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<strong>spectrum</strong><br />

October 2012<br />

METAL FORMING<br />

The Magazine for the Metalworking Industry<br />

Press Line Simulation Parallels Processes<br />

Fast Set-Up<br />

of Press Lines<br />

Servo-presses<br />

Energy-Saving<br />

Servo Technology<br />

Hydroforming<br />

Precise<br />

Repeatability


Contents <strong>spectrum</strong> METAL FORMING 2012<br />

page 14<br />

page 22<br />

page 24<br />

Wilhelm Media Sabatier / M. Laurent<br />

Andritz Metals, Bretten<br />

Andritz Kaiser manufactures<br />

servo-presses with energysaving<br />

drive concept<br />

Three-piece metal cans are<br />

produced in record time with<br />

Simotion<br />

Sinamics converters form<br />

the centerpiece of the<br />

cut-to-length line from Kohler<br />

<strong>spectrum</strong> METAL FORMING 2012<br />

Editor<br />

Siemens Aktiengesellschaft,<br />

Gleiwitzer Str. 555, 90475 Nuremberg<br />

Germany<br />

Drive Technologies Division<br />

CEO Ralf-Michael Franke<br />

Editorial Responsibility in Accordance<br />

with the German Press Law<br />

Benjamin Schröder<br />

Responsible for Technical Content<br />

Bernd Heuchemer<br />

Editorial Committee<br />

Elke Pilhöfer, Stephan Schäufele<br />

Cover picture: Siemens AG / P. Körber<br />

2 <strong>spectrum</strong> METAL FORMING 2012<br />

p Editorial<br />

p Press simulation<br />

4 Shortest Possible Set-Up Time<br />

for Press Lines<br />

Press Line Simulation (PLS)<br />

6 Productivity Boost for<br />

Press Lines<br />

Volkswagen AG, Germany<br />

p Press automation<br />

8 Automation Made Easy<br />

AP&T AB, Sweden<br />

p Servo-presses<br />

10 Servo-electric<br />

Hydraulic Pumps<br />

Lasco Umformtechnik GmbH,<br />

Germany<br />

12 New Approaches in<br />

Metal Forming<br />

ebu Burkhardt GmbH, Germany<br />

14 Pioneering Drive Concept<br />

Andritz Kaiser GmbH, Germany<br />

p Retrofi t<br />

16 Retrofi t Delivers New<br />

Maximum Output<br />

Automatic-Systeme Dreher GmbH,<br />

Germany<br />

Publishing House<br />

Publicis Publishing,<br />

P.O. box 32 40, 91050 Erlangen<br />

Germany<br />

Tel.: +49 (0) 91 31 91 92-5 01<br />

Fax: +49 (0) 91 31 91 92-5 94<br />

magazines@publicis.de<br />

Editorial staff: G. Stadlbauer, D. Pott<br />

Layout: R. Degenkolbe, N. Wachter<br />

Copy editors: S. Wanke, S. Zingelmann<br />

DTP: M. Willms<br />

Print: Druckerei Wünsch, Neumarkt<br />

Germany<br />

Circulation: 2.000<br />

The following products are trademarks<br />

of Siemens AG:<br />

ET 200, DRIVE-CLiQ, MICROMASTER, MP,<br />

MP377, S7-300, SCALANCE, SIMATIC,<br />

SIMATIC Multi Panel, SIMATIC NET, SIMATIC<br />

Panel PC, SIMATIC Safety Integrated,<br />

SIMOTICS, SIMOTION, SimoTrans, SINAMICS,<br />

SINUMERIK, SIPLUS, SITRANS, STEP, WinCC<br />

If trademarks, technical solutions or similar<br />

are not included in this list, it does not imply<br />

they are not protected.<br />

Job number: 002800/41994<br />

Order-Nr.: E20001-A1740-P620-X-7600<br />

p Deep drawing presses<br />

18 Optimally Tested<br />

S. Dunkes GmbH, Germany<br />

p Forging presses<br />

20 Hot Rolls<br />

TMP, Russia<br />

p Packaging machines<br />

22 Safely Packaged<br />

Sabatier S.A.S., France<br />

p Strip leveling<br />

24 Gentle, Fast, and Safe<br />

Kohler Maschinenbau GmbH,<br />

Germany<br />

p Hydroforming machines<br />

26 Precise Repeatability<br />

Silfax, France<br />

The information provided in this magazine<br />

contains merely general descriptions or<br />

characteristics of performance which in<br />

actual case of use do not always apply as<br />

described or which may change as a result of<br />

further development of the products. An<br />

obligation to provide the respective<br />

characteristics shall only exist if expressly<br />

agreed in the terms of contract.<br />

© 2012 by Siemens Aktiengesellschaft<br />

Munich and Berlin. All rights reserved by the<br />

publisher. This edition was printed on<br />

environmentally friendly chlorine-free paper.<br />

Printed in Germany


Editorial<br />

“ Extensive<br />

portfolio with<br />

press expertise”<br />

Metal-Forming Team<br />

Speed, productivity, and fl exibility are the key requirements for machines in the<br />

metal-forming industry. Siemens offers an extensive portfolio of solutions for<br />

servo-presses that is gaining increasing recognition worldwide. It is only possible<br />

to achieve this success because we constantly adapt our products to current<br />

requirements. As a result, we have supplemented our range of motors at the<br />

upper and lower end, respectively, with the Simotics T-1FW4 heavy-duty torque<br />

motor – perfect for large machines with just under 30,000 Nm of torque –<br />

and the Simotics T-1FW3 heavy-duty torque motor with a shaft height of 200,<br />

designed for smaller machines. In terms of software, we have extended our<br />

intelligent path control with multipoint and oscillation functions.<br />

There have also been a few changes with regard to energy management. We now<br />

offer the option of both kinetic and electrical storage. The key feature here is that<br />

the energy is kept in the system, resulting in a smaller connected load. We can<br />

also provide suggestions to help you optimize the design of your press. Against<br />

a background of increasingly scarce resources, energy effi ciency is rapidly gaining<br />

in importance. It is possible to operate hydraulic presses considerably more<br />

effi ciently with the help of Sinamics servo-pumps. The result is energy savings<br />

of up to 70 percent.<br />

The Press Line Simulation software is an additional highlight in our already<br />

extensive portfolio. It is used for comprehensive programming, analysis, and<br />

simulation of multistage presses with the aim of exploiting their potential to the<br />

fullest. Combining the planning simulation tool with automation is the most<br />

important innovation we have introduced in this area. It has created a direct link<br />

between two previously separate areas – a world fi rst with countless advantages<br />

from which you can benefi t.<br />

In order to make our extensive expertise completely available to you, each area is<br />

supervised by a designated specialist from our team. Regardless of the problem –<br />

the drafting of safety concepts, the hydraulics of a new press, or training courses<br />

for commissioning – we have the right contact with the right answers. See for<br />

yourself!<br />

Your Metal-Forming Team<br />

<strong>spectrum</strong> METAL FORMING 2012 3


Press simulation<br />

p Press Line Simulation (PLS)<br />

Shortest Possible Set-Up<br />

Time for Press Lines<br />

If the many independent process steps of a press line are simulated, it is<br />

possible to optimize tools, material fl ows, and press movements on the PC.<br />

The result is fast production start-up and high cycle rates.<br />

During press set-up – that is, the preparation,<br />

installation, and optimization of the press<br />

lines for a workpiece – it is necessary to<br />

coordinate and synchronize a large number of technological<br />

components, mechanical settings, and<br />

automation parameters while adhering to a chronological<br />

sequence of work steps. Due to the highly<br />

complex nature of this process, it is almost always<br />

necessary to carry out several time-consuming correction<br />

cycles on tools, transfer devices, and control<br />

parameters, and in the past this has made set-up<br />

both time-consuming and expensive.<br />

Using simulation to save time<br />

Mapping the press line set-up in a simulation environment<br />

such as Press Line Simulation (PLS) remedies<br />

this problem. Based on a technically precise and<br />

PLS at a glance<br />

3 Method planning and material fl ow: Checking<br />

whether the sheet metal parts can pass through the<br />

press in the way planned<br />

3 Determination of the stroke rate: Calculation of the<br />

maximum stroke rate for various scenarios of sheet<br />

metal part transport<br />

3 Tool verifi cation: Simulation of driver and slide<br />

combinations, testing of tools for internal collisions<br />

3 Final inspection and documentation: Checking for<br />

external collisions, issuing of certifi cates,<br />

communication with others involved in the process<br />

4 <strong>spectrum</strong> METAL FORMING 2012<br />

modularly designed model of the press line, PLS<br />

allows both the basic manufacturing process and all<br />

the process-relevant details to be defi ned on the PC,<br />

adapted to each other, optimized, and checked. It is<br />

also possible to compare and contrast alternative<br />

process strategies or motion sequences quickly and<br />

with very little effort, as well as to verify tools and<br />

fi xtures based on check calculations. As a result,<br />

a great deal of time is saved by simulation during<br />

press set-up. When using the conventional procedure,<br />

checking cannot begin until the relevant<br />

design phases are complete or the tools and fi xtures<br />

have already been constructed.<br />

Accurate mapping of the press line<br />

The Press Line Simulation software from Siemens<br />

comprises a standard basic software program with<br />

the simulation algorithm and user interface as well<br />

as libraries containing basic models adapted to the<br />

specific line of all the simulation components<br />

required (press stations, drawing cushions, blank<br />

and orientation stations, material supply and storage,<br />

tooling components, and control and drive system).<br />

This means that set-up using PLS is suitable for<br />

very different press designs but provides the maximum<br />

benefi t in servo-presses and press lines with<br />

electronic transfer.<br />

To use PLS in a real press line, the existing model<br />

components are adapted so that they match the<br />

conditions of the real press line as accurately as possible<br />

– particularly with regard to collision-relevant<br />

geometries and important programming parameters.<br />

The PLS software structure enables separate<br />

processing of each functional area of a press line,<br />

with the result that every PLS installation is equipped<br />

with the press-specific functions required in that


Siemens AG<br />

Install error-free tools<br />

particular case. Workpiece and tool data are imported<br />

from the CAD/CAM system in order to set up the line<br />

for a specifi c tool set. Then the production process is<br />

planned, verified, and optimized down to the last<br />

detail on the PC. The collision testing includes the<br />

installation space of the tool and possible collisions<br />

during sheet transport. In addition, a simplifi ed fi nite<br />

element method (FEM) process in the PLS calculates<br />

the dynamic deformation of the sheet metal according<br />

to the stroke rate. It is thus possible to achieve<br />

reliable, collision-free transport and precise positioning<br />

of the metal sheets even at very high stroke<br />

rates.<br />

Optimum combination of controller and PLS<br />

It is particularly easy to reliably link the simulation<br />

with the real press lines if the press simulation<br />

includes not only the actual software used on the<br />

press’s hardware controllers but also enables direct<br />

data exchange with the press controller. This is the<br />

case with PLS for Simotion, the motion control system<br />

used in many press lines. Thus, it is possible to<br />

query the current motion curves of the plunger,<br />

transfer them from the Simotion controllers, and<br />

visualize them in the simulation. Electronic cams<br />

optimized and verifi ed in the simulation can be<br />

loaded directly into the controller for the individual<br />

drives of the press and the transfer, which not only<br />

saves time but also considerably reduces the probability<br />

of transmission errors.<br />

Saving time, reducing costs, and<br />

improving productivity<br />

With PLS, press set-up becomes easier, faster, and<br />

safer, which speeds production start-up and reduces<br />

unproductive time. It is also possible to increase the<br />

productivity of the press line or at least utilize it better.<br />

What’s more, with PLS it becomes much easier to<br />

control additional manufacturing processes, such as<br />

the use of multicavity molds. Overall, the use of PLS<br />

leads to a signifi cant increase in production capacity<br />

and provides the fl exibility to respond to requests at<br />

short notice. For this reason, press line simulation is<br />

becoming increasingly essential in competitive markets<br />

such as contract manufacturing and component<br />

supply industries. p<br />

info<br />

contact<br />

PLS offers many advantages such as the<br />

calculation of the dynamic deformation of<br />

sheet metal at high stroke rates, for example<br />

Reduce set-up time<br />

www.siemens.com/plm<br />

ulrich.lorenz@siemens.com<br />

Increase stroke rate<br />

Improve fi xture construction<br />

<strong>spectrum</strong> METAL FORMING 2012 5


Press simulation<br />

6 <strong>spectrum</strong> METAL FORMING 2012<br />

p Volkswagen AG, Germany<br />

Productivity Boost<br />

for Press Lines<br />

Higher stroke rates, fl exible manufacturing, and quick<br />

product changeovers – these are just some of the benefi ts<br />

of implementing electronic transfer in the Volkswagen<br />

press p shop pin Wolfsburg. g<br />

Volkswagen AG / Siemens AG<br />

The manufacture of<br />

body panels in the<br />

Volkswagen press<br />

shop involves<br />

frequent product and<br />

tool changeovers


As part of a modernization of the press<br />

shop, Volkswagen Wolfsburg decided to<br />

retrofit three 15-year-old press lines.<br />

Because of the increasing diffi culty of sourcing<br />

spare parts for the control technology, the project<br />

team decided to change the mechanical transfer in<br />

the lines to motion-controlled servodrives.<br />

Retrofi t allows rapid resetting of the lines<br />

Volkswagen modernized the press lines itself, but<br />

Siemens was involved at an early stage as a partner<br />

for the electrotechnical equipment. With regard to<br />

the hardware and software, Volkswagen was able<br />

to use internal standards that had been drawn up<br />

jointly with Siemens in the course of previous projects.<br />

“For example, we are using fail-safe Simatic<br />

PLC and Simotion hardware controllers. On the<br />

software side we are using, among other things,<br />

a hydraulic controller developed by Siemens and<br />

Fraunhofer,” explains Mark Walz, Volkswagen project<br />

manager and responsible for press retrofi ts at<br />

the Wolfsburg press shop. The three press lines are<br />

being used to make various body panels, and this<br />

requires frequent changes of products and tools. It<br />

is therefore important for production planning to be<br />

able to reset the lines quickly when required. Also,<br />

the tools, settings, and motion profi les need to be<br />

interchangeable between the lines. This means that<br />

all three lines must be able to produce multiple<br />

parts.<br />

Press line simulation maximizes potential<br />

Despite the fact that the lines have different pressing<br />

forces, Volkswagen has equipped all three with<br />

identical components – that is, equivalent feeds,<br />

drive controls, and motors. “The savings far outweigh<br />

the extra costs of the individual components,”<br />

stresses Walz. The installation of the multiaxis<br />

electronic transfer system also enhances the<br />

possibilities for positioning the sheet metal. The<br />

performance of the planned transfer was checked<br />

in advance via simulation. To do this, the Press Line<br />

Simulation software produced a virtual model simulating<br />

all mechanical, electrical, and software components<br />

that are relevant for dynamic motion control.<br />

“Without being able to test it in this way, you<br />

can’t really fully exploit the potential of a servodriven<br />

transfer,” says Walz. Initial simulations then<br />

also confirmed that additional time would be<br />

required for reliable sheet metal transport at higher<br />

stroke rates. The time required to reduce the maximum<br />

acceleration was gained by means of a phase<br />

displacement of the plunger. This meant that safe<br />

parts transfer was possible despite the higher<br />

stroke rates.<br />

Increased productivity and high availability<br />

For the fi rst time, the modifi ed press lines now have<br />

a direct data connection between the press line simulation<br />

and the press line controllers. Thus, the prepared<br />

motion profi les can be transferred to the plant<br />

in a matter of seconds. Similarly, motion profi les that<br />

exist on the plant can be loaded into the simulation<br />

software, optimized, and transferred back to the<br />

controller. In this way the simulation not only<br />

reduces the set-up times for introducing new workpieces<br />

but also makes for quicker resumption of production<br />

after tool changeovers. In the long term,<br />

the associated increase in productivity meant that<br />

the number of press lines could be reduced from<br />

17 to 8. This offers considerable potential savings,<br />

but it also increases dependence upon the individual<br />

machines. Consequently, another important objective<br />

of the retrofit was to achieve availability of<br />

at least 96 percent. The press lines are therefore<br />

monitored by the Siplus CMS condition monitoring<br />

system.<br />

Another welcome outcome is the drastic reduction<br />

in energy consumption. Thanks to the DC link coupling<br />

of the Sinamics converter, the braking energy<br />

that is regularly produced during cyclical movements<br />

can be directly reused for acceleration processes.<br />

Moreover, high-maintenance uninterrupted power<br />

supplies can be eliminated completely. Because of<br />

the consistent DC link, the kinetic energy stored in<br />

the press is suffi cient to bring all the axes into a safe<br />

state in the event of a power outage and to run<br />

down all the control technology in an orderly manner.<br />

Simple, cost-effective, and fl exible<br />

Everyone involved was delighted by the greater simplicity<br />

of the automation system and has rated the<br />

project a huge success. The retrofit has made an<br />

important contribution toward standardizing<br />

machine automation in the press shop. In addition,<br />

maintenance is much simpler and more cost-effective<br />

because of the standardized technology. Electronic<br />

transfer also means that sheet metal transport<br />

is considerably more fl exible, and the sheets can<br />

now be positioned with greater accuracy as well.<br />

In view of the enormous boost to productivity in the<br />

press shop, the retrofi t has proved to be much more<br />

economical in the long term than buying new press<br />

lines with a comparable output. p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

joerg.pliskat@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 7


Press automation<br />

p AP&T AB, Sweden<br />

Automation Made Easy<br />

By using standardized electrical equipment, AP&T, a Swedish<br />

workfl ow automation specialist, has housed all the automation in<br />

one control cabinet and as a result has ggreatly y reduced costs.<br />

Automation, Press and Tooling (AP&T) develops,<br />

produces, and markets automation systems,<br />

presses, tools, and complete production<br />

lines for the metal-forming industry. One of<br />

AP&T’s core competencies is in the area of workfl ow<br />

automation. The company supplies complete solu-<br />

tions and considers itself responsible for all subareas.<br />

AP&T has now succeeded in standardizing the automation<br />

to such a degree that the required technology<br />

can be housed in just a single preassembled<br />

control cabinet. This is suffi cient to operate robots<br />

and other automation units.<br />

Use of Simotion provides freedom<br />

Christer Bäckdahl, development manager at AP&T,<br />

reports, “We concentrated very early on consistent<br />

modularization while pursuing the strict standardization<br />

of these modules. Our automation has now<br />

been based on the Simotion motion control system<br />

since 2006. In particular, Simotion allows the standardized<br />

modularity that we have established in the<br />

mechanical system to be transferred to the electrotechnical<br />

equipment and ultimately to be mapped in<br />

the software as well.” Summing up, he says, “The<br />

use of Simotion has greatly reduced our engineering<br />

8 <strong>spectrum</strong> METAL FORMING 2012<br />

costs.” Modularization and standardization also provided<br />

AP&T with freedom to become involved in<br />

other aspects of the process. The Simotion motion<br />

control system is now considered to be a basic<br />

requirement for modularization and standardization<br />

– and therefore also for the development of com-<br />

»End users particularly appreciate the<br />

guaranteed high quality of the products<br />

manufactured by Siemens.«<br />

Christer Bäckdahl, Development Manager, AP&T AB<br />

plete solutions in the area of workfl ow automation<br />

and the manufacture of customized control cabinet<br />

solutions.<br />

Fast commissioning and high level of<br />

customer acceptance<br />

Together with Siemens Sweden, AP&T was able to<br />

automate all units using a single control cabinet variant.<br />

For this purpose, the signal routings and designations<br />

were standardized, confl ict-free identifi ers<br />

for addresses and variables assigned, the power<br />

requirement and the connection values matched for<br />

all appropriate machine modules, and fail-safe<br />

Simatic ET 200S modules confi gured for all safety<br />

equipment. Siemens System Engineering Plant<br />

Chemnitz optimized the control cabinet layout based<br />

on these specifi cations. In this case, both IEC- and<br />

UL-certifi ed variants were created, and both can be<br />

ordered in either the electrically cooled or water


Photos: W. Marschner<br />

Consistent modularization permits<br />

the use of uniform, standardized<br />

control cabinets for the feeder,<br />

press, and stacker<br />

cooled variant. The control cabinets are brought<br />

fully pretested from the warehouse shortly before<br />

starting commissioning and are connected to the<br />

machine via Profi net and the motor cables. The service<br />

technician then installs the standard software<br />

and sets the customer-specifi c machine parameters<br />

on the CPU – then commissioning can begin immediately.<br />

Bäckdahl observes, “The standardized control<br />

cabinets not only result in reduced costs in terms<br />

of design engineering, installation, and commissioning,<br />

but the lead time is now shorter too. We profi t<br />

from this on every single job.” The control cabinets<br />

are very compact, which is also benefi cial for transport<br />

and storage. The development manager sums<br />

up: “The compactness also contributes to a high<br />

level of acceptance by end users; they particularly<br />

appreciate the guaranteed high quality of the products<br />

manufactured by Siemens.”<br />

The modularization and standardization of the control<br />

and drive technology provided by the control<br />

cabinets are also opening up new prospects. Now,<br />

depending on the production job, it is also possible<br />

to use recipe-controlled confi gurations with other<br />

stations to form press groups that process the current<br />

job over a specifi c period after the individual<br />

systems have been synchronized and coordinated<br />

with each other. When required by the next production<br />

job, the operator can activate another recipe<br />

and then use the press, including the feeder and<br />

stacker, as a stand-alone station or in a different line<br />

confi guration.<br />

New quality for standardized control<br />

cabinets<br />

Once again, AP&T has proved its competence in this<br />

area thanks to modules and standards that are easy<br />

to understand and that can be used fl exibly. Standardization<br />

of the electrical equipment for the modular<br />

machines of the metal-forming specialist has<br />

resulted in a new level of quality in the control cabinets.<br />

In addition to easier and faster completion of<br />

customer jobs, they enable even more fl exible, recipecontrolled<br />

confi guration of machine modules for the<br />

construction of complete manufacturing lines. p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

andreas.michalik@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 9


Servo-presses<br />

10 <strong>spectrum</strong> METAL FORMING 2012<br />

p Lasco Umformtechnik GmbH, Germany<br />

Servo-electric<br />

Hydraulic Pumps<br />

The press manufacturer Lasco uses an electric servo-pump<br />

control for mass forming and the optimization of large<br />

hydraulic presses, thus achieving energy savings as well as<br />

improved p dynamics. y<br />

Lasco Umformtechnik GmbH, a prestigious<br />

manufacturer of mass forming and sheet<br />

presswork equipment based in Germany, is<br />

always focused on improving its processes and technologies.<br />

One such technological milestone is the<br />

servo technology used in a recently delivered deep<br />

drawing press with a force of 800 tons for up to<br />

40 strokes per minute. This offers huge benefits<br />

» Among other things, our new<br />

servo technology enables<br />

operators to achieve<br />

appreciable energy savings. «<br />

Harald Barnickel, Head of Electrical Engineering Department,<br />

Lasco Umformtechnik GmbH<br />

from a technical point of view and also in terms<br />

of energy consumption. “Among other things, our<br />

new servo technology enables operators to achieve<br />

appreciable energy savings,” reports Harald Barnickel,<br />

head of Lasco’s electrical engineering<br />

department.<br />

Servo technology delivers<br />

outstanding results<br />

Servomotors that are flange-mounted directly onto<br />

the hydraulic pump form the heart of the solution.<br />

The power control of the drive is controlled by a<br />

Sinamics S120 frequency converter, while the<br />

Simotion D445 controller is responsible for the<br />

overall control of the axis path, speed, and position.<br />

“Initial operating data have indicated that this servo<br />

technology delivers outstanding results in many<br />

respects – with regard to both energy consumption<br />

and technology,” confirms the electrical engineer.<br />

The deep drawing press is to be used to manufacture<br />

seat rails for motor vehicles in six consecutive stations.<br />

For this, pressing force and stroke speed<br />

needed to be adapted to an individual movement<br />

profile. The pressing force can be adjusted at the servomotor<br />

by means of the torque. The plunger speed,<br />

however, is controlled via the motor speed and<br />

therefore via the flow rate of the pump. Thanks to<br />

this technique, valve technology savings of up to<br />

40 percent are possible in the press.<br />

Energy savings and system continuity<br />

The use of servo technology also results in a significant<br />

improvement in the energy balance. “It was previously<br />

necessary to use large cooling systems for<br />

the oil, but much smaller units can be used with the<br />

servo technology,” says Barnickel. The associated<br />

improvement in efficiency, which the press manufacturer<br />

considers to be well into double figures, is<br />

reflected by massive savings in electricity costs compared<br />

to the older machines. An added advantage is<br />

that energy can be recovered during decompression<br />

of the hydraulic fluid. “The opposite would be true of<br />

other concepts, where there would even be additional<br />

heat losses,” explains Barnickel.<br />

According to Barnickel, an additional plus point is<br />

the system consistency offered by the Siemens solutions.<br />

For example, the Simotics M-1PH8 servomotor,<br />

available as a synchronous or asynchronous<br />

motor, is automatically identified by the frequency


converter and its parameters are imported. The<br />

choice of motors depends upon the application,<br />

that is to say, the required dynamics. “Ultimately,<br />

this new drive concept for hydraulic presses, which<br />

is based on an electric servo-pump control, results<br />

in a significant overall improvement,” says Barnickel.<br />

“In addition to the possible energy savings already<br />

mentioned, we also have a great advantage over<br />

straight valve controls thanks to the incredibly precise<br />

controllability.”<br />

Integrated safety<br />

Lasco chose the fail-safe Simatic S7-319 F 3PN/DP to<br />

control the entire plant. “It offers us the freedom to<br />

implement all the safety technology without a lot of<br />

additional expenditure,” explains Barnickel. The failsafe<br />

signals are read via Simatic ET 200S distributed<br />

I/O stations and relayed to the control via Profisafe.<br />

It is an elegant overall solution, says Barnickel: “It<br />

enables us to achieve clear structures in the machine.”<br />

For example, there are normally two monitored valves<br />

that provide for the security of the press plunger<br />

during set-up. The new solution is now more<br />

refined: the reduced speed (Safety Limited Speed:<br />

SLS) and, among other things, safe stop (Safe Stop<br />

1: SS1) are monitored via the Sinamics S120 fail-safe<br />

frequency converter.<br />

Convincing overall concept<br />

The development of the new servo technology for<br />

large hydraulic presses, as based on the Simotion<br />

motion controller at Lasco Umformtechnik GmbH,<br />

has already aroused a great deal of interest among<br />

users, even after such a short time. Thanks to the<br />

standard concept consisting of the Simotics M-1PH8<br />

servomotor, Sinamics S120 frequency converter, and<br />

Simotion D445 motion control unit, there has been a<br />

significant improvement in dynamics, precision, and<br />

energy consumption. “And all because we dared to<br />

opt for electric servo-pump control in the hydraulic<br />

press as opposed to valve technology,” declares<br />

Barnickel. p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

jakob.einwag@siemens.com<br />

The electric servopump<br />

control in the<br />

Lasco press uses<br />

significantly less<br />

energy than<br />

traditional valve<br />

controls<br />

<strong>spectrum</strong> METAL FORMING 2012 11<br />

Lasco


Servo-presses<br />

p ebu Burkhardt GmbH, Germany<br />

New Approaches in<br />

Metal Forming<br />

A servo-electric drive and control unit expands the possibilities of<br />

cutting-edge automatic punching machines. The machine manufacturer<br />

is delighted with the fl exibility gained as a result.<br />

The core competence of ebu Burkhardt GmbH<br />

in Bayreuth, Germany, lies in the punching<br />

and metal-forming segment, with a focus on<br />

the manufacture of automatic punching machines.<br />

The product is the same as always, but the technology<br />

has evolved over time. While in the past an<br />

appropriately large fl ywheel mass ensured that the<br />

12 <strong>spectrum</strong> METAL FORMING 2012<br />

force required during the punching process was<br />

available, the Bavarian company now uses a servoelectric<br />

drive and control unit for this purpose.<br />

Creation of individual motion profi les<br />

At the metal-forming specialist’s premises in<br />

Bayreuth, this task is carried out in part by two<br />

The ebu Burkhardt<br />

servo press stands out<br />

due to its servoelectric<br />

drive concept<br />

All pictures: ebu Burkhardt GmbH


Simotics T-1FW4 heavy-duty torque motors, because<br />

with the help of this cutting-edge technology, the<br />

required energy can also be supplied by means of an<br />

electric fl ywheel mass. The mechanical fl ywheel mass<br />

is thus rendered obsolete. The major advantage is<br />

that the servo-electric drive solution makes it easy<br />

to transfer individual motion profi les to the plunger<br />

and thus to the tool. The use of servo technology<br />

will enable the company to pursue completely new<br />

possibilities in metal forming. Jörg Berger, managing<br />

director of ebu Burkhardt GmbH, explains the decision<br />

in favor of servo technology: “Servo technology<br />

holds massive potential. It’s very fl exible in use.<br />

What’s more, it can be used to achieve superior parts<br />

quality.”<br />

Intelligent temporary storage of<br />

electrical energy<br />

Berger continues, “Regardless of new technology,<br />

at the end of the day the energy balance must be<br />

right.” To ensure this, the excess electrical energy<br />

from the punching process is stored temporarily in<br />

other systems. This storage takes place with the help<br />

of the Sinamics S120 frequency converter, which<br />

determines the torque motor’s speed. Thanks to the<br />

integrated energy-regeneration capability of the<br />

water-cooled power sections, the unit is able to<br />

induce the recovered electricity from the braking<br />

processes into the DC link. The electricity is then<br />

» Due to this ongoing<br />

close collaboration<br />

with Siemens, we<br />

know at an early<br />

stage what inno va-<br />

tions we can expect in the fi eld<br />

of open-loop, closed-loop, and<br />

switching technology. This helps<br />

us meet our goal of building<br />

innovative machines.«<br />

Jörg Berger, Managing Director, ebu Burkhardt GmbH<br />

available again for the next punching process. There<br />

is also another option for storing excess energy. For<br />

this purpose, an additional asynchronous motor is<br />

brought up to speed in the automatic punching<br />

machine and thus serves as a kinetic energy accumulator.<br />

At the moment of punching, it acts as a<br />

generator and delivers the additionally required electricity<br />

when needed.<br />

Servo technology enables<br />

maximum fl exibility<br />

All processes are controlled by a Simotion 435D. But<br />

the motion control unit can handle more than just<br />

motion control. Because of its effi ciency, it also<br />

offers the option of controlling the whole machine<br />

– meaning that no additional controller is required.<br />

Berger sums up: “The servo-electric drive technology<br />

combined with Simotion allows us to get considerably<br />

closer to the technological limits than was previously<br />

possible.”<br />

The greatest advantage of the servo-electric drive<br />

technology, however, is the ability to adjust fl exibly<br />

to production processes and different workpieces.<br />

Berger reports, “We can map around 80 percent of<br />

the standard machines with this new solution.” The<br />

motion control unit can store different motion profi<br />

les, which the servodrive then transfers to the<br />

workpiece. Berger says, “No one yet has a curve<br />

changeover of this type that boasts such speed.”<br />

These variable motion profi les also make incremental<br />

metal-forming processes possible, which, in turn,<br />

allow not only the achievement of superior parts<br />

quality but also the realization of process improvements.<br />

Leading position thanks to system partner<br />

According to Berger, “We have gained this technological<br />

advantage in tandem with our system partner<br />

Siemens.” The servo technology described was<br />

developed and brought to market readiness thanks<br />

to the additional support provided during confi guration,<br />

design, and commissioning. The machine manufacturer<br />

focuses specifi cally on integration, following<br />

the Totally Integrated Automation model offered<br />

by Siemens. Berger stresses, “We benefit hugely<br />

from the fact that our system partner has a large<br />

number of tried-and-tested solutions in its portfolio<br />

that are all coordinated with each other. Due to this<br />

ongoing close collaboration, we also know at an<br />

early stage what innovations we can expect in the<br />

fi eld of open-loop, closed-loop, and switching technology.<br />

This helps us meet our goal of building<br />

innovative machines.” Berger comments happily,<br />

“After all, we want to become a technological leader<br />

– and with the new servo technology we are doing<br />

just that.” p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

jakob.einwag@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 13


Servo-presses<br />

14 <strong>spectrum</strong> METAL FORMING 2012<br />

p Andritz Kaiser GmbH, Germany<br />

Pioneering Drive<br />

Concept<br />

Andritz Kaiser has been able to signifi cantly increase the<br />

productivity and energy effi ciency of its stamping and forming<br />

presses by combining the time-tested drag link system with an<br />

innovative servodrive concept. p<br />

Over the last 20 years, the drag link system<br />

patented by Andritz Kaiser GmbH from<br />

Bretten, Germany, has stood the test of<br />

time in over 300 stamping and forming presses<br />

under harsh operating conditions. The “intelligent<br />

gear unit,” as managing director Stefan Kaiser refers<br />

to the drag link drive, features a variable transmission<br />

ratio and force paths within the operating<br />

range that are almost twice as large as those in<br />

eccentric presses. Using the servodrive means that<br />

the plunger motion also becomes programmable by<br />

the user. The press is therefore highly fl exible and<br />

Andritz Metals, Bretten<br />

Among other things, Hako<br />

Automotive produces<br />

challenging deep-drawn parts<br />

for the automotive industry on<br />

this KSTU 8000, an 800 t press<br />

by Andritz Kaiser<br />

can be adapted easily to different tasks or materials.<br />

For many parts, optimized motion control increases<br />

output by up to 80 percent compared to eccentric<br />

presses.<br />

Lower consumption thanks to energyeffi<br />

cient drives<br />

As the basic motion of a drag link drive approximates<br />

very closely the motion profi le of a servo-press, it is<br />

usually possible to signifi cantly reduce the number<br />

of drive motors required compared to a purely<br />

eccentric press, thereby considerably decreasing


energy consumption. Heavy-duty water-cooled complete<br />

torque motors of the Simotics T-1FW3 series<br />

were used in all the servo-presses. Mounted centrally<br />

above the press, one or several of these torque<br />

motors drive the drag link system and therefore the<br />

plunger via an internal gear. The drive system is<br />

completed by an energy accumulator, optionally in<br />

the form of capacitor modules or an additional compact<br />

asynchronous motor of the Simotics M-1PH8<br />

series. This temporarily stores the regenerative<br />

energy produced during braking and releases it<br />

again to cover peaks in demand during acceleration<br />

processes.<br />

Targeted motion control with Simotion<br />

The drag link servo-presses by Andritz Kaiser are<br />

controlled by the Simotion D445 motion control system<br />

in the modular mounting technology of the<br />

Sinamics S120 drive system. An optimized plunger<br />

travel profi le is generated automatically using the<br />

“curve generator” tool specially developed for use<br />

with Simotion in servo-presses. The press manufacturer<br />

has fl exibly integrated the tool into its operator<br />

interface under Simatic WinCC and created a simple<br />

operating screen for a Simatic Multi-Panel MP377.<br />

The installation of new tools is made easier with a<br />

handheld controller. Thanks to servodrive technology,<br />

the handheld device can also be used to arrive<br />

The Simotion curve generator automatically<br />

calculates an optimized plunger motion and<br />

determines the exact feed length or transfer time<br />

precisely at the required plunger position and to<br />

incorporate it into the program. The Multi-Point<br />

function is another new addition, enabling data<br />

points to be programmed at any point in the plunger’s<br />

travel. The forming motion can be reduced at<br />

such data points – for example, to cut threads or to<br />

introduce inserts. Wolfgang Wiedenmann, deputy<br />

sales manager at Andritz Kaiser, predicts that “hybrid<br />

processes such as this will be required more and<br />

more in the future.” The press manufacturer has also<br />

extended the tried-and-tested curve generator by an<br />

input fi eld for feed length or transfer time. The oper-<br />

ator can therefore see at a glance the feed length or<br />

transfer time generated by his or her entries. It is<br />

then easy to make a comparison with the transfer<br />

controller. This shows whether the machine can travel<br />

the motion profile selected. Wiedenmann says,<br />

“Processes are becoming increasingly complex, and<br />

therefore even semiskilled operators must still be<br />

able to manage the press easily and safely.” He adds,<br />

“It is possible to ensure this by using the Simotion<br />

curve generator.” In order to guarantee the necessary<br />

safety, the management at Andritz Kaiser decided<br />

on a Simatic S7-300F with fail-safe S7-317F-2 DP CPU.<br />

An additional library with press safety modules is<br />

also included in the dedicated Distributed Safety<br />

option package. The curve generator is an integral<br />

part of the press controller.<br />

Increase in productivity and product quality<br />

One of the fi rst users of the latest generation of<br />

servo-presses by Andritz Kaiser is Hako Automotive,<br />

a division of Ferdinand von Hagen Söhne & Koch<br />

GmbH & Co. KG. The stamping facility located in<br />

Wuppertal produces complex structural and assembly<br />

components for leading car manufacturers on<br />

a KSTU 8000 drag link servo-press with a press force<br />

of 800 t, a 400 mm stroke, and automatic stroke<br />

adjustment. The diversity of the stamped and formed<br />

parts requires a particularly flexible machine.<br />

»Processes are becoming increasingly<br />

complex, and therefore even semiskilled<br />

operators must still be able to<br />

manage the press easily and safely.<br />

It is possible to ensure this by using<br />

the Simotion curve generator.«<br />

Wolfgang Wiedenmann, Deputy Sales Manager, Andritz Kaiser GmbH<br />

Stefan Kaiser sums up, “The experience and results<br />

gained with and from Hako Automotive and other<br />

users were thoroughly convincing. Our expectations<br />

with regard to productivity, product quality, and<br />

energy efficiency were greatly exceeded. The userfriendliness<br />

is excellent as usual, and machine<br />

handling is still easy.” p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

stephan.hoja@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 15


Dreher GmbH<br />

Retrofit<br />

16 <strong>spectrum</strong> METAL FORMING 2012<br />

p Automatic-Systeme Dreher GmbH, Germany<br />

Retrofi t Delivers New<br />

Maximum Output<br />

A fast loader, user-programmable transfer systems, and shuttles<br />

form the basis of a completely reautomated press line for automotive<br />

structural components. The advantages are higher output, greater<br />

fl exibility, y and an assured long-term g supply pp y of spare p pparts.<br />

The press line modernized by Dreher Automation and<br />

Siemens delivers around 30 percent higher output


The electrical equipment of the established<br />

six-stage press line for automotive structural<br />

components at Audi AG in Neckarsulm,<br />

Germany, was showing its age. Total Productive<br />

Maintenance (TPM) measures increased and it<br />

became diffi cult to procure the necessary spare<br />

parts. As a result, the company decided on an<br />

extensive retrofi t of its press shop in Neckarsulm.<br />

In the course of this retrofi t, the rigid mechanical<br />

coupling of the transfer devices to the plunger<br />

motion was replaced with an up-to-date solution.<br />

Increasing the stroke rate as top priority<br />

The retrofi t was carried out by Automatic-Systeme<br />

Dreher GmbH, based in Sulz-Renfrizhausen. Dreher<br />

replaced the old mechanical automation system<br />

with an integrated electronic solution, while<br />

Siemens upgraded the controllers and the operator<br />

control and monitoring systems of the six presses.<br />

According to managing partner Klaudijo Dreher,<br />

Automatic-Systeme Dreher GmbH<br />

Automatic-Systeme Dreher GmbH is a leading global<br />

manufacturer of automation equipment for sheet<br />

metal and mass forming. The company has played a<br />

leading role in the development of press automation<br />

for the past 40 years. As a Siemens Solution Partner,<br />

Dreher analyzes requirements in dialogue with its<br />

customers and identifi es appropriate solutions.<br />

Established: 1970<br />

Company<br />

headquarters: Obere Talstraße 1–5<br />

72172 Sulz/Renfrizhausen, Germany<br />

Tel.: +49 (0) 74 54 / 88 10<br />

Fax: +49 (0) 74 54 / 88 111<br />

“As a Siemens Automation Solution Partner, we<br />

have already proved in several joint projects that<br />

we can also complete complex tasks such as these<br />

on schedule.” The operator’s specifi c requirements<br />

included increasing the stroke rate from 12 to<br />

16 per minute, or, in other words, increasing output<br />

by more than 30 percent. Up to that point, the<br />

stroke rate had been limited by the rigid sequences<br />

determined by mechanical cams and vertical shafts.<br />

Dreher has now replaced the mechanical automation<br />

with six electronic transfer systems in the<br />

presses, fi ve so-called shuttles, and a turning device<br />

between the presses. A new highly dynamic blank<br />

destacker was also designed jointly with Audi.<br />

Freely positionable and user-programmable<br />

Dreher’s electronic transfer systems consist of two<br />

identically constructed units for each end of the<br />

press. This means that the blanks can be freely positioned<br />

in all three axes – irrespective of the plunger<br />

motion. Now the traverse paths of the shuttles can<br />

also be programmed by the user independently of<br />

the plunger motion. It is possible to configure the<br />

motion sequence of the transfer systems and shuttles<br />

with a high level of fl exibility now that they have<br />

been decoupled mechanically. Waiting times are<br />

minimized, and the desired increase in productivity<br />

is achieved. The intermediate conveyor designed<br />

as a turning device can be used in any position,<br />

enabling even more fl exible processes. All connections<br />

were designed to be plug-in, so that the transfer<br />

units can be replaced. This was also one reason<br />

for using Simotics S-1FK7 servomotors in the highly<br />

dynamic version with Drive-Cliq, and for moving all<br />

ports to the outside. Four state-of-the-art motors<br />

with a further reduced moment of inertia were<br />

installed on the blank stacker.<br />

Complex motion control with Simotion<br />

Drive-based Simotion D445 motion controllers, one<br />

for each of the blank stackers and for each transfer<br />

system, ensure fast motion sequences that are nevertheless<br />

gentle on the mechanics. As the master,<br />

the Simotion assembly specifi es the guide value for<br />

all the other presses via the Drive-Cliq digital system<br />

bus integrated into the system, and for this purpose<br />

it is linked to a virtual master axis in the Simotion<br />

system. The actual press controllers are subordinate<br />

to the motion controllers as slaves on the Profi bus and<br />

in turn are synchronized with each other via Profi net<br />

in synchronous operation. All movements are userprogrammable<br />

and can be modifi ed at the touch of<br />

a button. Dreher has achieved this by using the prefabricated<br />

modules of the standard SimoTrans for<br />

Simotion application. STO (Safe Torque Off) and SLS<br />

(Safely Limited Speed) are used as safety functions.<br />

The press safety modules of the Simatic S7-F/P library<br />

were also used to create the safety program. These<br />

are easily integrated into the distributed safetyprogramming<br />

environment in Step 7.<br />

Availability and effi ciency assured<br />

Use of Siemens state-of-the-art control and drive<br />

technology means that the age-related malfunctions<br />

and downtimes no longer present a problem, and<br />

this in turn has permanently increased both the<br />

availability and the output of the press lines. Thanks<br />

to the retrofi t, it is now possible to create more fl exible<br />

motion sequences. The line’s overall energy consumption<br />

has also dropped signifi cantly due to the<br />

energy regeneration capability and energy effi ciency<br />

of the cutting-edge drives. In conjunction with the<br />

higher productivity, the result is a further reduction<br />

in the energy cost per item. p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

koenig.georg@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 17


Deep drawing presses<br />

18 <strong>spectrum</strong> METAL FORMING 2012<br />

p S. Dunkes GmbH, Germany<br />

Optimally Tested<br />

S. Dunkes has developed a frame deep drawing press that<br />

can be used in the auto parts industry to comprehensively<br />

try yout tools for subsequent q usability. y<br />

The variety of models produced by the automotive<br />

industry is continually increasing,<br />

while production cycles become shorter and<br />

shorter. In order to keep pace, new tools must constantly<br />

be developed. For more than 50 years,<br />

S. Dunkes GmbH from Kirchheim unter Teck in Germany,<br />

has been making machines and systems associated<br />

with forming and connection technology.<br />

The company has now made a hydraulic tryout<br />

Simatic Panel<br />

PC 677 Touch<br />

Simatic<br />

ET 200S HF<br />

Control elements<br />

Displays<br />

Interface<br />

Simatic<br />

CPU 319F<br />

Profinet Profibus<br />

Hydraulics<br />

Simatic Net<br />

Scalance X-000<br />

press for an auto parts supplier – it features a maximum<br />

force of 5,000 kN and is used for toolmaking.<br />

Precise coordination of all production<br />

parameters<br />

This HDZ 500 frame deep drawing press is used in<br />

toolmaking to try out stepped tools, transfer tools,<br />

and progressive dies. The press is also used to press<br />

out the fi rst lot sizes and to develop components<br />

ready for series production. In order to meet stringent<br />

requirements for precision, the press is<br />

General<br />

functions<br />

adjusted with an extremely high guidance ratio by<br />

means of an active parallel control for the plunger.<br />

The sensor technology of the highly dynamic control<br />

picks up the initial tilt that occurs particularly during<br />

tool contact, and the servo-valves integrated into<br />

the control circuit regulate this within milliseconds.<br />

The high variability of the closing and pressing<br />

speed allows the subsequent usability of the tools<br />

on mechanical presses to be comprehensively<br />

Siemens<br />

Micromaster 440<br />

Tryout process<br />

In the tryout process, the tool<br />

stages are tested individually<br />

and in succession until both<br />

the quality and the cycle time<br />

(output) are satisfactory.<br />

A prerequisite for this is the<br />

precise input of nominal physical<br />

values such as pressure (force),<br />

distance, speed, and time. All<br />

parameters must be regulated.<br />

tested. In order to be able to precisely coordinate the<br />

required production parameters, the press was also<br />

fi tted with a sensitive joystick control. This extensive<br />

equipment enables the required multifunctional and<br />

wide-ranging application of the press.<br />

Panel PC facilitates clear data handling<br />

Dunkes presses are generally known for their userfriendliness.<br />

For automation, the company relies on Siemens<br />

products due to the positive experiences to date.<br />

The tryout press uses a Simatic Panel PC 677 Touch


S. Dunkes GmbH<br />

in conjunction with the Simatic S7-319F CPU safety<br />

control. With this confi guration it is possible to operate<br />

the press in combination with the chosen HMI software;<br />

it also affords transparent programming, navigation,<br />

and storage and transfer of process and tool<br />

data. In this way Dunkes can easily manage parameter<br />

confi guration for the press. Moreover, the highly<br />

effi cient programmable logic controller (PLC) also<br />

offers the high performance required even for such<br />

a powerful press. The central component of the<br />

distributed I/O devices is the Simatic ET 200S HF –<br />

a multifunctional, modular distributed I/O system<br />

that can be adapted specifically to the automation<br />

task at hand. In this case it regulates not only the<br />

control elements, displays, and interfaces but also<br />

the hydraulics and other general functions. Communication<br />

between the control and the operator unit<br />

takes place via Profi net, and the connection to the<br />

I/O devices is via Industrial Ethernet.<br />

Users benefi t from high parts quality<br />

Thanks to the sound basic concept and the expansion<br />

potential for Dunkes tryout presses, manufacturers<br />

can try out their various tools at high speeds<br />

and, if necessary, rework them before delivery. Previously,<br />

tools were tried out on presses with only one<br />

station; individual stepped tools therefore had to be<br />

mechanically tested and were only brought together<br />

in the production press. This not only resulted in<br />

long tryout times but also frequently led to delays in<br />

the production process. The benefi ts of the new process,<br />

by contrast, soon became apparent: Not only is<br />

the running-in period required for a new tool much<br />

shorter, but users benefi t from higher parts quality<br />

right from the start. With the Siemens technology it<br />

is also possible to control the process parameters.<br />

Ideal collaboration<br />

The new solution was implemented in close collaboration<br />

between Dunkes and the designated Siemens<br />

consultants. In this way, any questions that arose<br />

could be discussed in advance and the solution<br />

thereby optimized. Both Dunkes and the auto parts<br />

supplier were extremely pleased with the complete<br />

plant that was delivered. The press manufacturer is<br />

therefore eager to continue its collaboration with<br />

Siemens in the future. p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

stephan.schaeufele@siemens.com<br />

With its extensive<br />

equipment, the<br />

Dunkes 5,000 kN<br />

tryout press offers a<br />

multifunctional range<br />

of application<br />

<strong>spectrum</strong> METAL FORMING 2012 19


Forging presses<br />

p TMP, Russia<br />

Hot Rolls<br />

The Russian company TMP successfully managed to increase the<br />

throughput of hot mills by increasing the degree of the production<br />

process automation. Programmed control systems and robotic<br />

handlers helped p them to achieve this aim.<br />

» The qualifi ed professionals at Siemens<br />

helped us select and confi gure the control<br />

system and debug the real-time programs<br />

on time and within budget.«<br />

Igor Valikov, Leading designer JSC TMP<br />

20 <strong>spectrum</strong> METAL FORMING 2012


TMP, based in the ancient city of Voronezh,<br />

Russia, is the largest developer and builder of<br />

equipment for the country’s metal forging<br />

industries. In terms of world presence, of the 17 hot<br />

forging presses with pressure greater than 10,000 t<br />

in current operation across the globe, 8 were built<br />

by TMP. Because of the tough market conditions<br />

that the world’s machine tool builders are faced<br />

with, companies try especially hard to secure business<br />

in their own domestic markets. This is particularly<br />

so in the BRICs (Brazil, Russia, India, and China).<br />

Against this diffi cult backdrop, the Russian machine<br />

builder TMP was awarded a contract to build an<br />

innovative new hot steel rolling project in Brazil.<br />

The main task of this project was building a hot rolling<br />

press system, called Rollers. The Rollers produce<br />

one of the suspension details of trucks and consist<br />

of the hot rolling press with special manipulator, the<br />

system of transport of hot billet and other technological<br />

equipment. For this mill, TMP developed an<br />

intelligent automated handling system, called Rollers,<br />

to manipulate the hot working material.<br />

Automating complex procedures<br />

The technological algorithm of rollers is divided into<br />

several parts. First, the general receiving manipulator<br />

transfers a red-hot billet to the feed conveyer by an<br />

exactly defi ned path calculated according to the safety<br />

standards. The feed conveyer transfers the billet to the<br />

roller manipulator, which grips the billet and begins<br />

the multiple rolling process. Each roll has four deep<br />

grooves. A billet is rolled through couple rolls which<br />

are formed in the shape of a billet. Usually after four<br />

forming cycles, the roll manipulator transfers the billet<br />

to the outfeed conveyor, which in turn transfers the<br />

billet on to the next manufacturing stage. The control<br />

system within rollers performs a variety of important<br />

tasks. In addition to the precision movement of the<br />

working material, it controls system temperatures,<br />

the hydroelectric equipment, and braking control.<br />

The PLC also coordinates the functioning of the rollers<br />

with other systems such as the furnace and other<br />

handlers, with communication passing via Profi bus.<br />

Drive-based motion control platform<br />

The intelligent control driving the rollers is based on<br />

Simotion D435, a compact drive-based motion control<br />

platform combining motion control, logic control,<br />

and drive control within a single hardware<br />

environment. Simotion is the natural successor to<br />

earlier PLC approaches based on the S7-300 plat-<br />

form. Its greater power enables a larger volume of<br />

programs to be run simultaneously. For the main<br />

drive, Sinamics S120 was chosen. Sinamics S120 is<br />

a modular motion control drive system for complex<br />

tasks. It carries out the complex motion control of<br />

two axes of the roller manipulator, with each axis<br />

being equipped with 5 kW Simotics S-1FT6 motors.<br />

The distributed I/O system is an ET 200M station,<br />

connected to the Simotion D435 via Profi bus. The<br />

control provides the operators with system information<br />

such as the drive operating hours, number of<br />

cycles, axis drive currents, and fault reports. For the<br />

Rollers project the programs are written using<br />

Simotion Scout, the network topology is performed<br />

in NetPro, and the HMI is provided via WinCC Flexible.<br />

These different systems all integrate seamlessly<br />

with the hardware platform. The open system integration<br />

enabled the TMP engineers to clearly specify<br />

and implement scalable solutions for complex technological<br />

tasks.<br />

Variable behavior<br />

The main challenge in developing the rollers was the<br />

two-axis motion control of the roller manipulator.<br />

When a hot billet is rolled, its shape changes dramatically,<br />

with each billet behaving in a slightly different<br />

manner. Because of this variance, the precise position<br />

of the billet as it exits from the rollers cannot be<br />

predicted by mathematical modeling. In order to<br />

achieve accurate control of the handling, a motion<br />

control system with on-the-fl y switching of control<br />

algorithms for each axis was developed. The main<br />

principle of the algorithm is the capability to switch<br />

from master to slave mode on-the-fly. With the<br />

sophisticated control system implemented by TMP,<br />

the roller achieved a throughput of 130 billets per<br />

hour. This Rollers project was TMP’s first motion<br />

automation project using Simotion controls and<br />

Sinamics drives. Despite their relative lack of experience<br />

with this environment, the TMP engineers were<br />

successful in accomplishing an ambitious project<br />

that included the fast switching algorithms for the<br />

roller manipulator. The experience gained opens up<br />

opportunities for TMP in the development of further<br />

complex integrated machines. p<br />

info<br />

contact<br />

www.siemens.com/simotion<br />

alexey.taranchenko@siemens.com<br />

Siemens AG<br />

<strong>spectrum</strong> METAL FORMING 2012 21


Packaging machines<br />

22 <strong>spectrum</strong> METAL FORMING 2012<br />

All photos: Sabatier / M. Laurent<br />

p Sabatier S.A.S., France<br />

Safely<br />

Packaged<br />

Sabatier, manufacturer of machines<br />

for metal packaging, uses the<br />

Simotion D motion control system for<br />

the axis control of a production<br />

machine that was fi rst launched at<br />

Metpack last year. The machine was<br />

equipped q pp with 27 axes in record time.<br />

For more than 40 years, the French company<br />

Sabatier, a member of the Swiss Soudronic<br />

Group, has been developing and producing<br />

machines for the manufacture of three-piece metal<br />

cans in Vitrolles (Bouches-du-Rhône), France. The<br />

metal cans – consisting of base, body, and lid – are<br />

used mainly for industrial products such as oils, solvents,<br />

lacquers, and paints.<br />

Electrical axes revolutionize<br />

production processes<br />

The ability to produce metal cans of this type<br />

requires the use of a large number of axes. Motion<br />

control is therefore a key factor for a machine producer<br />

like Sabatier. Due to the diversity of the containers,<br />

some of Sabatier’s machines have up to 60<br />

numerically controlled axes. Although this guarantees<br />

great fl exibility, it also means that motion control<br />

becomes a signifi cant challenge. Originally,<br />

hydraulic actuators were used at Sabatier for forming<br />

the container body and for seaming. However,<br />

this required as many machines as there were operations<br />

– at that time the production line alone was<br />

around 60 meters long. Then 15 years ago, Sabatier<br />

started a small revolution with its decision to drive<br />

all the axes electrically. The improvements in the<br />

production sequence were noticeable immediately:<br />

from then on, a single machine could manage the<br />

different production stages on a line only 12 meters<br />

long. Nevertheless, it was still necessary to fi nd a


permanent solution for the axis control, because<br />

only in this way would it also be possible to achieve<br />

the required improvements in machine safety. As a<br />

result, Sabatier completely redefi ned its strategy for<br />

control of the electrical axes.<br />

Centralized control intelligence<br />

thanks to Simotion D<br />

To begin with, the architecture of the Simotion D<br />

motion control system and the Sinamics S120 inverters<br />

enabled the machine producer to centralize the<br />

program. Daniel Levert, automation engineer at<br />

Sabatier, explains, “At fi rst each inverter connected<br />

to the direct current bus had its own control program,<br />

which meant that multiple programs had to<br />

be managed using an equal number of modules.<br />

Now, with Simotion D, we only need a single one.”<br />

This has meant a signifi cant reduction in development<br />

time and has also made it possible to design<br />

the machine so that maintenance is considerably<br />

more consistent, particularly when it comes to<br />

replacing the inverters. “In this case, it’s no longer<br />

necessary to reload the program. Replacement itself<br />

is suffi cient to restart the machine,” says Levert.<br />

Improved safety and shorter downtimes<br />

Thanks to this fundamental restructuring of the<br />

automation systems, Sabatier also had the opportunity<br />

to replace signal transmission via cable with an<br />

AS-i bus solution. In this case, 15 door-monitoring<br />

sensors are linked to a single bus, and the AS-i master<br />

integrates a Profi safe transition for the connection<br />

to Simotion D. Levert adds, “This solution<br />

matches our linear backup process precisely. The<br />

additional material costs have already paid for themselves<br />

due to the time saved on installation and the<br />

useful functions for operation and maintenance.<br />

Another positive effect we have noticed is the reduction<br />

in downtimes.” The continuous connection from<br />

safety sensor to motor controller means that it is<br />

also possible to use the SLS (Safely Limited Speed)<br />

safety function via Simotion D. Levert stresses,<br />

“Access to Safely Limited Speed via a dead man’s<br />

switch when a door is open radically alters the possibilities<br />

for control and maintenance.” Not only that,<br />

but the system also notes the address of the opened<br />

doors. As a result, the machine stops completely<br />

when a further safety protection circuit is interrupted.<br />

Thus the controllers also inherently offer the<br />

STO (Safe Torque Off) safety function.<br />

Signifi cant productivity increase<br />

By choosing Simotion, Sabatier considerably<br />

improved the ergonomics of its machines and their<br />

functionality, with the end objective of a signifi cant<br />

productivity increase. Levert confi rms, “There are<br />

lots of advantages.” The Sinamics S120 inverters, for<br />

example, radiate appreciably less heat, which means<br />

there is no longer any need for air-conditioning of<br />

the control cabinet. They are also able to feed back<br />

electricity into the direct current bus or even into the<br />

mains supply. According to Levert, “This leads to a<br />

reduction in power consumption in the order of 10<br />

to 20 percent.” Brake resistors become superfl uous<br />

due to the feedback of the current. Last but not<br />

least, Simotion D guarantees smooth start-up of the<br />

machine during pilot control of the motion. Levert<br />

sums up: “The result is signifi cantly less wastage<br />

during commissioning.” p<br />

info<br />

contact<br />

Top: The machines of the Bodypack series produce cans or<br />

drums with a capacity ranging from 1 to 200 liters<br />

Bottom: One of the servomotor axes that is supplied directly<br />

via Sinamics S120<br />

www.siemens.com/metalforming<br />

david.baillet@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 23


Strip leveling<br />

p Kohler Maschinenbau GmbH, Germany<br />

Gentle, Fast,<br />

and Safe<br />

Modular Sinamics converters with<br />

integrated safety functions form the<br />

centerpiece of a new cut-to-length line<br />

for surface-sensitive thin sheet metals<br />

produced p by y Kohler.<br />

24 <strong>spectrum</strong> METAL FORMING 2012<br />

Thin metal sheets with<br />

highly sensitive surfaces<br />

must be handled gently<br />

Thin sheet metals with coated and sensitive<br />

surfaces are considered to be particularly<br />

demanding during the coil-to-plate process,<br />

as they are very susceptible to damage and therefore<br />

must be handled gently. Kohler Maschinenbau<br />

GmbH in Friesenheim, Germany, specializes in the<br />

production of machines that can guarantee this protection.<br />

The company, which is based in the Black<br />

Forest, recently completed a custom-designed cutto-length<br />

line for a leading German manufacturer of<br />

surface-treated aluminum and copper strip metals.<br />

Keeping the line structure<br />

Using this line, it is possible to process sheet metals<br />

at throughput speeds of up to 80 m/min. The existing<br />

intermediate layer is initially leveled and coiled<br />

in the process, so that a fi lm with good adhesion can<br />

be reapplied as required to protect the sensitive surfaces.<br />

This can either be left on the sheet metal or<br />

removed again prior to the cutting process. Tobias<br />

Frank, project manager at Kohler, explains, “The new<br />

machine also offers a highly dynamic stacking station.<br />

Palleted stacks of plates come out ready for<br />

transport at the end of the process – virtually at the


touch of a button.” The entire plant is controlled<br />

using a fail-safe Simatic S7-CPU 416F. The modular<br />

drive assemblies of the various plant sections and<br />

the other units are linked to the controller via<br />

Profinet. For this Kohler relies throughout on the<br />

Sinamics S120 drive system, thus following the line<br />

structure. As a result, the plant sections can be constructed<br />

independently of each other, commissioned,<br />

and then quickly linked together. The Simatic S7<br />

F-CPU also coordinates the combination of 46 frequency-controlled<br />

axes and more than 40 auxiliary<br />

axes. In addition, it reliably monitors the whole<br />

plant’s functional safety.<br />

Safety functions ease pressure on<br />

the controller<br />

Safety functions within the drive itself ease pressure<br />

on the controller. Frank explains, “At Kohler we use<br />

the Safe Torque Off, Safely Limited Speed, and Safe<br />

Operating Stop safety functions. With this project,<br />

however, we also used the Safe Direction safety function<br />

for the fi rst time.” It is hereby possible to safely<br />

monitor the direction of motion in combination with<br />

Safely Limited Speed. According to Frank, “Using this<br />

new function means that we can ensure that the<br />

drive rolls inside the system always rotate toward the<br />

operator.” This prevents accidents because no one<br />

can be accidentally drawn in between the rolls.<br />

“Reliable monitoring of the direction of rotation also<br />

enables the drive rolls to be cleaned safely. And<br />

thanks to these safety functions within the drive,<br />

we eliminate not only the need for additional safety<br />

hardware but also any wiring requirements,” says<br />

Frank, summing up the advantages.<br />

Precise and inexpensive processes<br />

Those in charge also save themselves a great deal<br />

of effort when assigning parameters by using the<br />

Drive-Cliq digital system bus, which links a drive<br />

assembly to the relevant control units. It also links<br />

virtually all the motors of the Simotics models<br />

M-1PH7 and S-1FK7/1FT7 used throughout. The<br />

electronic nameplate is read out automatically,<br />

rendering time-consuming and often error-prone<br />

manual parameterization unnecessary. The highly<br />

dynamic Simotics servomotors ensure high stacking<br />

speeds in the stacking system at the end of the 45 m<br />

long line. Frank says, “The lifting tables here, which<br />

are often operated hydraulically in other companies,<br />

are moved via servomotors and rigid chains.” He<br />

adds, “This process is fast, precise, and leak-free, so<br />

it meets our requirements perfectly. Overall, I have<br />

to say that we are absolutely delighted with the col-<br />

laboration with Siemens. Complex projects such as<br />

this require perfect coordination between all those<br />

involved. Everything has run perfectly smoothly in<br />

our case – from advice in the run-up through to<br />

commissioning and beyond.”<br />

Energy effi ciency gaining importance<br />

Last but not least, energy effi ciency in cut-to-length<br />

lines is gaining increasing importance. Frank explains,<br />

“So that we can work as energy effi ciently as possible,<br />

we operate the frequency converters of our systems<br />

via a common DC link and feed the energy generated<br />

during deceleration back into the supply network<br />

afterward.” This means that the energy can be<br />

reused, whereas with units supplied individually the<br />

energy would need to be reduced via braking resistors<br />

and would inevitably be lost as a result. p<br />

info<br />

contact<br />

» Complex projects such as this<br />

require perfect coordination<br />

between all those involved.<br />

This collaboration has always<br />

functioned perfectly with Siemens<br />

– from advice in the run-up to<br />

commissioning and beyond. «<br />

Tobias Frank, Project Manager, Kohler Maschinenbau GmbH<br />

www.siemens.com/metalforming<br />

koenig.georg@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 25<br />

Photos: Wilhelm Media


Hydroforming machines<br />

p Silfax, France<br />

Precise Repeatability<br />

The French company Silfax specializes in tubebending<br />

machines. These machines are used<br />

to produce bent metal tubes with thin walls.<br />

Jean-Paul Bruyas, one of the founders and the company’s<br />

CEO, stresses, “As a specialist company for<br />

tube-bending machines, we always strive to fulfi ll<br />

our customers’ wishes. To do this we have developed<br />

machines that are specifi cally adapted to certain<br />

markets.”<br />

Manual intervention is unnecessary thanks<br />

to new technology<br />

The Silfax machines enable a wide variety of forming<br />

and bending applications for metal tubes. According<br />

to Bruyas, “The aerospace and automotive industries<br />

are two segments where we are particularly well<br />

26 <strong>spectrum</strong> METAL FORMING 2012<br />

Thanks to its precision and repeat accuracy, the<br />

Sinumerik 840D sl CNC has enabled tube-bending<br />

machine manufacturer Silfax to hydroform tubes<br />

for exhaust ggas<br />

recirculation.<br />

Inserting the tubes that are to undergo the hydroforming process<br />

represented. And with our range, which consists of<br />

bending and forming machines plus hydroforming<br />

machines, we can satisfy the requirements of both<br />

of these industries to a high level.” For the aerospace<br />

industry, for example, the Silfax machines are used<br />

to bend titanium tubes for the Airbus A380. Silfax’s<br />

CEO explains, “When it comes to bending tubes for<br />

the automotive industry, it is virtually impossible for<br />

any of the relevant industry representatives to avoid<br />

us.” The company’s success began in the automotive<br />

industry in 1998. Back then, Silfax developed the<br />

fi rst completely electric production machine for vehicle<br />

exhaust pipes. In the case of tube-bending<br />

machine SE 76, the hydraulics gave way to electrical<br />

motorization of the power axes, which resulted in<br />

better repeat accuracy of the procedures, substantial<br />

All photos: Picasa


» In view of the large number of axes and<br />

the complexity of our machines, the<br />

Sinumerik 840D sl offers us the necessary<br />

fl exibility and also the axis interpolation<br />

function that is essential for saving time and<br />

achieving precision during the various<br />

movements. «<br />

Jean-Paul Bruyas, Technical Director, Silfax<br />

energy savings, and a 30 percent productivity<br />

increase. Bruyas explains, “As a result, all the previous<br />

problems that we were used to from using<br />

hydraulic machines became a thing of the past.<br />

There were no longer any heating times, and it was<br />

not necessary to make adjustments between the<br />

operating times. Instead, the settings were permanently<br />

fi xed. This was a fantastic innovation for us<br />

and made any manual intervention completely<br />

unnecessary. It also brought noticeable advantages<br />

for the user – from material savings to increased<br />

eliability in production.”<br />

Sinumerik enables hydroforming in the<br />

automotive industry<br />

This innovation enabled Silfax to conquer the crucial<br />

automotive market completely. Bruyas says, “Silfax’s<br />

technology is also suitable for what is known as<br />

hydroforming, which is used to manufacture bellows.”<br />

Bellows are stainless steel tubes with thin<br />

walls that can withstand thermal expansions in hightemperature<br />

ranges and are therefore used in the<br />

exhaust gas recirculation systems of motor vehicles.<br />

This is an environmental protection device with<br />

which a proportion of the exhaust gases from internal<br />

combustion engines can be recirculated to the<br />

intake manifold. The “bellows” enable the tube to<br />

expand in high-temperature environments without<br />

fracturing at some point.<br />

“Using the Sinumerik 840D sl guarantees the precision<br />

and repeat accuracy of the hydroforming process.<br />

Of course, choosing the right controller played<br />

a very important role,” emphasizes Bruyas. The<br />

Sinumerik 840D sl can manage up to 93 axes with its<br />

Sinamics S120 converters. The open, distributed,<br />

scalable, and network-capable system has its own<br />

Simatic S7-300 PLC and a distributed Simatic ET 200S<br />

peripheral system. Bruyas says, “The low-voltage<br />

devices that are used in this case also come from<br />

Siemens.” He lists the advantages of this solution:<br />

“In view of the large number of axes and the complexity<br />

of the axis system in Silfax machines, this<br />

controller offers us the necessary fl exibility and also<br />

the axis interpolation function that is essential for<br />

saving time and achieving precision during the various<br />

movements.” The folding process is carried out<br />

on the Silfax SHD4 machine. The complete cycle<br />

takes only 14 seconds. Bruyas says enthusiastically,<br />

“The speed of the process is impressive. With our<br />

machines it is possible to produce up to 40 successive<br />

folds in one single process step, while with<br />

other processes this fi gure is only around 10. This<br />

means that not only is our process faster and more<br />

reliable but at the same time it is also distinguished<br />

by greater repeat accuracy. And all this is because<br />

the movements conventionally carried out using<br />

hydraulics have been replaced by NC axes, which are<br />

operated in turn by a CNC controller.” p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

louis.boyer@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 27


» In view of the large number of axes and<br />

the complexity of our machines, the<br />

Sinumerik 840D sl offers us the necessary<br />

fl exibility and also the axis interpolation<br />

function that is essential for saving time and<br />

achieving precision during the various<br />

movements. «<br />

Jean-Paul Bruyas, Technical Director, Silfax<br />

energy savings, and a 30 percent productivity<br />

increase. Bruyas explains, “As a result, all the previous<br />

problems that we were used to from using<br />

hydraulic machines became a thing of the past.<br />

There were no longer any heating times, and it was<br />

not necessary to make adjustments between the<br />

operating times. Instead, the settings were permanently<br />

fi xed. This was a fantastic innovation for us<br />

and made any manual intervention completely<br />

unnecessary. It also brought noticeable advantages<br />

for the user – from material savings to increased<br />

eliability in production.”<br />

Sinumerik enables hydroforming in the<br />

automotive industry<br />

This innovation enabled Silfax to conquer the crucial<br />

automotive market completely. Bruyas says, “Silfax’s<br />

technology is also suitable for what is known as<br />

hydroforming, which is used to manufacture bellows.”<br />

Bellows are stainless steel tubes with thin<br />

walls that can withstand thermal expansions in hightemperature<br />

ranges and are therefore used in the<br />

exhaust gas recirculation systems of motor vehicles.<br />

This is an environmental protection device with<br />

which a proportion of the exhaust gases from internal<br />

combustion engines can be recirculated to the<br />

intake manifold. The “bellows” enable the tube to<br />

expand in high-temperature environments without<br />

fracturing at some point.<br />

“Using the Sinumerik 840D sl guarantees the precision<br />

and repeat accuracy of the hydroforming process.<br />

Of course, choosing the right controller played<br />

a very important role,” emphasizes Bruyas. The<br />

Sinumerik 840D sl can manage up to 93 axes with its<br />

Sinamics S120 converters. The open, distributed,<br />

scalable, and network-capable system has its own<br />

Simatic S7-300 PLC and a distributed Simatic ET 200S<br />

peripheral system. Bruyas says, “The low-voltage<br />

devices that are used in this case also come from<br />

Siemens.” He lists the advantages of this solution:<br />

“In view of the large number of axes and the complexity<br />

of the axis system in Silfax machines, this<br />

controller offers us the necessary fl exibility and also<br />

the axis interpolation function that is essential for<br />

saving time and achieving precision during the various<br />

movements.” The folding process is carried out<br />

on the Silfax SHD4 machine. The complete cycle<br />

takes only 14 seconds. Bruyas says enthusiastically,<br />

“The speed of the process is impressive. With our<br />

machines it is possible to produce up to 40 successive<br />

folds in one single process step, while with<br />

other processes this fi gure is only around 10. This<br />

means that not only is our process faster and more<br />

reliable but at the same time it is also distinguished<br />

by greater repeat accuracy. And all this is because<br />

the movements conventionally carried out using<br />

hydraulics have been replaced by NC axes, which are<br />

operated in turn by a CNC controller.” p<br />

info<br />

contact<br />

www.siemens.com/metalforming<br />

louis.boyer@siemens.com<br />

<strong>spectrum</strong> METAL FORMING 2012 27

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