19.07.2005

Flexible ProfiLine stamping plant

Production launch at TWB Fahrzeugtechnik in Artern, Germany

Entrepreneurial commitment and long-term partnership

TWB’s entrepreneurial commitment to the German state of Thuringia was highly praised during the opening speeches. Guests included the Minister President of Thuringia, Dieter Althaus, whose state is fast developing into a major center for European parts suppliers thanks to its central location and targeted investment and development policy. Wilfried Jakob, until April 2005 Member of the Board of Management of Schuler AG, stressed in his speech the successful partnership between TWB and Schuler, spanning over 30 years, which had reached a new level with the complete fitting of the Artern stamping plant. He particularly praised the flexibility of the new production facility, which is capable of supplying almost the complete range of parts required by European car manufacturers and thus provides an important backup function – an outstanding USP within the sector.

Prepared for everything: hydraulic press line

The hydraulic ProfiLine press line with feeder linkage consists of six presses offering a total capacity of 135,000 kN. The double-action drawing press with a capacity of 35,000 kN is equipped with a fully hydraulic 6-point bed cushion system, which optimizes the drawing process and enables consistent part quality. The force of each individual cylinder can be independently programmed for the entire drawing process. This guarantees a high degree of quality especially for the production of complex parts – for example in aluminum – as well as for two-out parts. The presses two through five, with 20,000 kN capacity each, are also fitted with an hydraulic bed cushion as well as a pneumatic slide cushion. The second and third station also feature cutting impact dampers, which help protect press and die – especially when high-strength materials are being processed. Parts which only require five forming stages can be discharged between the fifth and sixth press. The final press can thus be used as a sixth forming station or – in the case of just five processing steps – as a separate hydraulic tryout press. The final press also offers a capacity of 20,000 kN and is fitted – like the drawing press – with a 6-point bed cushion, which ensures optimal tryout of the dies.
With its technical capabilities, the Schuler ProfiLine press line for TWB in Artern is unique within Europe. Its numerous features provide maximum flexibility and ensure a level of quality which meets the most discerning criteria for the production of high-grade and complex car body panels – even with high-strength materials, aluminum and tailored blanks. With a bed size of 5,000 x 2,500 mm, the line can produce the maximum part size common in the car industry.

Seven steps to success: mechanical transfer press

With a press capacity of 25,000 kN and a speed of up to 25 strokes per minute, the plant’s mechanical transfer press is well equipped to meet a wide range of production requirements. Smaller to mid-size panel and structural parts can be produced in seven stages with a transport step of 900 mm. Stages 1 to 6 are fitted both with pneumatic bed cushions for improved control of the drawing process as well as with pneumatic slide cushions to eject parts from the die. The knuckle-joint drive provides a motion sequence which can reduce drawing speeds in the forming area by up to a third compared with eccentric-drive presses. This not only optimizes the drawing process and part quality, but also reduces wear on both press and die.
Parts are transported by Schuler’s electronic 3-axis transfer system, whose axes are freely programmable. A special feeder technology permanently transmits the slide position to the transfer control system. Using a specially defined motion law, the optimal transfer motion for each part is set after entering the die data. The transfer system also boasts high rigidity and low mass movement. It plays an important role in securing longer die life, as parts are placed in the dies with absolute precision – even under extreme acceleration and deceleration. By optimizing motion sequences, the press can reach high stroking speeds under reliable operating conditions.

Clean cut for all shapes: mechanical blanking line

The design of the blanking line is also geared toward the manufacturing needs of the car industry. With a coil weight of up to 35 tons, thicknesses of 0.5 to 3 mm and widths of 400 to 2,000 mm, the line can produce blanks for high-quality exterior and interior car body parts. The line is capable of processing coil material with tensile strengths of up to 1,200 N/mm2. It is thus suitable for high-strength materials, which are increasingly being used by car manufacturers. Moreover, the line is also capable of processing aluminum. The mechanical 800-ton blanking press with a die clamping surface of 4,750 x 2,750 mm can reach speeds of up to 65 strokes per minute. The stacking unit features an NC-controlled stop system for rectangular, trapezoidal, parallelogram and contoured blanks, which can be placed in two stacking stations.