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Deep drawing presses 18 <strong>spectrum</strong> METAL FORMING 2012 p S. Dunkes GmbH, Germany Optimally Tested S. Dunkes has developed a frame deep drawing press that can be used in the auto parts industry to comprehensively try yout tools for subsequent q usability. y The variety of models produced by the automotive industry is continually increasing, while production cycles become shorter and shorter. In order to keep pace, new tools must constantly be developed. For more than 50 years, S. Dunkes GmbH from Kirchheim unter Teck in Germany, has been making machines and systems associated with forming and connection technology. The company has now made a hydraulic tryout Simatic Panel PC 677 Touch Simatic ET 200S HF Control elements Displays Interface Simatic CPU 319F Profinet Profibus Hydraulics Simatic Net Scalance X-000 press for an auto parts supplier – it features a maximum force of 5,000 kN and is used for toolmaking. Precise coordination of all production parameters This HDZ 500 frame deep drawing press is used in toolmaking to try out stepped tools, transfer tools, and progressive dies. The press is also used to press out the fi rst lot sizes and to develop components ready for series production. In order to meet stringent requirements for precision, the press is General functions adjusted with an extremely high guidance ratio by means of an active parallel control for the plunger. The sensor technology of the highly dynamic control picks up the initial tilt that occurs particularly during tool contact, and the servo-valves integrated into the control circuit regulate this within milliseconds. The high variability of the closing and pressing speed allows the subsequent usability of the tools on mechanical presses to be comprehensively Siemens Micromaster 440 Tryout process In the tryout process, the tool stages are tested individually and in succession until both the quality and the cycle time (output) are satisfactory. A prerequisite for this is the precise input of nominal physical values such as pressure (force), distance, speed, and time. All parameters must be regulated. tested. In order to be able to precisely coordinate the required production parameters, the press was also fi tted with a sensitive joystick control. This extensive equipment enables the required multifunctional and wide-ranging application of the press. Panel PC facilitates clear data handling Dunkes presses are generally known for their userfriendliness. For automation, the company relies on Siemens products due to the positive experiences to date. The tryout press uses a Simatic Panel PC 677 Touch
S. Dunkes GmbH in conjunction with the Simatic S7-319F CPU safety control. With this confi guration it is possible to operate the press in combination with the chosen HMI software; it also affords transparent programming, navigation, and storage and transfer of process and tool data. In this way Dunkes can easily manage parameter confi guration for the press. Moreover, the highly effi cient programmable logic controller (PLC) also offers the high performance required even for such a powerful press. The central component of the distributed I/O devices is the Simatic ET 200S HF – a multifunctional, modular distributed I/O system that can be adapted specifically to the automation task at hand. In this case it regulates not only the control elements, displays, and interfaces but also the hydraulics and other general functions. Communication between the control and the operator unit takes place via Profi net, and the connection to the I/O devices is via Industrial Ethernet. Users benefi t from high parts quality Thanks to the sound basic concept and the expansion potential for Dunkes tryout presses, manufacturers can try out their various tools at high speeds and, if necessary, rework them before delivery. Previously, tools were tried out on presses with only one station; individual stepped tools therefore had to be mechanically tested and were only brought together in the production press. This not only resulted in long tryout times but also frequently led to delays in the production process. The benefi ts of the new process, by contrast, soon became apparent: Not only is the running-in period required for a new tool much shorter, but users benefi t from higher parts quality right from the start. With the Siemens technology it is also possible to control the process parameters. Ideal collaboration The new solution was implemented in close collaboration between Dunkes and the designated Siemens consultants. In this way, any questions that arose could be discussed in advance and the solution thereby optimized. Both Dunkes and the auto parts supplier were extremely pleased with the complete plant that was delivered. The press manufacturer is therefore eager to continue its collaboration with Siemens in the future. p info contact www.siemens.com/metalforming stephan.schaeufele@siemens.com With its extensive equipment, the Dunkes 5,000 kN tryout press offers a multifunctional range of application <strong>spectrum</strong> METAL FORMING 2012 19
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