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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