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spectrumMETAL FORMING

October 2012

The Magazine for the Metalworking Industry

Servo-presses

Energy-Saving Servo TechnologyHydroforming

Precise Repeatability

Press Line Simulation Parallels Processes

Fast Set-Upof Press Lines

C o n t e n t s s p e c t r u m M E T A L F O R M I N G 2 0 1 2

p Editorial

p Press simulation

4 Shortest Possible Set-Up Time for Press LinesPress Line Simulation (PLS)

6 Productivity Boost for Press LinesVolkswagen AG, Germany

p Press automation

8 Automation Made EasyAP&T AB, Sweden

p Servo-presses

10 Servo-electric Hydraulic PumpsLasco Umformtechnik GmbH, Germany

12 New Approaches in Metal Formingebu Burkhardt GmbH, Germany

14 Pioneering Drive ConceptAndritz Kaiser GmbH, Germany

p Retrofi t

16 Retrofi t Delivers New Maximum OutputAutomatic-Systeme Dreher GmbH, Germany

p Deep drawing presses

18 Optimally TestedS. Dunkes GmbH, Germany

p Forging presses

20 Hot RollsTMP, Russia

p Packaging machines

22 Safely PackagedSabatier S.A.S., France

p Strip leveling

24 Gentle, Fast, and SafeKohler Maschinenbau GmbH, Germany

p Hydroforming machines

26 Precise RepeatabilitySilfax, France

EditorSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 NurembergGermany

Drive Technologies DivisionCEO Ralf-Michael Franke

Editorial Responsibility in Accordance with the German Press LawBenjamin Schröder

Responsible for Technical ContentBernd Heuchemer

Editorial CommitteeElke Pilhöfer, Stephan Schäufele

Cover picture: Siemens AG / P. Körber

Publishing House

Publicis Publishing, P.O. box 32 40, 91050 ErlangenGermany

Tel.: +49 (0) 91 31 91 92-5 01

Fax: +49 (0) 91 31 91 92-5 94

[email protected]

Editorial staff: G. Stadlbauer, D. Pott

Layout: R. Degenkolbe, N. Wachter

Copy editors: S. Wanke, S. Zingelmann

DTP: M. Willms

Print: Druckerei Wünsch, NeumarktGermany

Circulation: 2.000

The following products are trademarks of Siemens AG:

ET 200, DRIVE-CLiQ, MICROMASTER, MP, MP377, S7-300, SCALANCE, SIMATIC, SIMATIC Multi Panel, SIMATIC NET, SIMATIC Panel PC, SIMATIC Safety Integrated, SIMOTICS, SIMOTION, SimoTrans, SINAMICS, SINUMERIK, SIPLUS, SITRANS, STEP, WinCC

If trademarks, technical solutions or similar are not included in this list, it does not imply they are not protected.

Job number: 002800/41994

Order-Nr.: E20001-A1740-P620-X-7600

The information provided in this magazine contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

© 2012 by Siemens Aktiengesellschaft

Munich and Berlin. All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

Printed in Germany

spectrum METAL FORMING 2012

Sinamics converters form the centerpiece of the cut-to-length line from Kohler

page 24

Three-piece metal cans are produced in record time with Simotion

page 22

Andritz Kaiser manufactures servo-presses with energy-saving drive concept

page 14

2 spectrum METAL FORMING 2012

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spectrum METAL FORMING 2012 3

“ Extensive portfolio with press expertise”

E d i t o r i a l

Metal-Forming Team

Speed, productivity, and fl exibility are the key requirements for machines in the metal-forming industry. Siemens offers an extensive portfolio of solutions for servo-presses that is gaining increasing recognition worldwide. It is only possible to achieve this success because we constantly adapt our products to current requirements. As a result, we have supplemented our range of motors at the upper and lower end, respectively, with the Simotics T-1FW4 heavy-duty torque motor – perfect for large machines with just under 30,000 Nm of torque – and the Simotics T-1FW3 heavy-duty torque motor with a shaft height of 200, designed for smaller machines. In terms of software, we have extended our intelligent path control with multipoint and oscillation functions.

There have also been a few changes with regard to energy management. We now offer the option of both kinetic and electrical storage. The key feature here is that the energy is kept in the system, resulting in a smaller connected load. We can also provide suggestions to help you optimize the design of your press. Against a background of increasingly scarce resources, energy effi ciency is rapidly gaining in importance. It is possible to operate hydraulic presses considerably more effi ciently with the help of Sinamics servo-pumps. The result is energy savings of up to 70 percent.

The Press Line Simulation software is an additional highlight in our already extensive portfolio. It is used for comprehensive programming, analysis, and simulation of multistage presses with the aim of exploiting their potential to the fullest. Combining the planning simulation tool with automation is the most important innovation we have introduced in this area. It has created a direct link between two previously separate areas – a world fi rst with countless advantages from which you can benefi t.

In order to make our extensive expertise completely available to you, each area is supervised by a designated specialist from our team. Regardless of the problem – the drafting of safety concepts, the hydraulics of a new press, or training courses for commissioning – we have the right contact with the right answers. See for yourself!

Your Metal-Forming Team


P r e s s s i m u l a t i o n

modularly designed model of the press line, PLS allows both the basic manufacturing process and all the process-relevant details to be defi ned on the PC, adapted to each other, optimized, and checked. It is also possible to compare and contrast alternative process strategies or motion sequences quickly and with very little effort, as well as to verify tools and fi xtures based on check calculations. As a result, a great deal of time is saved by simulation during press set-up. When using the conventional proce-dure, checking cannot begin until the relevant design phases are complete or the tools and fi xtures have already been constructed.

Accurate mapping of the press lineThe Press Line Simulation software from Siemens comprises a standard basic software program with the simulation algorithm and user interface as well as libraries containing basic models adapted to the specific line of all the simulation components required (press stations, drawing cushions, blank and orientation stations, material supply and stor-age, tooling components, and control and drive sys-tem). This means that set-up using PLS is suitable for very different press designs but provides the maxi-mum benefi t in servo-presses and press lines with electronic transfer.

To use PLS in a real press line, the existing model components are adapted so that they match the conditions of the real press line as accurately as pos-sible – particularly with regard to collision-relevant geometries and important programming parame-ters. The PLS software structure enables separate processing of each functional area of a press line, with the result that every PLS installation is equipped with the press-specific functions required in that

p Press Line Simulation (PLS)

Shortest Possible Set-Up Time for Press Lines

During press set-up – that is, the preparation, installation, and optimization of the press lines for a workpiece – it is necessary to

coordinate and synchronize a large number of tech-nological components, mechanical settings, and automation parameters while adhering to a chrono-logical sequence of work steps. Due to the highly complex nature of this process, it is almost always necessary to carry out several time-consuming cor-rection cycles on tools, transfer devices, and control parameters, and in the past this has made set-up both time-consuming and expensive.

Using simulation to save timeMapping the press line set-up in a simulation envi-ronment such as Press Line Simulation (PLS) reme-dies this problem. Based on a technically precise and

If the many independent process steps of a press line are simulated, it is

possible to optimize tools, material fl ows, and press movements on the PC.

The result is fast production start-up and high cycle rates.

P L S a t a g l a n c e

3 Method planning and material fl ow: Checking whether the sheet metal parts can pass through the press in the way planned

3 Determination of the stroke rate: Calculation of the maximum stroke rate for various scenarios of sheet metal part transport

3 Tool verifi cation: Simulation of driver and slide combinations, testing of tools for internal collisions

3 Final inspection and documentation: Checking for external collisions, issuing of certifi cates, communication with others involved in the process


particular case. Workpiece and tool data are imported from the CAD/CAM system in order to set up the line for a specifi c tool set. Then the production process is planned, verified, and optimized down to the last detail on the PC. The collision testing includes the installation space of the tool and possible collisions during sheet transport. In addition, a simplifi ed fi nite element method (FEM) process in the PLS calculates the dynamic deformation of the sheet metal accord-ing to the stroke rate. It is thus possible to achieve reliable, collision-free transport and precise position-ing of the metal sheets even at very high stroke rates.

Optimum combination of controller and PLSIt is particularly easy to reliably link the simulation with the real press lines if the press simulation includes not only the actual software used on the press’s hardware controllers but also enables direct data exchange with the press controller. This is the case with PLS for Simotion, the motion control sys-tem used in many press lines. Thus, it is possible to query the current motion curves of the plunger, transfer them from the Simotion controllers, and visualize them in the simulation. Electronic cams optimized and verifi ed in the simulation can be

infocontact

www.siemens.com/[email protected]

loaded directly into the controller for the individual drives of the press and the transfer, which not only saves time but also considerably reduces the proba-bility of transmission errors.

Saving time, reducing costs, and improving productivityWith PLS, press set-up becomes easier, faster, and safer, which speeds production start-up and reduces unproductive time. It is also possible to increase the productivity of the press line or at least utilize it bet-ter. What’s more, with PLS it becomes much easier to control additional manufacturing processes, such as the use of multicavity molds. Overall, the use of PLS leads to a signifi cant increase in production capacity and provides the fl exibility to respond to requests at short notice. For this reason, press line simulation is becoming increasingly essential in competitive mar-kets such as contract manufacturing and component supply industries. p

Reduce set-up time

Increase stroke rate

Improve fi xture construction

Install error-free tools

PLS offers many advantages such as the calculation of the dynamic deformation of sheet metal at high stroke rates, for example

Siem

ens

AG


P r e s s s i m u l a t i o n

Higher stroke rates, fl exible manufacturing, and quick

product changeovers – these are just some of the benefi ts

of implementing electronic transfer in the Volkswagen

press shop in Wolfsburg.p p g

p Volkswagen AG, Germany

Productivity Boost for Press Lines

The manufacture of body panels in the Volkswagen press shop involves frequent product and tool changeovers

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As part of a modernization of the press shop, Volkswagen Wolfsburg decided to retrofit three 15-year-old press lines.

Because of the increasing diffi culty of sourcing spare parts for the control technology, the project team decided to change the mechanical transfer in the lines to motion-controlled servodrives.

Retrofi t allows rapid resetting of the lines

Volkswagen modernized the press lines itself, but Siemens was involved at an early stage as a partner for the electrotechnical equipment. With regard to the hardware and software, Volkswagen was able to use internal standards that had been drawn up jointly with Siemens in the course of previous proj-ects. “For example, we are using fail-safe Simatic PLC and Simotion hardware controllers. On the software side we are using, among other things, a hydraulic controller developed by Siemens and Fraunhofer,” explains Mark Walz, Volkswagen proj-ect manager and responsible for press retrofi ts at the Wolfsburg press shop. The three press lines are being used to make various body panels, and this requires frequent changes of products and tools. It is therefore important for production planning to be able to reset the lines quickly when required. Also, the tools, settings, and motion profi les need to be interchangeable between the lines. This means that all three lines must be able to produce multiple parts.

Press line simulation maximizes potentialDespite the fact that the lines have different press-ing forces, Volkswagen has equipped all three with identical components – that is, equivalent feeds, drive controls, and motors. “The savings far out-weigh the extra costs of the individual compo-nents,” stresses Walz. The installation of the multi-axis electronic transfer system also enhances the possibilities for positioning the sheet metal. The performance of the planned transfer was checked in advance via simulation. To do this, the Press Line Simulation software produced a virtual model simu-lating all mechanical, electrical, and software com-ponents that are relevant for dynamic motion con-trol. “Without being able to test it in this way, you can’t really fully exploit the potential of a servo-driven transfer,” says Walz. Initial simulations then also confirmed that additional time would be required for reliable sheet metal transport at higher stroke rates. The time required to reduce the maxi-mum acceleration was gained by means of a phase displacement of the plunger. This meant that safe parts transfer was possible despite the higher stroke rates.

Increased productivity and high availabilityFor the fi rst time, the modifi ed press lines now have a direct data connection between the press line sim-ulation and the press line controllers. Thus, the pre-pared motion profi les can be transferred to the plant in a matter of seconds. Similarly, motion profi les that exist on the plant can be loaded into the simulation software, optimized, and transferred back to the controller. In this way the simulation not only reduces the set-up times for introducing new work-pieces but also makes for quicker resumption of pro-duction after tool changeovers. In the long term, the associated increase in productivity meant that the number of press lines could be reduced from 17 to 8. This offers considerable potential savings, but it also increases dependence upon the individual machines. Consequently, another important objec-tive of the retrofit was to achieve availability of at least 96 percent. The press lines are therefore monitored by the Siplus CMS condition monitoring system.

Another welcome outcome is the drastic reduction in energy consumption. Thanks to the DC link cou-pling of the Sinamics converter, the braking energy that is regularly produced during cyclical movements can be directly reused for acceleration processes. Moreover, high-maintenance uninterrupted power supplies can be eliminated completely. Because of the consistent DC link, the kinetic energy stored in the press is suffi cient to bring all the axes into a safe state in the event of a power outage and to run down all the control technology in an orderly man-ner.

Simple, cost-effective, and fl exibleEveryone involved was delighted by the greater sim-plicity of the automation system and has rated the project a huge success. The retrofit has made an important contribution toward standardizing machine automation in the press shop. In addition, maintenance is much simpler and more cost-effec-tive because of the standardized technology. Elec-tronic transfer also means that sheet metal transport is considerably more fl exible, and the sheets can now be positioned with greater accuracy as well. In view of the enormous boost to productivity in the press shop, the retrofi t has proved to be much more economical in the long term than buying new press lines with a comparable output. p

infocontact



P r e s s a u t o m a t i o n

Automation, Press and Tooling (AP&T) devel-ops, produces, and markets automation sys-tems, presses, tools, and complete produc-

tion lines for the metal-forming industry. One of AP&T’s core competencies is in the area of workfl ow automation. The company supplies complete solu-

By using standardized electrical equipment, AP&T, a Swedish

workfl ow automation specialist, has housed all the automation in

one control cabinet and as a result has greatly reduced costs.g y

tions and considers itself responsible for all subareas. AP&T has now succeeded in standardizing the auto-mation to such a degree that the required technol-ogy can be housed in just a single preassembled control cabinet. This is suffi cient to operate robots and other automation units.

Use of Simotion provides freedomChrister Bäckdahl, development manager at AP&T, reports, “We concentrated very early on consistent modularization while pursuing the strict standardiza-tion of these modules. Our automation has now been based on the Simotion motion control system since 2006. In particular, Simotion allows the stan-dardized modularity that we have established in the mechanical system to be transferred to the electro-technical equipment and ultimately to be mapped in the software as well.” Summing up, he says, “The use of Simotion has greatly reduced our engineering

costs.” Modularization and standardization also pro-vided AP&T with freedom to become involved in other aspects of the process. The Simotion motion control system is now considered to be a basic requirement for modularization and standardization – and therefore also for the development of com-

plete solutions in the area of workfl ow automation and the manufacture of customized control cabinet solutions.

Fast commissioning and high level of customer acceptanceTogether with Siemens Sweden, AP&T was able to automate all units using a single control cabinet vari-ant. For this purpose, the signal routings and desig-nations were standardized, confl ict-free identifi ers for addresses and variables assigned, the power requirement and the connection values matched for all appropriate machine modules, and fail-safe Simatic ET 200S modules confi gured for all safety equipment. Siemens System Engineering Plant Chemnitz optimized the control cabinet layout based on these specifi cations. In this case, both IEC- and UL-certifi ed variants were created, and both can be ordered in either the electrically cooled or water-

p AP&T AB, Sweden

Automation Made Easy

»End users particularly appreciate the

guaranteed high quality of the products

manufactured by Siemens.«Christer Bäckdahl, Development Manager, AP&T AB


infocontact


Consistent modularization permits the use of uniform, standardized control cabinets for the feeder, press, and stacker

cooled variant. The control cabinets are brought fully pretested from the warehouse shortly before starting commissioning and are connected to the machine via Profi net and the motor cables. The ser-vice technician then installs the standard software and sets the customer-specifi c machine parameters on the CPU – then commissioning can begin imme-diately. Bäckdahl observes, “The standardized con-trol cabinets not only result in reduced costs in terms of design engineering, installation, and commission-ing, but the lead time is now shorter too. We profi t from this on every single job.” The control cabinets are very compact, which is also benefi cial for trans-port and storage. The development manager sums up: “The compactness also contributes to a high level of acceptance by end users; they particularly appreciate the guaranteed high quality of the prod-ucts manufactured by Siemens.”

The modularization and standardization of the con-trol and drive technology provided by the control cabinets are also opening up new prospects. Now, depending on the production job, it is also possible to use recipe-controlled confi gurations with other stations to form press groups that process the cur-rent job over a specifi c period after the individual systems have been synchronized and coordinated with each other. When required by the next produc-tion job, the operator can activate another recipe and then use the press, including the feeder and stacker, as a stand-alone station or in a different line confi guration.

New quality for standardized control cabinetsOnce again, AP&T has proved its competence in this area thanks to modules and standards that are easy to understand and that can be used fl exibly. Stan-dardization of the electrical equipment for the mod-ular machines of the metal-forming specialist has resulted in a new level of quality in the control cabi-nets. In addition to easier and faster completion of customer jobs, they enable even more fl exible, recipe-controlled confi guration of machine modules for the construction of complete manufacturing lines. p

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S e r v o - p r e s s e s

Lasco Umformtechnik GmbH, a prestigious manufacturer of mass forming and sheet presswork equipment based in Germany, is

always focused on improving its processes and tech-nologies. One such technological milestone is the servo technology used in a recently delivered deep drawing press with a force of 800 tons for up to 40 strokes per minute. This offers huge benefi ts

from a technical point of view and also in terms of energy consumption. “Among other things, our new servo technology enables operators to achieve appreciable energy savings,” reports Harald Bar-nickel, head of Lasco’s electrical engineering department.

Servo technology delivers outstanding resultsServomotors that are fl ange-mounted directly onto the hydraulic pump form the heart of the solution. The power control of the drive is controlled by a Sinamics S120 frequency converter, while the

The press manufacturer Lasco uses an electric servo-pump

control for mass forming and the optimization of large

hydraulic presses, thus achieving energy savings as well as

improved dynamics.p y

Simotion D445 controller is responsible for the overall control of the axis path, speed, and position. “Initial operating data have indicated that this servo technology delivers outstanding results in many respects – with regard to both energy consumption and technology,” confi rms the electrical engineer. The deep drawing press is to be used to manufacture seat rails for motor vehicles in six consecutive sta-tions. For this, pressing force and stroke speed needed to be adapted to an individual movement profi le. The pressing force can be adjusted at the ser-vomotor by means of the torque. The plunger speed, however, is controlled via the motor speed and therefore via the fl ow rate of the pump. Thanks to this technique, valve technology savings of up to 40 percent are possible in the press.

Energy savings and system continuityThe use of servo technology also results in a signifi -cant improvement in the energy balance. “It was pre-viously necessary to use large cooling systems for the oil, but much smaller units can be used with the servo technology,” says Barnickel. The associated improvement in effi ciency, which the press manufac-turer considers to be well into double figures, is refl ected by massive savings in electricity costs com-pared to the older machines. An added advantage is that energy can be recovered during decompression of the hydraulic fl uid. “The opposite would be true of other concepts, where there would even be addi-tional heat losses,” explains Barnickel.

According to Barnickel, an additional plus point is the system consistency offered by the Siemens solu-tions. For example, the Simotics M-1PH8 servomo-tor, available as a synchronous or asynchronous motor, is automatically identifi ed by the frequency

» Among other things, our new

servo technology enables

operators to achieve

appreciable energy savings. «Harald Barnickel, Head of Electrical Engineering Department,

Lasco Umformtechnik GmbH

p Lasco Umformtechnik GmbH, Germany

Servo-electric Hydraulic Pumps


converter and its parameters are imported. The choice of motors depends upon the application, that is to say, the required dynamics. “Ultimately, this new drive concept for hydraulic presses, which is based on an electric servo-pump control, results in a signifi cant overall improvement,” says Barnickel. “In addition to the possible energy savings already mentioned, we also have a great advantage over straight valve controls thanks to the incredibly pre-cise controllability.”

Integrated safetyLasco chose the fail-safe Simatic S7-319 F 3PN/DP to control the entire plant. “It offers us the freedom to implement all the safety technology without a lot of additional expenditure,” explains Barnickel. The fail-safe signals are read via Simatic ET 200S distributed I/O stations and relayed to the control via Profi safe. It is an elegant overall solution, says Barnickel: “It enables us to achieve clear structures in the machine.” For example, there are normally two monitored valves that provide for the security of the press plunger during set-up. The new solution is now more

refi ned: the reduced speed (Safety Limited Speed: SLS) and, among other things, safe stop (Safe Stop 1: SS1) are monitored via the Sinamics S120 fail-safe frequency converter.

Convincing overall conceptThe development of the new servo technology for large hydraulic presses, as based on the Simotion motion controller at Lasco Umformtechnik GmbH, has already aroused a great deal of interest among users, even after such a short time. Thanks to the standard concept consisting of the Simotics M-1PH8 servomotor, Sinamics S120 frequency converter, and Simotion D445 motion control unit, there has been a signifi cant improvement in dynamics, precision, and energy consumption. “And all because we dared to opt for electric servo-pump control in the hydraulic press as opposed to valve technology,” declares Barnickel. p

infocontact


The electric servo-pump control in the Lasco press uses signifi cantly less energy than traditional valve controls

The drive unit for the pump control comprises a servomotor, a Sinamics S120 frequency converter, and a Simotion D445 motion controller

All photos: Lasco



force required during the punching process was available, the Bavarian company now uses a servo-electric drive and control unit for this purpose.

Creation of individual motion profi lesAt the metal-forming specialist’s premises in Bayreuth, this task is carried out in part by two

p ebu Burkhardt GmbH, Germany

New Approaches in Metal Forming

The core competence of ebu Burkhardt GmbH in Bayreuth, Germany, lies in the punching and metal-forming segment, with a focus on

the manufacture of automatic punching machines. The product is the same as always, but the technol-ogy has evolved over time. While in the past an appropriately large fl ywheel mass ensured that the

A servo-electric drive and control unit expands the possibilities of

cutting-edge automatic punching machines. The machine manufacturer

is delighted with the fl exibility gained as a result.

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The ebu Burkhardt servo press stands out

due to its servo-electric drive concept


infocontact


Simotics T-1FW4 heavy-duty torque motors, because with the help of this cutting-edge technology, the required energy can also be supplied by means of an electric fl ywheel mass. The mechanical fl ywheel mass is thus rendered obsolete. The major advantage is that the servo-electric drive solution makes it easy to transfer individual motion profi les to the plunger and thus to the tool. The use of servo technology will enable the company to pursue completely new possibilities in metal forming. Jörg Berger, managing director of ebu Burkhardt GmbH, explains the deci-sion in favor of servo technology: “Servo technology holds massive potential. It’s very fl exible in use. What’s more, it can be used to achieve superior parts quality.”

Intelligent temporary storage of electrical energyBerger continues, “Regardless of new technology, at the end of the day the energy balance must be right.” To ensure this, the excess electrical energy from the punching process is stored temporarily in other systems. This storage takes place with the help of the Sinamics S120 frequency converter, which determines the torque motor’s speed. Thanks to the integrated energy-regeneration capability of the water-cooled power sections, the unit is able to induce the recovered electricity from the braking processes into the DC link. The electricity is then

available again for the next punching process. There is also another option for storing excess energy. For this purpose, an additional asynchronous motor is brought up to speed in the automatic punching machine and thus serves as a kinetic energy accu-mulator. At the moment of punching, it acts as a generator and delivers the additionally required elec-tricity when needed.

Servo technology enables maximum fl exibilityAll processes are controlled by a Simotion 435D. But the motion control unit can handle more than just motion control. Because of its effi ciency, it also offers the option of controlling the whole machine – meaning that no additional controller is required. Berger sums up: “The servo-electric drive technology combined with Simotion allows us to get consider-ably closer to the technological limits than was pre-viously possible.”

The greatest advantage of the servo-electric drive technology, however, is the ability to adjust fl exibly to production processes and different workpieces. Berger reports, “We can map around 80 percent of the standard machines with this new solution.” The motion control unit can store different motion pro-fi les, which the servodrive then transfers to the workpiece. Berger says, “No one yet has a curve changeover of this type that boasts such speed.” These variable motion profi les also make incremen-tal metal-forming processes possible, which, in turn, allow not only the achievement of superior parts quality but also the realization of process improve-ments.

Leading position thanks to system partnerAccording to Berger, “We have gained this techno-logical advantage in tandem with our system part-ner Siemens.” The servo technology described was developed and brought to market readiness thanks to the additional support provided during confi gura-tion, design, and commissioning. The machine man-ufacturer focuses specifi cally on integration, follow-ing the Totally Integrated Automation model offered by Siemens. Berger stresses, “We benefit hugely from the fact that our system partner has a large number of tried-and-tested solutions in its portfolio that are all coordinated with each other. Due to this ongoing close collaboration, we also know at an early stage what innovations we can expect in the fi eld of open-loop, closed-loop, and switching tech-nology. This helps us meet our goal of building innovative machines.” Berger comments happily, “After all, we want to become a technological leader – and with the new servo technology we are doing just that.” p

» Due to this ongoing

close collaboration

with Siemens, we

know at an early

stage what inno va-

tions we can expect in the fi eld

of open-loop, closed-loop, and

switching technology. This helps

us meet our goal of building

innovative machines.«

Jörg Berger, Managing Director, ebu Burkhardt GmbH



Over the last 20 years, the drag link system patented by Andritz Kaiser GmbH from Bretten, Germany, has stood the test of

time in over 300 stamping and forming presses under harsh operating conditions. The “intelligent gear unit,” as managing director Stefan Kaiser refers to the drag link drive, features a variable transmis-sion ratio and force paths within the operating range that are almost twice as large as those in eccentric presses. Using the servodrive means that the plunger motion also becomes programmable by the user. The press is therefore highly fl exible and

p Andritz Kaiser GmbH, Germany

Pioneering Drive Concept

Andritz Kaiser has been able to signifi cantly increase the

productivity and energy effi ciency of its stamping and forming

presses by combining the time-tested drag link system with an

innovative servodrive concept.p

can be adapted easily to different tasks or materials. For many parts, optimized motion control increases output by up to 80 percent compared to eccentric presses.

Lower consumption thanks to energy-effi cient drivesAs the basic motion of a drag link drive approximates very closely the motion profi le of a servo-press, it is usually possible to signifi cantly reduce the number of drive motors required compared to a purely eccentric press, thereby considerably decreasing

Among other things, Hako Automotive produces challenging deep-drawn parts for the automotive industry on this KSTU 8000, an 800 t press by Andritz Kaiser

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energy consumption. Heavy-duty water-cooled com-plete torque motors of the Simotics T-1FW3 series were used in all the servo-presses. Mounted cen-trally above the press, one or several of these torque motors drive the drag link system and therefore the plunger via an internal gear. The drive system is completed by an energy accumulator, optionally in the form of capacitor modules or an additional com-pact asynchronous motor of the Simotics M-1PH8 series. This temporarily stores the regenerative energy produced during braking and releases it again to cover peaks in demand during acceleration processes.

Targeted motion control with Simotion The drag link servo-presses by Andritz Kaiser are controlled by the Simotion D445 motion control sys-tem in the modular mounting technology of the Sinamics S120 drive system. An optimized plunger travel profi le is generated automatically using the “curve generator” tool specially developed for use with Simotion in servo-presses. The press manufac-turer has fl exibly integrated the tool into its operator interface under Simatic WinCC and created a simple operating screen for a Simatic Multi-Panel MP377. The installation of new tools is made easier with a handheld controller. Thanks to servodrive technol-ogy, the handheld device can also be used to arrive

precisely at the required plunger position and to incorporate it into the program. The Multi-Point function is another new addition, enabling data points to be programmed at any point in the plung-er’s travel. The forming motion can be reduced at such data points – for example, to cut threads or to introduce inserts. Wolfgang Wiedenmann, deputy sales manager at Andritz Kaiser, predicts that “hybrid processes such as this will be required more and more in the future.” The press manufacturer has also extended the tried-and-tested curve generator by an input fi eld for feed length or transfer time. The oper-

The Simotion curve generator automatically calculates an optimized plunger motion and determines the exact feed length or transfer time

infocontact


»Processes are becoming increasingly

complex, and therefore even semi-

skilled operators must still be able to

manage the press easily and safely.

It is possible to ensure this by using

the Simotion curve generator.«Wolfgang Wiedenmann, Deputy Sales Manager, Andritz Kaiser GmbH

ator can therefore see at a glance the feed length or transfer time generated by his or her entries. It is then easy to make a comparison with the transfer controller. This shows whether the machine can travel the motion profile selected. Wiedenmann says, “Processes are becoming increasingly complex, and therefore even semiskilled operators must still be able to manage the press easily and safely.” He adds, “It is possible to ensure this by using the Simotion curve generator.” In order to guarantee the neces-sary safety, the management at Andritz Kaiser decided on a Simatic S7-300F with fail-safe S7-317F-2 DP CPU. An additional library with press safety modules is also included in the dedicated Distributed Safety option package. The curve generator is an integral part of the press controller.

Increase in productivity and product qualityOne of the fi rst users of the latest generation of servo-presses by Andritz Kaiser is Hako Automotive, a division of Ferdinand von Hagen Söhne & Koch GmbH & Co. KG. The stamping facility located in Wuppertal produces complex structural and assem-bly components for leading car manufacturers on a KSTU 8000 drag link servo-press with a press force of 800 t, a 400 mm stroke, and automatic stroke adjustment. The diversity of the stamped and formed parts requires a particularly flexible machine.

Stefan Kaiser sums up, “The experience and results gained with and from Hako Automotive and other users were thoroughly convincing. Our expectations with regard to productivity, product quality, and energy efficiency were greatly exceeded. The user-friendliness is excellent as usual, and machine handling is still easy.” p


R e t r o f i t

A fast loader, user-programmable transfer systems, and shuttles

form the basis of a completely reautomated press line for automotive

structural components. The advantages are higher output, greater

fl exibility, and an assured long-term supply of spare parts.y g pp y p p

p Automatic-Systeme Dreher GmbH, Germany

Retrofi t Delivers New Maximum Output

The press line modernized by Dreher Automation and Siemens delivers around 30 percent higher output

Dre

her

Gm

bH


The electrical equipment of the established six-stage press line for automotive struc-tural components at Audi AG in Neckarsulm,

Germany, was showing its age. Total Productive Maintenance (TPM) measures increased and it became diffi cult to procure the necessary spare parts. As a result, the company decided on an extensive retrofi t of its press shop in Neckarsulm. In the course of this retrofi t, the rigid mechanical coupling of the transfer devices to the plunger motion was replaced with an up-to-date solution.

Increasing the stroke rate as top priority

The retrofi t was carried out by Automatic-Systeme Dreher GmbH, based in Sulz-Renfrizhausen. Dreher replaced the old mechanical automation system with an integrated electronic solution, while Siemens upgraded the controllers and the operator control and monitoring systems of the six presses. According to managing partner Klaudijo Dreher,

“As a Siemens Automation Solution Partner, we have already proved in several joint projects that we can also complete complex tasks such as these on schedule.” The operator’s specifi c requirements included increasing the stroke rate from 12 to 16 per minute, or, in other words, increasing out-put by more than 30 percent. Up to that point, the stroke rate had been limited by the rigid sequences determined by mechanical cams and vertical shafts. Dreher has now replaced the mechanical automa-tion with six electronic transfer systems in the presses, fi ve so-called shuttles, and a turning device between the presses. A new highly dynamic blank destacker was also designed jointly with Audi.

Freely positionable and user-programmable

Dreher’s electronic transfer systems consist of two identically constructed units for each end of the press. This means that the blanks can be freely posi-tioned in all three axes – irrespective of the plunger motion. Now the traverse paths of the shuttles can also be programmed by the user independently of the plunger motion. It is possible to configure the motion sequence of the transfer systems and shuttles with a high level of fl exibility now that they have been decoupled mechanically. Waiting times are minimized, and the desired increase in productivity is achieved. The intermediate conveyor designed as a turning device can be used in any position, enabling even more fl exible processes. All connec-tions were designed to be plug-in, so that the trans-fer units can be replaced. This was also one reason for using Simotics S-1FK7 servomotors in the highly dynamic version with Drive-Cliq, and for moving all ports to the outside. Four state-of-the-art motors with a further reduced moment of inertia were installed on the blank stacker.

Complex motion control with SimotionDrive-based Simotion D445 motion controllers, one for each of the blank stackers and for each transfer system, ensure fast motion sequences that are nev-ertheless gentle on the mechanics. As the master, the Simotion assembly specifi es the guide value for all the other presses via the Drive-Cliq digital system bus integrated into the system, and for this purpose it is linked to a virtual master axis in the Simotion system. The actual press controllers are subordinate to the motion controllers as slaves on the Profi bus and in turn are synchronized with each other via Profi net in synchronous operation. All movements are user-programmable and can be modifi ed at the touch of a button. Dreher has achieved this by using the pre-fabricated modules of the standard SimoTrans for Simotion application. STO (Safe Torque Off) and SLS (Safely Limited Speed) are used as safety functions. The press safety modules of the Simatic S7-F/P library were also used to create the safety program. These are easily integrated into the distributed safety- programming environment in Step 7.

Availability and effi ciency assuredUse of Siemens state-of-the-art control and drive technology means that the age-related malfunctions and downtimes no longer present a problem, and this in turn has permanently increased both the availability and the output of the press lines. Thanks to the retrofi t, it is now possible to create more fl ex-ible motion sequences. The line’s overall energy con-sumption has also dropped signifi cantly due to the energy regeneration capability and energy effi ciency of the cutting-edge drives. In conjunction with the higher productivity, the result is a further reduction in the energy cost per item. p

infocontact


A u t o m a t i c - S y s t e m e D r e h e r G m b H

Automatic-Systeme Dreher GmbH is a leading global manufacturer of automation equipment for sheet metal and mass forming. The company has played a leading role in the development of press automation for the past 40 years. As a Siemens Solution Partner, Dreher analyzes requirements in dialogue with its customers and identifi es appropriate solutions.

Established: 1970Company headquarters: Obere Talstraße 1–5

72172 Sulz/Renfrizhausen, GermanyTel.: +49 (0) 74 54 / 88 10Fax: +49 (0) 74 54 / 88 111


D e e p d r a w i n g p r e s s e s

The variety of models produced by the auto-motive industry is continually increasing, while production cycles become shorter and

shorter. In order to keep pace, new tools must con-stantly be developed. For more than 50 years, S. Dunkes GmbH from Kirchheim unter Teck in Ger-many, has been making machines and systems asso-ciated with forming and connection technology. The company has now made a hydraulic tryout

press for an auto parts supplier – it features a maxi-mum force of 5,000 kN and is used for toolmaking.

Precise coordination of all production parametersThis HDZ 500 frame deep drawing press is used in toolmaking to try out stepped tools, transfer tools, and progressive dies. The press is also used to press out the fi rst lot sizes and to develop components ready for series production. In order to meet strin-gent requirements for precision, the press is

S. Dunkes has developed a frame deep drawing press that

can be used in the auto parts industry to comprehensively

try out tools for subsequent usability.y q y

adjusted with an extremely high guidance ratio by means of an active parallel control for the plunger. The sensor technology of the highly dynamic control picks up the initial tilt that occurs particularly during tool contact, and the servo-valves integrated into the control circuit regulate this within milliseconds. The high variability of the closing and pressing speed allows the subsequent usability of the tools on mechanical presses to be comprehensively

tested. In order to be able to precisely coordinate the required production parameters, the press was also fi tted with a sensitive joystick control. This extensive equipment enables the required multifunctional and wide-ranging application of the press.

Panel PC facilitates clear data handlingDunkes presses are generally known for their userfriend-liness. For automation, the company relies on Siemens products due to the positive experiences to date. The tryout press uses a Simatic Panel PC 677 Touch

p S. Dunkes GmbH, Germany

Optimally Tested

Control elementsDisplaysInterface

General functions

Hydraulics

Profinet Profibus

Simatic PanelPC 677 Touch Simatic

CPU 319FSiemensMicromaster 440

Simatic ET 200S HF

Simatic NetScalance X-000

T r y o u t p r o c e s s

In the tryout process, the tool stages are tested individually and in succession until both the quality and the cycle time (output) are satisfactory. A prerequisite for this is the precise input of nominal physical values such as pressure (force), distance, speed, and time. All parameters must be regulated.


in conjunction with the Simatic S7-319F CPU safety control. With this confi guration it is possible to operate the press in combination with the chosen HMI soft-ware; it also affords transparent programming, navi-gation, and storage and transfer of process and tool data. In this way Dunkes can easily manage parame-ter confi guration for the press. Moreover, the highly effi cient programmable logic controller (PLC) also offers the high performance required even for such a powerful press. The central component of the distributed I/O devices is the Simatic ET 200S HF – a multifunctional, modular distributed I/O system that can be adapted specifically to the automation task at hand. In this case it regulates not only the control elements, displays, and interfaces but also the hydraulics and other general functions. Commu-nication between the control and the operator unit takes place via Profi net, and the connection to the I/O devices is via Industrial Ethernet.

Users benefi t from high parts qualityThanks to the sound basic concept and the expan-sion potential for Dunkes tryout presses, manufac-turers can try out their various tools at high speeds and, if necessary, rework them before delivery. Previ-ously, tools were tried out on presses with only one station; individual stepped tools therefore had to be

mechanically tested and were only brought together in the production press. This not only resulted in long tryout times but also frequently led to delays in the production process. The benefi ts of the new pro-cess, by contrast, soon became apparent: Not only is the running-in period required for a new tool much shorter, but users benefi t from higher parts quality right from the start. With the Siemens technology it is also possible to control the process parameters.

Ideal collaborationThe new solution was implemented in close collabo-ration between Dunkes and the designated Siemens consultants. In this way, any questions that arose could be discussed in advance and the solution thereby optimized. Both Dunkes and the auto parts supplier were extremely pleased with the complete plant that was delivered. The press manufacturer is therefore eager to continue its collaboration with Siemens in the future. p

infocontact


With its extensive equipment, the Dunkes 5,000 kN tryout press offers a multifunctional range of application

S. D

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F o r g i n g p r e s s e s

p TMP, Russia

Hot RollsThe Russian company TMP successfully managed to increase the

throughput of hot mills by increasing the degree of the production

process automation. Programmed control systems and robotic

handlers helped them to achieve this aim.p

» The qualifi ed professionals at Siemens

helped us select and confi gure the control

system and debug the real-time programs

on time and within budget.«Igor Valikov, Leading designer JSC TMP


TMP, based in the ancient city of Voronezh, Russia, is the largest developer and builder of equipment for the country’s metal forging

industries. In terms of world presence, of the 17 hot forging presses with pressure greater than 10,000 t in current operation across the globe, 8 were built by TMP. Because of the tough market conditions that the world’s machine tool builders are faced with, companies try especially hard to secure busi-ness in their own domestic markets. This is particu-larly so in the BRICs (Brazil, Russia, India, and China). Against this diffi cult backdrop, the Russian machine builder TMP was awarded a contract to build an innovative new hot steel rolling project in Brazil. The main task of this project was building a hot roll-ing press system, called Rollers. The Rollers produce one of the suspension details of trucks and consist of the hot rolling press with special manipulator, the system of transport of hot billet and other techno-logical equipment. For this mill, TMP developed an intelligent automated handling system, called Roll-ers, to manipulate the hot working material.

Automating complex proceduresThe technological algorithm of rollers is divided into several parts. First, the general receiving manipulator transfers a red-hot billet to the feed conveyer by an exactly defi ned path calculated according to the safety standards. The feed conveyer transfers the billet to the roller manipulator, which grips the billet and begins the multiple rolling process. Each roll has four deep grooves. A billet is rolled through couple rolls which are formed in the shape of a billet. Usually after four forming cycles, the roll manipulator transfers the billet to the outfeed conveyor, which in turn transfers the billet on to the next manufacturing stage. The control system within rollers performs a variety of important tasks. In addition to the precision movement of the working material, it controls system temperatures, the hydroelectric equipment, and braking control. The PLC also coordinates the functioning of the roll-ers with other systems such as the furnace and other handlers, with communication passing via Profi bus.

Drive-based motion control platformThe intelligent control driving the rollers is based on Simotion D435, a compact drive-based motion con-trol platform combining motion control, logic con-trol, and drive control within a single hardware environment. Simotion is the natural successor to earlier PLC approaches based on the S7-300 plat-

form. Its greater power enables a larger volume of programs to be run simultaneously. For the main drive, Sinamics S120 was chosen. Sinamics S120 is a modular motion control drive system for complex tasks. It carries out the complex motion control of two axes of the roller manipulator, with each axis being equipped with 5 kW Simotics S-1FT6 motors. The distributed I/O system is an ET 200M station, connected to the Simotion D435 via Profi bus. The control provides the operators with system informa-tion such as the drive operating hours, number of cycles, axis drive currents, and fault reports. For the Rollers project the programs are written using Simotion Scout, the network topology is performed in NetPro, and the HMI is provided via WinCC Flexi-ble. These different systems all integrate seamlessly with the hardware platform. The open system inte-gration enabled the TMP engineers to clearly specify and implement scalable solutions for complex tech-nological tasks.

Variable behaviorThe main challenge in developing the rollers was the two-axis motion control of the roller manipulator. When a hot billet is rolled, its shape changes dramat-ically, with each billet behaving in a slightly different manner. Because of this variance, the precise posi-tion of the billet as it exits from the rollers cannot be predicted by mathematical modeling. In order to achieve accurate control of the handling, a motion control system with on-the-fl y switching of control algorithms for each axis was developed. The main principle of the algorithm is the capability to switch from master to slave mode on-the-fly. With the sophisticated control system implemented by TMP, the roller achieved a throughput of 130 billets per hour. This Rollers project was TMP’s first motion automation project using Simotion controls and Sinamics drives. Despite their relative lack of experi-ence with this environment, the TMP engineers were successful in accomplishing an ambitious project that included the fast switching algorithms for the roller manipulator. The experience gained opens up opportunities for TMP in the development of further complex integrated machines. p

infocontact


Siem

ens

AG


For more than 40 years, the French company Sabatier, a member of the Swiss Soudronic Group, has been developing and producing

machines for the manufacture of three-piece metal cans in Vitrolles (Bouches-du-Rhône), France. The metal cans – consisting of base, body, and lid – are used mainly for industrial products such as oils, sol-vents, lacquers, and paints.

Electrical axes revolutionize production processesThe ability to produce metal cans of this type requires the use of a large number of axes. Motion control is therefore a key factor for a machine pro-ducer like Sabatier. Due to the diversity of the con-tainers, some of Sabatier’s machines have up to 60 numerically controlled axes. Although this guaran-tees great fl exibility, it also means that motion con-trol becomes a signifi cant challenge. Originally, hydraulic actuators were used at Sabatier for form-ing the container body and for seaming. However, this required as many machines as there were opera-tions – at that time the production line alone was around 60 meters long. Then 15 years ago, Sabatier started a small revolution with its decision to drive all the axes electrically. The improvements in the production sequence were noticeable immediately: from then on, a single machine could manage the different production stages on a line only 12 meters long. Nevertheless, it was still necessary to fi nd a

p Sabatier S.A.S., France

Safely Packaged

Sabatier, manufacturer of machines

for metal packaging, uses the

Simotion D motion control system for

the axis control of a production

machine that was fi rst launched at

Metpack last year. The machine was

equipped with 27 axes in record time.q pp

P a c k a g i n g m a c h i n e s

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M.

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permanent solution for the axis control, because only in this way would it also be possible to achieve the required improvements in machine safety. As a result, Sabatier completely redefi ned its strategy for control of the electrical axes.

Centralized control intelligence thanks to Simotion DTo begin with, the architecture of the Simotion D motion control system and the Sinamics S120 invert-ers enabled the machine producer to centralize the program. Daniel Levert, automation engineer at Sabatier, explains, “At fi rst each inverter connected to the direct current bus had its own control pro-gram, which meant that multiple programs had to be managed using an equal number of modules. Now, with Simotion D, we only need a single one.” This has meant a signifi cant reduction in develop-ment time and has also made it possible to design the machine so that maintenance is considerably more consistent, particularly when it comes to replacing the inverters. “In this case, it’s no longer necessary to reload the program. Replacement itself is suffi cient to restart the machine,” says Levert.

Improved safety and shorter downtimesThanks to this fundamental restructuring of the automation systems, Sabatier also had the opportu-nity to replace signal transmission via cable with an AS-i bus solution. In this case, 15 door-monitoring sensors are linked to a single bus, and the AS-i mas-ter integrates a Profi safe transition for the connec-tion to Simotion D. Levert adds, “This solution matches our linear backup process precisely. The additional material costs have already paid for them-selves due to the time saved on installation and the useful functions for operation and maintenance. Another positive effect we have noticed is the reduc-tion in downtimes.” The continuous connection from safety sensor to motor controller means that it is also possible to use the SLS (Safely Limited Speed) safety function via Simotion D. Levert stresses, “Access to Safely Limited Speed via a dead man’s switch when a door is open radically alters the possi-bilities for control and maintenance.” Not only that, but the system also notes the address of the opened doors. As a result, the machine stops completely

when a further safety protection circuit is inter-rupted. Thus the controllers also inherently offer the STO (Safe Torque Off) safety function.

Signifi cant productivity increaseBy choosing Simotion, Sabatier considerably improved the ergonomics of its machines and their functionality, with the end objective of a signifi cant productivity increase. Levert confi rms, “There are lots of advantages.” The Sinamics S120 inverters, for example, radiate appreciably less heat, which means there is no longer any need for air-conditioning of the control cabinet. They are also able to feed back electricity into the direct current bus or even into the mains supply. According to Levert, “This leads to a reduction in power consumption in the order of 10 to 20 percent.” Brake resistors become superfl uous due to the feedback of the current. Last but not least, Simotion D guarantees smooth start-up of the machine during pilot control of the motion. Levert sums up: “The result is signifi cantly less wastage during commissioning.” p

Top: The machines of the Bodypack series produce cans or drums with a capacity ranging from 1 to 200 litersBottom: One of the servomotor axes that is supplied directly via Sinamics S120

infocontact



S t r i p l e v e l i n g

p Kohler Maschinenbau GmbH, Germany

Gentle, Fast, and Safe

Modular Sinamics converters with

integrated safety functions form the

centerpiece of a new cut-to-length line

for surface-sensitive thin sheet metals

produced by Kohler.p y

Thin sheet metals with coated and sensitive surfaces are considered to be particularly demanding during the coil-to-plate process,

as they are very susceptible to damage and there-fore must be handled gently. Kohler Maschinenbau GmbH in Friesenheim, Germany, specializes in the production of machines that can guarantee this pro-tection. The company, which is based in the Black Forest, recently completed a custom-designed cut-to-length line for a leading German manufacturer of surface-treated aluminum and copper strip metals.

Keeping the line structureUsing this line, it is possible to process sheet metals at throughput speeds of up to 80 m/min. The exist-ing intermediate layer is initially leveled and coiled in the process, so that a fi lm with good adhesion can be reapplied as required to protect the sensitive sur-faces. This can either be left on the sheet metal or removed again prior to the cutting process. Tobias Frank, project manager at Kohler, explains, “The new machine also offers a highly dynamic stacking sta-tion. Palleted stacks of plates come out ready for transport at the end of the process – virtually at the

Thin metal sheets with highly sensitive surfaces must be handled gently


touch of a button.” The entire plant is controlled using a fail-safe Simatic S7-CPU 416F. The modular drive assemblies of the various plant sections and the other units are linked to the controller via Profinet. For this Kohler relies throughout on the Sinamics S120 drive system, thus following the line structure. As a result, the plant sections can be con-structed independently of each other, commissioned, and then quickly linked together. The Simatic S7 F-CPU also coordinates the combination of 46 fre-quency-controlled axes and more than 40 auxiliary axes. In addition, it reliably monitors the whole plant’s functional safety.

Safety functions ease pressure on the controllerSafety functions within the drive itself ease pressure on the controller. Frank explains, “At Kohler we use the Safe Torque Off, Safely Limited Speed, and Safe Operating Stop safety functions. With this project, however, we also used the Safe Direction safety func-tion for the fi rst time.” It is hereby possible to safely monitor the direction of motion in combination with Safely Limited Speed. According to Frank, “Using this new function means that we can ensure that the drive rolls inside the system always rotate toward the operator.” This prevents accidents because no one can be accidentally drawn in between the rolls. “Reliable monitoring of the direction of rotation also enables the drive rolls to be cleaned safely. And thanks to these safety functions within the drive, we eliminate not only the need for additional safety hardware but also any wiring requirements,” says Frank, summing up the advantages.

Precise and inexpensive processesThose in charge also save themselves a great deal of effort when assigning parameters by using the Drive-Cliq digital system bus, which links a drive assembly to the relevant control units. It also links virtually all the motors of the Simotics models M-1PH7 and S-1FK7/1FT7 used throughout. The electronic nameplate is read out automatically, rendering time-consuming and often error-prone manual parameterization unnecessary. The highly dynamic Simotics servomotors ensure high stacking speeds in the stacking system at the end of the 45 m long line. Frank says, “The lifting tables here, which are often operated hydraulically in other companies, are moved via servomotors and rigid chains.” He adds, “This process is fast, precise, and leak-free, so it meets our requirements perfectly. Overall, I have to say that we are absolutely delighted with the col-

laboration with Siemens. Complex projects such as this require perfect coordination between all those involved. Everything has run perfectly smoothly in our case – from advice in the run-up through to commissioning and beyond.”

Energy effi ciency gaining importanceLast but not least, energy effi ciency in cut-to-length lines is gaining increasing importance. Frank explains, “So that we can work as energy effi ciently as possi-ble, we operate the frequency converters of our sys-tems via a common DC link and feed the energy gen-erated during deceleration back into the supply net-work afterward.” This means that the energy can be reused, whereas with units supplied individually the energy would need to be reduced via braking resis-tors and would inevitably be lost as a result. p

infocontact


» Complex projects such as this

require perfect coordination

between all those involved.

This collaboration has always

functioned perfectly with Siemens

– from advice in the run-up to

commissioning and beyond. «Tobias Frank, Project Manager, Kohler Maschinenbau GmbH

Phot

os:

Wilh

elm

Med

ia


The French company Silfax specializes in tube-bending machines. These machines are used to produce bent metal tubes with thin walls.

Jean-Paul Bruyas, one of the founders and the com-pany’s CEO, stresses, “As a specialist company for tube-bending machines, we always strive to fulfi ll our customers’ wishes. To do this we have devel-oped machines that are specifi cally adapted to cer-tain markets.”

Manual intervention is unnecessary thanks to new technologyThe Silfax machines enable a wide variety of forming and bending applications for metal tubes. According to Bruyas, “The aerospace and automotive industries are two segments where we are particularly well

p Silfax, France

Precise RepeatabilityThanks to its precision and repeat accuracy, the

Sinumerik 840D sl CNC has enabled tube-bending

machine manufacturer Silfax to hydroform tubes

for exhaust gas recirculation.g

represented. And with our range, which consists of bending and forming machines plus hydroforming machines, we can satisfy the requirements of both of these industries to a high level.” For the aerospace industry, for example, the Silfax machines are used to bend titanium tubes for the Airbus A380. Silfax’s CEO explains, “When it comes to bending tubes for the automotive industry, it is virtually impossible for any of the relevant industry representatives to avoid us.” The company’s success began in the automotive industry in 1998. Back then, Silfax developed the fi rst completely electric production machine for vehi-cle exhaust pipes. In the case of tube-bending machine SE 76, the hydraulics gave way to electrical motorization of the power axes, which resulted in better repeat accuracy of the procedures, substantial

Inserting the tubes that are to undergo the hydroforming process

H y d r o f o r m i n g m a c h i n e s

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energy savings, and a 30 percent productivity increase. Bruyas explains, “As a result, all the previ-ous problems that we were used to from using hydraulic machines became a thing of the past. There were no longer any heating times, and it was not necessary to make adjustments between the operating times. Instead, the settings were perma-nently fi xed. This was a fantastic innovation for us and made any manual intervention completely unnecessary. It also brought noticeable advantages for the user – from material savings to increased eliability in production.”

Sinumerik enables hydroforming in the automotive industryThis innovation enabled Silfax to conquer the crucial automotive market completely. Bruyas says, “Silfax’s technology is also suitable for what is known as hydroforming, which is used to manufacture bel-lows.” Bellows are stainless steel tubes with thin walls that can withstand thermal expansions in high-temperature ranges and are therefore used in the exhaust gas recirculation systems of motor vehicles. This is an environmental protection device with which a proportion of the exhaust gases from inter-nal combustion engines can be recirculated to the intake manifold. The “bellows” enable the tube to expand in high-temperature environments without fracturing at some point.

“Using the Sinumerik 840D sl guarantees the preci-sion and repeat accuracy of the hydroforming pro-cess. Of course, choosing the right controller played

a very important role,” emphasizes Bruyas. The Sinumerik 840D sl can manage up to 93 axes with its Sinamics S120 converters. The open, distributed, scalable, and network-capable system has its own Simatic S7-300 PLC and a distributed Simatic ET 200S peripheral system. Bruyas says, “The low-voltage devices that are used in this case also come from Siemens.” He lists the advantages of this solution: “In view of the large number of axes and the com-plexity of the axis system in Silfax machines, this controller offers us the necessary fl exibility and also the axis interpolation function that is essential for saving time and achieving precision during the vari-ous movements.” The folding process is carried out on the Silfax SHD4 machine. The complete cycle takes only 14 seconds. Bruyas says enthusiastically, “The speed of the process is impressive. With our machines it is possible to produce up to 40 succes-sive folds in one single process step, while with other processes this fi gure is only around 10. This means that not only is our process faster and more reliable but at the same time it is also distinguished by greater repeat accuracy. And all this is because the movements conventionally carried out using hydraulics have been replaced by NC axes, which are operated in turn by a CNC controller.” p

infocontact


» In view of the large number of axes and

the complexity of our machines, the

Sinumerik 840D sl offers us the necessary

fl exibility and also the axis interpolation

function that is essential for saving time and

achieving precision during the various

movements. «Jean-Paul Bruyas, Technical Director, Silfax

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