06.05.2008

Twice the performance and greater flexibility:
ZF Sachs modernizes production with new press line and retrofit by Schuler

Ongoing strong demand is providing metalworking companies with considerable order backlogs. As is the case with ZF Sachs in Schweinfurt, Germany. Up to now, the company’s production line consisted of four presses for gearbox components used by commercial vehicles. In order to raise the line’s output, it was replaced in early 2005 by a new press line supplied by Schuler. In addition to the new line, an existing deep drawing press was also modernized by Schuler. Thanks to this extensive press retrofit, performance has doubled and the line can be used much more flexibly.

ZF Sachs has been manufacturing casing covers for commercial vehicles on its line in Schweinfurt since the nineties. Due to strong demand and high capacity utilization, output on the existing line had long been insufficient. It was therefore replaced by a new press line consisting of three hydraulic Schuler presses. In a second step, the existing deep drawing press was modernized by means of a retrofit. With regard to the current high demand and full utilization of production capacity, Bernd Burger, responsible for the project at ZF Sachs, states: “As with the press line, we chose Schuler as an experienced partner because we could be sure that the line would be up and running within the shortest possible time.”

Technology guarantees high output and maximum flexibility

The technological basis of the new production line for ZF Sachs is a hydraulic press line supplied by Schuler. This comprises a lead-off press with a force of 1.600 t and two presses of the SH line, each with 630 t of press force. The three presses are linked by a Schuler electronic three-axis transfer system. Together with the newly equipped deep drawing press, ZF Sachs can now use the line in two different operating modes. As an automated 4-machine line, the blanks are fed to the deep drawing press by feeders and transfer and subsequently run through the entire line. ZF Sachs was able to double output in this operating mode. Additional flexibility is guaranteed by the possibility of operation as an automated 3-machine line, in which blanks or formed parts are fed directly into the second press. The deep drawing press can also be operated as a stand-alone press and can produce other parts via manual operation against the feed direction. Following modernization, ZF Sachs can therefore produce a far greater range of parts on the line than previously possible.

Retrofit increases economic efficiency of existing machines

The successful retrofit of the deep drawing press plays a decisive role with regard to economic aspects. Schuler overhauled the entire hydraulics of the 800 t press and equipped it with completely new electrical and control systems. The press was also equipped with Schuler’s newly developed modular electronic three-axis transfer. Thanks to its ability to flexibly adapt to a wide variety of applications, it is ideally suited for use by ZF Sachs. Its direct drive, for example, enables the space-saving positioning of the coil magazine and blank feeder directly at the entry side of the press. Due to the extreme rigidity of the new transfer, only one clamping box is required. This means that the deep drawing press is accessible for manual operation on the exit side.

Moreover, the retrofit is a perfect example of how users can gain maximum benefit from their existing machine situation. Falk Plaschke, Project Manager Service and Sales at Schuler, explains the benefits of targeted retrofitting as follows: “Considering the high price of steel at present, the general rule is: if the mechanics of the basic frame are adequate, a retrofit can raise the output of existing lines in such a way that they fit seamlessly into a modern manufacturing environment.”