14.08.2008

“Schuler Power Feed” – new roll feed system ensures more dynamic and flexible manufacturing

In the part supply industry there is a constant desire for faster cycle times as companies strive to enhance the efficiency of their manufacturing and the utilization of their press shop capacities. In order to reach these targets, the whole process needs to be optimized. Coil feeding plays a decisive role in these efforts. Schuler has recognized this requirement and launched a new roll feed system called the “Schuler Power Feed” – an innovative automation solution tailored to current market needs.

In developing the new system, Schuler’s engineers focused on that part of the production process in which the coil stock is transported through the roll feed. This so-called automation time is key to determining the machine’s utilization rate. “The aim has to be to reduce automation time to a minimum,” explains Sven Vosse, head of the product division Modular Coil Feed Equipment at Schuler Automation in Hessdorf, Germany. For highly dynamic presses – such as Schuler’s servo press range – the new roll feed system will lead to an immediate reduction in automation time. Servo direct drives and low-clearance, maintenance-free planetary gears ensure a more dynamic and reliable system. This means that a system accuracy of ± 0.05 mm can be achieved even over longer periods. In addition, the coating of the rollers was optimized to ensure that high accelerations can be effectively transferred to the material. These factors allow highly dynamic presses to exploit their full potential. The “Schuler Power Feed” is available in three performance variants according to the mass to be transported. Customers can choose between “L” (Light) with up to 100 kilograms of movable mass, “M” (Medium) with up to 180 kilograms of movable mass and “H” (Heavy) with up to 300 kilograms of movable mass.

Modular and versatile system

To ensure that the “Schuler Power Feed” can be easily implemented into new and existing lines, the entire system has been designed with flexibility in mind. “We made sure that the roll feed’s connection with existing system interfaces was very slim and open for all common field bus systems,” explains Sven Vosse. Users can also easily adapt system performance. A customer who initially opted for the “BP” pack (Basis Performance with up to 30m/s²) based on current needs, can subsequently retrofit a stronger performance pack. The available upgrade packs include the “HP” (high performance with approx. 30 percent more performance) and the “EHP” (extra high performance with approx. 60 percent more performance). The same applies to the dimensions of the roll feed system: due to its modular design, even maximum coil width can be subsequently adapted to customer needs at any time.

Customer survey provides key insight

During the planning phase, Schuler conducted a survey of customer requirements. Criteria such as material specifics, system accuracy, acceleration values, roller materials and accessibility all played a major role. The result: a highly flexible – and for customers highly convenient – drivetrain. In many comparable products, the individual drivetrain components – motor, gearbox and clutches – are still produced as special components. “For our new roll feed system, we rely entirely on components which can be sourced globally,” explains Sven Vosse. This was made possible, for example, by using sophisticated control technology and avoiding all design details which had no clear customer benefit.

Short delivery times

The roll feed’s avoidance of special parts and its modular design mean that large quantities of individual components can be pre-built. As a consequence, the new product and its control system can be supplied very quickly – approx. three months after ordering.

The new “Schuler Power Feed” will be displayed on Schuler’s fair stand at the Euroblech 2008 from October 21 – 25, 2008: Hall 27, Stand D24.