 4-Column Moulding Press for SMC/FRP components

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315T 4-Column Servo Mechanical Press with Hydraulic Cushion


63T Straight-Sided Servo Mechanical Press with Hydraulic Cushion




Available as single, double or triple action presses in ring frame or column tie rod constructions

Slide motion and power from AC servo motor powered multiple reduction gear train and link mechanism

Adjustable 8-point bearing arrangement for slides with wear-resistant liners

Slide adjustment

Hydraulic overload protection

Pneumatic slide counter-balance

Provided with necessary safety features and on-line monitoring systems

Electropneumatics’ advanced CNC controls and user interface for optimum process sequencing, monitoring and diagnostics

Cushions- conventional, multi-point, hydraulic, pneumatic, electric AC servo

Ejectors

Blank holder

Mechanical knockouts

Shock absorbers


Loading and unloading systems

Transfer systems

�A�d�v�a�n�t�a�g�e�sEnergy consumption less than conventional presses

Great flexibility for different forming processes through slide/cushion speed, stroke and motion sequence programming

Low noise levels. Blanking break-through noise can be reduced by controlling the slide motion

Smaller footprint, especially for large bed presses

Highly productive since motion sequences can be optimally tuned and also synchronised with automation devices

Superior part quality

Improved die life due to reduced vibration and impact

Suitable for all materials, especially high strength steel

Flexibility and energy saving is what defines Electropneumatics’ Servo Mechanical Presses.

Flexibility is derived by individually programming the slide/cushion speeds and motion sequences to adapt to various forming processes such as blanking, drawing, trimming, coining, etc. Energy saving is obtained by the machine’s ability to deliver tonnage when and where it is needed.

Servo Mechanical Presses are most suited for high-speed blanking, shallow forming, tryout, transfer and progressive die operations.

The combination of benefits of a conventional mechanical press and hydraulic press is a compelling reason to consider Servo Mechanical Presses for your next application.

forming presses index - electropneumatics presses.pdfforming presses pioneering forming ... pvt....

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