Knucle Joint Press

THE ENtIRE WORLD OF MEtAL FORMING
Components for sheet metal forming.
TaBLE OF CONtENts / THe entIre wOrLD Of MetaL fOrMIng
TABLE OF CONTENTS. THE ENtIRE WORLD OF MEtAL FORMING.
WeLcOMe tO tHe staMpIng pLant. WeLcOMe tO ScHULer. 01 | BLanKIng LInes

Individual solutions for your production.
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07 | TrYOUt sYsteMs
Cost-effective die startup with hydraulic and mechanical tryout presses, tryout centers, die
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turnover devices and simulators.
08 | LIgHtweIgHt tecHnOLOgIes 02 | HYDraULIc sIngLe presses

Flexible presses for suppliers to the automobile industry, the household appliance industry and for multiple metalforming applications.
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Lines for press hardening (hot stamping), for cold and aluminum forming. For forming fiber-reinforced plastics and for hydroforming.
09 | PrOcess tecHnOLOgY 03 | MecHanIcaL sIngLe presses

Fast, flexible and cost-effective. C-frame presses, blanking presses, knuckle-joint presses, transfer & prog-die presses and servo presses.
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From simulation to series production.
10 | SYsteMs Large pIpe ManUfactUrInG

Spiral pipe welding lines and system solutions for longitudinally welded pipes.
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04 | AUtOMatIOn Of sIngLe presses

Coil lines, roll feed units, tri-axis transfer systems and destackers.
42 11 | LOcatIOns anD ScHULer serVIce

Technical customer service, components and accessories, project business, special services and
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05 | Press LInes
Hydraulic, hybrid, mechanical or servo press lines are fully automated system solutions.
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used machines on your doorstep, worldwide.
06 | AUtOMatIOn Of press LInes

Schuler press lines are equipped with the appropriate mechanization concept for the range of parts, productivity and space requirements.
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Subject to technical modifications and amendments to content. 3
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WELcOME tO tHE stAMPING PLANt. WELcOME tO ScHULER.
Transfer press with ServoDirect technology. 4
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WELCOME tO SCHULER / THe entIre wOrLD Of MetaL fOrMIng
As a world market leader in the technology of metal forming, Schuler offers presses, automation solutions, dies, process technology and service for the entire metal working industry and lightweight automotive construction. Its customers include automobile manufacturers and components suppliers as well as companies in the forging, domestic appliances, packaging, energy and electrical industries. Schuler is a leader in coin minting technology and produces system solutions for the aerospace, railway and large pipe industries. 5,500 people work for the company worldwide. The Schuler Group is present in 40 countries and is majority-owned by the Austrian AnDrItZ-GrOUp. We support you in all phases of a project, in planning new stamping plants through to integrating forming lines into existing structures. In close cooperation with your planning departments, technical purchasing, stamping plant and maintenance, we handle the installation, commissioning and production startup of lines and automation components. In this process, you also benefit from the extensive know-how of our project teams installations all over the world. We are also in daily contact with users of mechanical and hydraulic press technology regarding modernization, rebuilding, relocation and performance enhancements available for existing forming lines. Together we can find solutions that improve the cost-effectiveness of the stamping plant. This book provides you with an overview of our range of products and services. We are just right for the job wherever the highest parts quality, maximum plant availability and reliable press engineering is required day-in, day-out. From blanking and the forming process through stacking the finished components our lines offer the right answer to future requirements including increased use of high and extra high-strength steels or integration of additional process steps in the forming process. Put us to the test.
SCHULER ONLINE Would you like to find out more about our selections? Further information is available on the Internet at www.schulergroup.com. You can also follow us on Facebook at www.facebook.com/schulergroup or on Youtube at http://bit.ly/1gQpND8. There you will find interesting news and worthwhile information.
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BLaNKINg LINEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
BLANKING LINEs
Blanking lines from Schuler offer the complete process sequence from the coil through the blank stack from a single source. You work with the latest safety and control concepts. Their modular structure permits solutions that are individually tailored to the user. All the components of the line have been tested in practical operations, are precisely adapted to one another and guarantee the highest levels of availability and reliability. Expansions for processing aluminum and high-strength steels can be easily retrofitted. And it does not matter where the Schuler line will be used our services are available worldwide.
BLANKING LINE WITH PRESS BLANKING LINE WITH CROSS-CUT SHEAR BLANKING LINE WITH LASER CELL
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SCHULER ONLINE Would you like to find out more about our blanking lines? You can find our complete product range at www.schulergroup.com/automotive. There, you will find extensive information about our system solutions for large-scale mass production.
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BLanKIng LInes
INDIVIDUAL sOLUtIONs, FLEXIbLE APPLIcAtIONs
MaXIMUM PRODUCtIVItY wItH SERVODIRECt PREssEs In addition to the use of conventional presses (mechanical or hydraulic), lines for manufacturing shaped blanks are preferably equipped with servo presses nowadays. ServoDirect technology from Schuler enables movement sequences of the press to be adapted individually to the different blanking dies. This increases productivity and the service lives of dies significantly. Also, lines with this technology are configured for processing an extremely wide range of materials such as aluminum or high-strength steels. Material with a sensitive surface can also be processed carefully, using a press blanking line with the highest productivity. All upstream and downstream automation components, such as the roll feed unit driven directly by servomotors or the flexible Stop2Drop stacker, support the impressive
Blanking line with servo press.
press performance and ensure powerful dynamic properties in blanking. A high level of automation ensures quick production changes and a smooth production process.
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Blanking line with cross-cut shear.
Blanking line with laser cell.
BLaNKINg wItH CROss-CUt sHEaR tHE sOLUtION FOR stRaIgHtFORwaRD BLaNK sHaPEs Schuler offers blanking lines equipped with cross-cut shears for manufacturing blanks with a rectangular, parallelogram or curved shape. If the manufacturing process is restricted to straightforward blank shapes, then cross-cut shears represent the ideal solution both with regard to purchase costs and their productivity. Optionally, the shears can be equipped with an automatic die change. LasER CUttINg: FLEXIBLE PRODUCtION, COMPaCt LINE DEsIgN Blanking lines with lasers are particularly suitable for production sequences with frequent product changes as well, because no tooling is used for laser cutting.
This means there is no need, whatsoever, to invest in dies, die maintenance and die warehousing. The compact design of the line means it can be used even when space is limited and overhead heights are low. With their innovative DynamicFlow technology, they offer the most flexible possible production conditions with comparatively low investment costs. The laser cutting line processes an extremely wide range of materials such as aluminum or high-strength steels, and guarantees high productivity even with skin panels that have sensitive surfaces.
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BLanKIng LInes
BLANKING LINE WItH PREss
Blank shapes when using a press with die (max. stroke rate 105 spm).
OUtPUt RatE OF BLaNKINg LINE wItH sERVO PREss

Feed length [mm] Servo press basic version [strokes/min] Servo press with more powerful motor [strokes/min] 300 75 91 500 71 79 750 64 70 1,000 59 64 1,500 51 51 2,000 42 42 2,500 35 35 3,000 30 30 3,500 28 28 4,000 28 28
ADVaNtagEs Ideal for producing shaped blanks High output performance High level of automation Reducing die wear with ServoDirect technology Proven technology
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BLanKIng LInes
BLANKING LINE WItH cROss-cUt sHEAR
Blank shapes when using a cross-cut shear (max. stroke rate 120 spm).
OUtPUt RatE OF BLaNKINg LINE wItH 4-COLUMN CROss-CUt sHEaR

Feed length [mm] Cross-cut shear [strokes/min] 300 100 500 80 750 66 1,000 57 1,500 47 2,000 41 2,500 35 3,000 30 3,500 28 4,000 28
ADVaNtagEs Ideal for producing blanks with a rectangular, parallelogram or curved shape Attractive price/performance ratio High output performance High level of automation Proven technology
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BLanKIng LInes
BLANKING LINE WItH LAsER cELL
Blank shapes when using laser cutting heads.
OUtPUt RatE OF a BLaNKINg LINE wItH LasER The productivity of a laser line must always be seen in the context of sheet metal thickness, blank contour and laser power. We would be happy to calculate the possible productivity for you on the basis of your product data.
ADVaNtagEs Suitable for all blank shapes No costs for dies and die warehousing Fast product change, delivering a high level of availability Adaptation of blank contours after production startup Simultaneous production of different blank shapes Reduced material costs High energy efficiency Reduced investment volume Space-saving line design
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BLanKIng LIne wItH SerVODIrect tecHnOLOgY
IN PRActIcE
CUstOMer: AUtOMOtIVe sUppLIer, PeOpLe's RepUbLIc Of CHIna
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1.Decoiler 2. Coil infeed 3. Crop shear 4. Coil washing machine 5. Leveling machine 6. Loop pit
7. Roll feed unit 8. Telescopic roller train with left-over coil feed 9. Blanking press with ServoDirect technology 10. Cutting die
11. Telescopic conveyor 12. Vacuum blower for stacking aluminum blanks 13. Blank stacker 14. Stack cart 15. Hydraulic unit
THE REQUIREMENts: Delivery of a blanking line for producing shaped blanks with the shortest downtimes during a coil change. Cutting steel, aluminum and high-strength steels up to 1200newtons/square millimeter Coil width: 2,150 millimeters Coil thickness: 0.5 to 2.5 millimeters Coil weight: 35 tonnes
THE sOLUtION: Fully automated blanking line with blanking press in ServoDirect technology. Coil loading cart for two coils Moving decoiler for 35 tons Threading unit with dirt and clean rolls Cropping station Coil washing machine
Leveling machine with crowning function with 2 cassettes (17 rolls) Loop equipment Roll feed unit with weld detection Blanking press with 8,000 kilonewtons in ServoDirect technology Stacker in Fly2Drop and Stop2Drop stacker technology (energy-efficient vacuum generation by blower)
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HYDRaULIC sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
HYDRAULIc INDIVIDUAL PREssEs
You've got to be flexible. We've got the machines to help. Hydraulic press systems from Schuler are extraordinarily versatile and make it possible for you to achieve efficient series production of a wide range of components from the blank through the finished part. At the same time, innovative hydraulic solutions ensure high output levels, production reliability and the best quality. Whether in classic metal forming, die tryout, die hardening, tubular hydroforming, precision blanking or processing fiber-reinforced plastics: hydraulic presses from Schuler can cope with any challenge round the clock, seven days a week.
HYDraULIc InDIVIDUaL presses Presses fOr tHe nOn-aUtOMOtIVe InDUstrY HYDraULIc transfer presses
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SCHULER ONLINE Would you like to find out more about our hydraulic presses? You can find our complete selection at www.schulergroup.com/hydraulic_press. In addition, you can download the Hydraulic press systems. For the best component quality in the stamping plant brochure as a PDF file.
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HYDraULIc InDIVIDUaL presses
FLEXIbLE APPLIcAtION WItH HIGH PRODUctION RELIAbILItY

ECONOMICaL, FLEXIBLE aND FOR RELIaBLE PRODUCtION Because of their versatility, hydraulic presses offer a wide range of applications in the stamping plant. They can be used as a single press, automated press line, transfer press or, with slight modifications, as a tryout press. In combination with a coil line, destacker or tri-axis transfer, this creates turnkey system solutions for economical parts production. These have a modular structure and offer users a wide range of expansion options. Equipped with a hydraulic bed cushion, impact shock dampening, slide parallelism control and cylinder mode switching, hydraulic presses provide all the prerequisites for efficient production in the component supplier's stamping plant. A data analysis system assists the press operator in straightforward fault diagnosis of the entire
Hydraulic presses offer flexible applications.
system, at the same time as increasing productivity and optimizing the process.
ADVaNtagEs They can be used as a single press, in press lines or as a transfer press Production alternative for a wide range of parts Reduction in unit costs by dynamic cylinder mode switching Simple operation by slide comfort control High process quality through impact shock dampening and a hydraulic bed cushion Parallelism control increases parts quality and reduces die wear Precise eight-way slide guidance
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HYDraULIc press wItH a press fOrce Of 4000 KILOnewtOns
1. Press cylinder
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2. Adjustable eight-way precision slide guidance with solid guide 3. Hydraulic drawing cushion 4. Hydraulically operated slide locking in upper end position as per UVV (safety codes and regulations) 5. AC drive motors designed to suit application 6. High-performance axial piston pumps with electronic pump control 7. Torsion-resistant press frame 8. Slide/piston connection 9. Slide/limitation/impact shock dampening
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10. Impact shock dampening cylinder
MODEL OVERVIEw HYDRAULIC PRESSES 1,600 tO 16,000 KILONEwtONs

Press force [kN] Bed length [mm] 1,000 1,300 1,300 1,600 2,000 1,600 2,000 2,500 1,300 1,600 2,000 1,600 2,000 2,500 1,300 1,600 2,000 1,600 2,000 2,500 3,000 2,500 1,300 1,600 2,000 1,600 2,000 2,500 3,000 2,500 3,000 1,600 2,000 2,500 3,000 2,500 3,000 1,600 2,000 2,500 3,000 2,500 3,000 1,600 2,000 2,500 3,000 2,500 3,000 2,000 2,500 3,000 2,500 3,000 2,500 3,000 2,500 3,000 1,600 2,500 3,150 4,000 5,000 6,300 8,000 10,000 12,500 16,000 Daylight [mm] Standard 700 Option 1,000 Bed width
850
1,300
1,600
2,500 3,000
2,500 3,000
1,100
1,600
On request, hydraulic presses are available with alternative bed sizes and press forces up to 100,000 kN. 17
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HYDraULIc DrawIng press fOr ManUfactUrIng sIDe sILL pLates
IN PRActIcE
CUstOMer: AUtOMOtIVe cOMpOnents sUppLIer, CZecH RepUbLIc
Hydraulic press for producing side sill plates and roof bows.
Maximum output rate of the line: 12strokes/minute.
Semi-automatic die change in 15 minutes.
THE REQUIREMENts: Delivery of a production line for finish-processing of preformed side sill plates and roof bows. Perform pick-up Component transfer through the press Hole punching and forming of specified contours THE sOLUtION: Hydraulic blanking and coining press with tri-axis gripper transfer, blanking and forming dies. Press force: 2,500 kilonewtons Bed size: 2,500 1,300 millimeters Slide parallelism control with screw adjustment Roll-formed component pick-up by robot Part transfer into the press and through the die stations Semi-automatic die change in 15 minutes Maximum output rate: 12 strokes/minute
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PREssEs FOR tHE NON-AUtOMOtIVE INDUstRY
HYDRaULIC PREssEs FOR tHE NON-aUtOMOtIVE INDUstRY Hydraulic presses represent an efficient alternative for a wide range of production tasks in the domestic appliance industry as well as for manufacturers of components made from stainless steel. Both single presses and automated production systems increase users' competitiveness. The lines are characterized by high reliability, availability, fast die changes as well as straightforward adaptation to modified production conditions. Pre-engineered press configurations in conjunction with a wide variety of modular automation options and die change techniques permit customer-specific manufacturing solutions. The lines are also noted for their high degree of user-friendliness.
Hydraulic presses for producing stainless steel sinks.
ADVaNtagEs Reliable equipment with high levels of uptime Maximum flexibility Optimum line configuration using proven components Maintenance-friendly because of easy accessibility of all components High part quality due to sturdy design Process analyses with integrated data analysis system
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HYDraULIc press fOr ManUfactUrIng Heat eXcHanger pLates
IN PRActIcE
CUstOMer: ManUfactUrer Of Heat eXcHanger pLates, USA
Hydraulic coining press. Press force: 25,000 kN.
Fully automatic production system for manufacturing heat exchanger plates.
Heat exchangers of various sizes.
THE REQUIREMENts: High requirements apply to fully automated forming of heat exchanger plates: high stamping forces, many different plate geometries, close tolerances in stamping depth, production process reliability and high equipment availability.
THE sOLUtION: The fully automated production system has at its heart the hydraulic coining press with a multi-cylinder system in short-stroke technology. The system permits flexible adaptation of press force ranges to the different geometries and process technology sequences.
THE PRODUCTION SYSTEM: Blanking system with coil line Lifting bar transfer system for transporting parts in the press Loading and unloading feeder Foil winding units Fully automated die change systems Master controller Presses for edge trimming and hole-punching for fluid outlets
ADVaNtagEs Flexible adjustment of the pressure circuits, adapted to various plate shapes Optimal press force distribution and material flow control thanks to pre-selection of individual pressure circuits and adjustment of individual cylinder pressures Bowing or shimming of the dies no longer required Deflection between bed and slide reduced to a minimum
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HYDRAULIc tRANsFER PREssEs
Hydraulic transfer press. Press force: 25,000 kN.
Feeder loading station with blank singling.
EFFICIENCY, stEP BY stEP Hydraulic transfer presses permit part production on multi-station transfer dies. High throughput rates can be achieved due to hydraulic solutions such as the Schuler ring valve technology and dynamic cylinder mode switching. In single-slide or multi-slide design (with options for one or more bed and/or slide cushions), the capacity range for these presses is 5,000 to 30,000kilonewtons. The active electrohydraulic slide parallelism control and hydraulic impact shock dampening ensure superior part quality and reliability in the forming process. Other auxiliary functions can be directly integrated into the die.
ADVaNtagEs Easy to adapt to different dies Freely programmable slide motion curves Programmable pressure dwell in BDC High level of availability Production of deep components by counter drawing Nominal capacity available over the entire stroke Simple die startup
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MECHaNICaL sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
MEcHANIcAL INDIVIDUAL PREssEs
Blanking and forming systems from Schuler are used successfully in a very wide range of industries. Sheet metal parts produced flexibly and economically with the best quality, and overcome challenges such as large part quantities, complicated part geometries and processing high-strength materials. The breadth of our product range for economical series production of high-quality components is matched only by the requirements of the various industries. Whether C-frame presses, automatic blanking presses, knuckle-joint presses, servo presses or conventional mechanical transfer/prog-die presses together, we can find the right solution for your success.
C-fraMe presses AUtOMatIc bLanKIng presses KnUcKLe-JOInt presses Presses wItH SerVODIrect tecHnOLOgY Presses wItH TwInSerVO tecHnOLOgY Transfer presses MULtIpLe-sLIDe transfer presses
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SCHULER ONLINE Would you like to find out more about mechanical single presses? You can find our complete selection at www.schulergroup.com/stamping_cutting. In addition, you can download the At Home in Every Industry. Blanking and Forming Systems from Schuler. brochure as a PDF file.
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MecHanIcaL InDIVIDUaL presses
C-FRAME PREssEs
FOR UNIVERsaL aPPLICatION C-frame presses provide small and medium-size companies high product quality at low per unit cost. Innovative solutions for equipment and controls ensure an integrated manufacturing process. The machines are configured for manual loading (CB series) and either manual loading or automatic mode (C series). MODULAR FLEXIBLE ERGONOMIC The newly developed C-FLEX line (CFL) series is based on a combination of experience gained from users and more than 70 years of experience in building C-frame presses. The modular structure makes it possible to adapt to changing production conditions at any time from straightforward manual loading to fully automatic production. The presses are converted quickly and ergonomically, while two different control concepts
C- FLEX line 630 kN comfort with foot pedal.
allow the presses to be adapted to individual customer requirements.
MODEL OVERVIEw OF C-FRaME PREssEs

Model Press force [kN] Drive capacity [kW] Stroke rate [spm/] Adjustable slide stroke [mm] Slide adjustment [mm] Bed dimensions [mm] Slide dimensions [mm] Shut height* [mm] Throat [mm] Weight with normal equipment [kg] CB-250 250 1.5 150 5 75 50 465 360 220 160 270 185 2,000 CB-400C-400 400 2.2 60 140 5 100 70 650 480 370 300 240 220 3,000 CFL-630 630 4 30 120 8 120 100 820 590 470 410 320 280 5,000 CFL-1000 1,000 7.5 30 90 10 130 100 950 660 540 510 370 330 7,000 CFL-1600 1,600 18.5 20 70 12 180 110 1,250 750 850 630 440 370 14,000 C-2500 2,500 18.5 19 57 19 250 130 1,400 860 1,000 700 470 430 28,000
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AUtOMAtIc bLANKING PREssEs
MOtION CHaRaCtERIstICs
Stroke [mm] max.
Time [s]
Sinusoidal profile Modified sequence (servo drive) Automatic blanking presses: The optimum solution for straightforward components.
WIDE RaNgE OF PaRts HIgH OUtPUt Blanking presses (MC series) are standard machines with extensive basic equipment for blanking classic sheet metal components from the coil. In the range from 1,250 to 5,000 kilonewtons, they represent an optimally-priced solution for manufacturing components with high output rate.
The blanking presses are also available up to 2,000 kilonewtons with servo drive as well (MSC series). Eight predefined slide speed profiles enable optimum adaptation to the components to be produced. In combination with an integrated high-performance transfer system, it is also possible to manufacture stampings with complex geometry directly from the die.
ADVaNtagEs Little bowing due to rigid welded construction Long slideways ideally absorb off-center forces Two transverse shafts compensate for rotational forces without additional masses Low-noise drive with helical gearing Optional servo drive permits optimized speed profiles for higher output with the same component quality and longer die service lives Quick conversion to new die Hydraulic overload protection protects the machine and the die
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BLANKING PRESS
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1. Flywheel with pneumatic clutch 2. Torsion-resistant press frame 3. Press drive by helical gearing 4. Bolt fittings for high pull-back forces 5. Lubricated, re-adjustable eight-way precision guiding 6. Press bed openings provided for scrap removal 7. Hydraulic overload protection 8. Slide counterbalance 9. Intermediate gear for diametrically opposed running of eccentric gears
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MODEL OVERVIEw OF BLANKING PRESSES (MC) aND BLaNKINg PREssEs wItH sERVO DRIVE (MSC)
Model Press force [kN] Bed length [mm] 1,400 1,800 2,200 3,000 Shut height [mm] Slide adjustment [mm] Adjustable slide stroke [mm] Stroke rate MC [spm] Stroke rate MSC [spm] 450 150 20180 30150 130 550 150 20220 30130 100 650 150 40315 25100 1,000 1,100 1,300 1,300 750 200 40315 2080 1,400 800 250 40315 2070 MC-1250 MSC-1250 1,250 MC-2000 MSC-2000 2,000 MC-3000 3,000 Bed width MC-4000 4,000 MC-5000 5,000
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HIgH-sPEED BLaNKINg PREss The two-rod high-speed blanking press (MCF series) is designed for producing components with output rates of up to 300 strokes/minute. The slide guidance system with preloaded, play-free roller bearing units also guarantees the necessary precision in the process: the best prerequisite for series production of small components with tight die clearances. In these lines and processes, perfect synchronization between automation and the blanking press is of great importance. Users can fully tap the output potential of the new press generation in practical operation. THE aDVaNtagEs: Fast and reliable press type Output rate up to 300 strokes/minute Stress-relief annealed frame
MCF twin-rod high-speed blanking press.
Long die service lives Longitudinal shaft machines with rotary mechanical counterbalance Linear roller bearings Planetary gear unit ensures high available power, even at low speeds Fully automatic stroke and slide adjustment reduces die change times Infinitely variable overload protection for die and machine
MODEL OVERVIEw OF HIgH-sPEED BLANKING PRESSES (MCF)

Model Press force [kN] Bed length [mm] 1,000 1,300 1,600 Shut height [mm] Slide adjustment [mm] Adjustable slide stroke [mm] Stroke rate [spm] 350 70 1280 30300 350 70 12100 30300 400 100 10100 30280 400 100 10120 30280 700 700 800 800 1,000 500 100 10120 30260 1,000 500 100 10130 30260 MCF-630 630 MCF-800 800 MCF-1000 1,000 Bed width MCF-1250 1,250 MCF-1600 1,600 MCF-2000 2,000
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KNUcKLE-JOINt PREssEs
Knuckle-joint press with servo drive. Press force: 8,000 kN.
Control panel of the overall machine.
PRECIsE IN OPERatION The very rigid press concept and the slide movement that is characteristic of knuckle-joint presses guarantee that ready-to-install precision parts can be manufactured economically. Each machine permits efficient blanking, drawing, embossing, punching and calibrating in one operating sequence, while the various stations can also ADVaNtagEs Optimized slide motion by modified knuckle-joint drive and maximum production flexibility with user-programmable stroke heights and motion sequences in knuckle-joint presses with servo drive Drawing, bending, cleaning, blanking and calibrating operations in one press cycle High system rigidity for close component tolerances and reduced cutting impact Excellently suited for processing high-strength steels Reliable repeat accuracies, even with fluctuating material thicknesses and strengths Shorter die startup times by precision setup using hand wheel be combined with one another. The optional use of ServoDirect technology also ensures extra flexibility and productivity. The new PSK and PSK PLUS series are the perfect solution for components with increased requirements for precision and smooth cutting proportion.
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MODEL OVERVIEw OF KNUCKLE-JOINt PREssEs (TMK)

Press force [kN] Bed length [mm] 1,500 2,000 2,500 3,000 3,660 Shut height [mm] Stroke down Adjustment up Slide adjustment [mm] Slide stroke [mm] with stroke adjustment with fixed stroke Stroke rate [spm/] with stroke adjustment with fixed stroke 20140 20110 20140 20110 20120 2095 20120 2095 2090 2075 2090 2075 2080 2070 2065 2050 40160 160 40160 160 60200 200 60200 200 60200 250 80250 250 80250 250 300 300 400 500 150 500 600 150 600 700 150 700 800 150 700 800 150 800 900 200 800 900 200 800 1,100 200 800 1,100 200 1,000 1,000 1,000 1,000 1,000 1,000 1,100 1,100 1,100 1,100 1,100 1,100 1,200 1,200 1,200 1,400 1,400 1,400 1,500 1,500 1,500 1,500 1,500 1,500 2,000 2,500 3,150 4,000 Bed width 5,000 6,300 8,000 10,000 15,000
MODEL OVERVIEw OF KNUCKLE-JOINt PREssEs wItH sERVO DRIVE (MSK)

Press force [kN] Bed length [mm] 2,000 2,500 3,500 Stroke rate [spm/] 3160 3120 1,000 1,000 1,300 380 1,300 370 1,300 360 1,300 360 2,500 4,000 6,300 Bed width 8,000 10,000 15,000
All information for systems with two-conrod design. Stroke rate depending on programmed stroke height and kinematics.
MODEL OVERVIEw OF KNUCKLE-JOINt PREssEs wItH sERVO DRIVE FOR PRECIsION BLaNKINg aND FORMINg PROCEssEs (PSK)
Model Press force [kN] Stroke height in full stroke [mm] Stroke height in oscillating mode [mm] Stroke rate* [spm/] Bed length [mm] 2,000 2,500 3,000 3,500 Shut height [mm] Slide adjustment [mm] 600 150 700 150 1,000 1,000 1,100 1,100 1,100 1,300 1,300 1,300 800 200 1,300 1,300 1,300 800 200 1,300 1,300 900 200 1,300 1,300 900 200 PSK/PSK Plus2-250 2,500 160 40120 3160 PSK/PSK Plus2-400 4,000 200 50150 3140 PSK/PSK Plus2-630 6,300 300 75225 3100 Bed width PSK/PSK Plus2-800 8,000 300 75225 380 PSK/PSK Plus2-1000 10,000 300 75225 370 PSK/PSK Plus2-1500 15,000 300 75225 360
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PREssEs WItH SERVODIREct tEcHNOLOGY
Operating panel of a servo press.
Production with optimally matched system components.
SUCCEss CaN BE PROgRaMMED Presses with ServoDirect technology open completely new perspectives: maximum flexibility in production, economical production of complex parts geometries and a high level of productivity with optimum parts quality. In combination with highly dynamic Schuler roll feed units, coil lines, destackers or tri-axis transfer systems, fully automatic forming systems are created for a broad range of parts. The presses are driven directly by torque motors which permit highly dynamic forming processes thanks to their high torque. The lack of a flywheel and clutch/brake combination makes the presses flexible, energy efficient and cuts down the maintenance required.
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FLEXIBILITY AND EFFICIENCY
Stroke [mm] max. max. Reduction in cycle time Time [s]
Stroke [mm]
Time [s]
Motion profile of conventionally driven eccentric press Motion profile of the servo press with optimized performance Operation in oscillating stroke Individual programming of the slide motion reduces the cycle time while keeping the forming speed constant.
Oscillating mode, small stroke Oscillating mode with rest position Pass-through mode ServoDirect technology allows the slide motion to be programmed individually.
PROgRaMMaBLE sLIDE MOtION CURVEs The use of highly dynamic torque motors permits straightforward and rapid programming of different movement profiles in one press cycle. This means the slide kinematics can be quickly and easily adapted to the process parameters of the die and the automation system, and optimized for a high stroke rate.
OsCILLatINg stROKE MODE Oscillating stroke mode permits user-programmable slide stroke heights. The reversing movement of the torque motor means that the eccentric drive of the slide has an oscillating motion and alternates between forward in one stroke and backward in the next stroke. This significantly improves cycle count and energy efficiency.
ADVaNtagEs Significant increase in productivity compared to conventionally driven mechanical presses Maximum production flexibility due to user-programmable stroke heights and motion sequences Increased parts quality and die lives due to motion sequences optimally adapted to the particular forming requirements Greatest availability for production mode Best suited for processing high-strength steels Short delivery times and optimized spare part management due to standardized modules Shorter die tryout times because of setup and tryout functions with hand wheel Lower energy costs due to efficient drive solution Easier maintenance compared to conventionally driven mechanical presses, because there are fewer mechanical components.
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Servo press in monoblock design. Press force: 2,500 kN.
Servo presses in monoblock design. Press force: 4,000 kN each.
MODEL OVERVIEw OF sERVO PREssEs IN MONOBLOCK DEsIgN

Modell Press force [kN] Bed length [mm] 2,000 2,500 3,050 4,000 Shut height [mm] Slide stroke [mm] Slide adjustment [mm] Stroke rate [rpm]* 550 32160 150 3160 600 40200 200 3 140 700 60300 250 390 1,100 1,100 1,400 1,800 1,000 80400 300 360 1,800 1,000 80400 300 360 MSD250 2,500 MSD 400 4,000 Bed width MSD 630 6,300 MSD800 8,000
All information for systems with two-point connecting rod design. Subject to technical modification. *Stroke rate depending on programmed stroke height and kinematics.
ENERgY MaNagEMENt Energy accumulators can be used as an option in order to reduce the connected load. This means energy is returned to the energy accumulator during the press cycle in the generative braking phase. This stored energy is available during the subsequent motor acceleration phase, without imposing any additional load on the electrical system.
RELIaBLE COMPONENts The monoblock press body is implemented as a stress-free annealed welded structure. The eccentric gears have a double herringbone profile to provide axial guidance and to reduce noise. The slide roller guide is preloaded to eliminate play. This results in components that guarantee high availability of the machine.
TRYOUt Starting up new dies demands the greatest flexibility. The setup speed can be varied by a hand wheel. The slide can be stopped in any position and the direction of movement can be reversed if required. The quick-lift function makes it possible to move the slide to the maximum top reversing point at any moment during the setup procedure.
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SerVO press In MOnObLOcK DesIgn wItH aUtOMatIOn
LEGEND
1. Coil feed line 2. Decoiler 3. Leveling machine 4. Loop pit 5. Roll feed unit 6. Servo press in monoblock design 7. Electronic, modular tri-axis transfer 8. Operator panel 9. Energy accumulator
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HIgHEst LINE aVaILaBILItY The "Kurvengenerator" (curve generator) software developed by Schuler allows optimum tuning of slide motion properties and automation parameters for the highest process reliability. The design of all components has been optimized using FEM calculation methods. The press bodies are built as welded structures and annealed to reduce stress. REDUCED staRtUP aND sEtUP tIMEs Wide range of tryout functions for the production press using hand wheel function: Die closing movement with variable setup speed Intermittent movement with reversing movement when required Spotting function with selectable die force Quick-lift function for rapid die opening
Servo press in tie rod design. Press force: 11,000 kN.
Different die change systems such as tandem change cart or an extendable bed plate achieve short changeover times.
MODEL OVERVIEw OF sERVO PREssEs wItH tIE ROD DEsIgN

Model Press force [kN] Bed length [mm] 4,000 4,600 5,000 5,100 6,000 6,100 7,000 Shut height [mm] Slide stroke [mm] Slide adjustment [mm] Stroke rate** [rpm] TSD TSC 900 100350 300 1,100/1,100 120450/120500 300/300 1,100 120450 300 1,200 150600 300 345 336 1,100/1,200 120450/150600 300/300 1,100/1,300 150450/200600 300/300 1,800/2,200* 1,600 1,800 1,800/2,200* 1,800 2,200* 2,200 1,800/2,200* 1,800 2,500* 1,800/2,500* 2,500* 2,500* 1,400 200700 300 2,500* 2,500* 1,400 230700 300 2,500* 2,500* 1,400 230700 300 TSD 630 TSC 630 6,300 TSD 800 TSD 1000 TSC 800 TSC 1000 8,000 10,000 TSD 1100 TSC 1100 11,000 TSD 1250 TSC 1250 12,500 Bed width TSD 1600 TSD 2000 TSD 2500 TSD 3200 TSC 1600 TSC 2000 TSC 2500 TSC 3200 16,000 20,000 25,000 32,000
370
360/350 350
350
345/340 338/334
340/336332
334
330
330
34
All information for systems with two-point connecting rod design. Subject to technical modification. *Four-point connecting rod design. **Stroke rate depending on programmed stroke height and kinematics.
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SerVO press In tIe rOD DesIgn wItH aUtOMatIOn
10
11
13
12
LEGEND
1. Material feed (operation either with coil feed line or destacker) 2. Decoiler 3. Leveling machine 4. Destacker, two destacker carts including scissor-lift table and double-blank depositing station 5. Roll feed unit 6. Coil or blank lubricating unit 7. Transfer and centering station 8. Servo press in tie rod design 9. Electronic, modular tri-axis transfer 10. Combined sequential or transfer die 11. Exit conveyor 12. Hydraulic, modular drawing cushion 13. Scrap disposal
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SerVO presses
IN PRActIcE
BLanKIng trIaLs anD prOcess IntegratIOn
Seat shell.
Component with welded nut.
Cylinder head gasket.
INtEgRatION OF FOLLOw-ON PROCEssEs Frequently, component production involves several production steps which performed one after another take up time and productivity. Highly dynamic servomotors from Schuler
allow completely new working methods. Processes such as welding or laser cutting can be integrated directly into the press cycle in a reliable process and with high output rates because of the opportunities for user-programmable time/distance
sequences, as well as by providing rest times. The results are economical production of complex parts geometries and highest output rates with maximum quality. For extra efficiency.
Formed part Flange Gas generator holder Holder Cage Cross plate Cover Center console Insert cup Support Tank filler neck Seat shell Side panel
Mode Progressive Progressive Progressive Progressive Progressive Progressive Transfer Transfer Transfer Transfer Transfer Transfer
Component-specific press force [kN] 1,200 1,300 2,000 2,400 4,000 6,900 6,000 6,600 7,190 9,650 12,600 14,750
Depth of draw [mm] 30 60 40 50 90 40 190 130 67 145 130 80
Max. stroke rate Conventional 30 25 30 30 23 15 12 8 14 14 16 19
Max. stroke rate Servo 56 40 60 50 33 34 17 15 30 18 24 29
Increase + 87 % + 60 % +100 % + 67 % + 43 % + 126% + 42 % + 88% +114% + 29% + 50% + 53%
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SerVO presses
IN PRActIcE
CUstOMer: AUtOMOtIVe cOMpOnents sUppLIer, GerManY anD AUstrIa
Servo press in tie rod design with 16,000 kN press force, coil feed line and destacker combination.
THE REQUIREMENts: Delivery of a servo press for producing a wide range of parts. THE sOLUtION: Servo press in monoblock design with a maximum press force of 4000 kilonewtons. Automated with coil line and feed unit. Monoblock design Bed surface: 2,500 1,100 millimeters Slide stroke 300 millimeters Maximum stroke rate in continuous operation: 80strokes/minute
THE REQUIREMENts: Delivery of a servo transfer press with complete automation for manufacturing structural components in progressive or transfer mode. THE sOLUtION: Servo press in tie rod design with a press force of 16,000kilonewtons and Schuler automation components. Coil line/destacker combination Roll feed unit Electronic, modular tri-axis transfer Conveyor belt Bed surface: 6,000 2,500 millimeters Slide stroke: 600 millimeters Tie rod design
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PREssEs WItH TWINSERVO tEcHNOLOGY
ADVaNCED tHINKINg IN sERVO tECHNOLOgY Following the market launch of ServoDirect technology, the next milestone in a success story was set with TwinServo technology. The new press generation is driven by decentralized TwinServo technology, which offers users additional interesting possibilities in sheet metal forming. The performance capabilities of this innovative press technology are impressively demonstrated by Schuler at its UmformCenter Erfurt on a new transfer press. The new press system produces at a press force of 16,000 kilonewtons and is fully automated with components from Schuler.
TwinServo transfer press at the Schuler UmformCenter Erfurt.
MODEL OVERVIEw OF TwINSERVO PREssEs

Press force [kN] Bed length [mm] 5,000 6,000 7,000 8,000 Slide stroke [mm] Slide adjustment [mm] Press force millimeters before BDT [mm] Number of connection points Stroke rate at max. stroke** and constant speed [spm]/rated capacity [kJ] Oscillating stroke rate 1/3 stroke**[spm] /rated capacity [kJ] 600 300 6 4 40/400 50/250 600 300 6 4 35/500 50/250 600 300 6 4 40/900 60/400 750 300 6 4 30/1,200 40/650 2,200 2,200* 2,500 10,000 16,000 20,000 2,500*/2,200* 2,500*/2,200* 25,000 3,000/2,500* 3,000/2,500* 3,000/2,500* 3,000*/2,500* 3,000/2,500* 3,000/2,500* 750 300 6 4 25/1,500 35/700 3,000* 3,000* 3,000 750 300 6 4 25/1,500 30/900 30,000 35,000 Bed width standard and option*
* Option. ** Deviations possible depending on the motion curve and force profile. 38
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AUtOMateD transfer press wItH TwInSerVO tecHnOLOgY
IN PRActIcE
ScHULer FOrMIng Center ErfUrt
Coil line with decoiler and leveling machine.
Transfer press with TwinServo technology. Press force: 16,000 kN.
Die change by moving bolster.
SCHULER UMFORMCENtER ERFURt: The first transfer press with TwinServo technology was installed at the UmformCenter Erfurt.
THE sOLUtION: Press Decentralized TwinServo drive Press force: 16,000 kilonewtons Main motors: 2 AC servo torque motors 503 kilowatts Four contact points Bed dimensions (L W): 5000 2200millimeters Slide stroke: 600 millimeters Slide adjustment: 300 0.1millimeter Stroke rate: Controllable 330/minute, in oscillating mode without transfer 340/minute Coil feed line Coil line with decoiler, leveling machine, coil-end welding device, PowerFeed roll feed unit and spraying system, can be used with aluminum
Destacker Schuler destacker with removal feeder and shuttle device in the press Transfer Electronic tri-axis rhombus transfer from Schuler Additional equipment Two moving bolsters and parts outfeed belt Dimensions Total length of the machine: 25meters Press height over floor: 6.50 meters Required foundation depth: 5.30meters
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TRANsFER PREssEs
INDIVIDUaLLY aDJUstaBLE FORMINg statIONs Multi-station presses differ from transfer presses mainly in the ability to adjust individual forming stations. Another difference in multi-station presses is the externally mounted blanking slide for integrated blank production. Multi-station presses are built both as single-slide and multi-slide machines with a press force range from 2500kilonewtons to 60,000 kilonewtons. Either mechanical or electronic rail transfer systems are used for parts transport. The advantages are high output and high availability, individual station adjustment in each station and, if necessary, the externally mounted blanking slide for integrated blank production.
Mechanical multi-station press.
MULtI-statION PREss wItH EXtERNaLLY MOUNtED BLaNKINg sLIDE

1. Crown with press drive
1
2 Press upright 3. Drawing slide

2
4. Transfer system 5. Die change cart 6. Blanking slide 7. Drawing cushion
3 4
5 7
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MULtIPLE-sLIDE tRANsFER PREssEs
MULtIFUNCtIONaL Mass PRODUCtION Multi-slide transfer presses deliver impressive practical performance as a functional unit comprising press, transfer and material feed. The configuration is based on the parts spectrum, die size and forming process. Singleslide, double-slide or triple-slide machines are used, depending on the parts spectrum, which also influences the size and number of dies. Parts are transported by a rail transfer system which can be equipped either with cam-controlled or electronic drive.
Multi-slide transfer press.
MULtI-sLIDE tRaNsFER PREss

1 2 3
1. Destacker 2. Transfer press

4
3. Tie rod 4. Crown 5. Upright 6. Slide 7. Finished part unloading belt 8. Moving bolster
7
5 6
9. Damping element 10. Drawing cushion
10
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AUtOMatION OF sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
AUtOMAtION OF sINGLE PREssEs
Our automation ideally combines the press, automation devices and die, offering impressive precision and process reliability. With automation components from Schuler, you benefit from a greater output rate even when processing high-strength steels or aluminum.
DestacKer cOIL feeD LInes ROLL feeD UnIt TRI-aXIs transfer
44 45 48 50
SCHULER ONLINE Would you like to find out more about automating single presses? You can find our complete selection at www.schulergroup.com/automation. In addition, you can download the Performance Along the Line Automation from Schuler brochure as a PDF file.
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AUtOMatIOn Of sIngLe presses
DEstAcKER
Destacker with transfer system for blank destacking.
Integrated system solution. Destacker and coil line on a servo press. Press force: 16,000 kN.
In order to automate transfer presses, Schuler not only offers tried-and-tested destackers but also a special solution. This consists of a mobile combination of coil line in short design with a destacker. For the press owner, this solution opens a wide range of options regarding material and flexibility for efficient part production. It represents a flexible solution for blank and coil processing on a single line. The control is compatible with both the press and transfer, and meets all production requirements.
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COIL FEED LINEs
COIL FEED LINEs IN sHORt DEsIgN Our coil feed lines in short design have been specially developed for the requirements of customers in the components industry. They offer process reliability while meeting the highest material requirements. The lines are optimally suited for producing structural components and processing high-strength materials even in the higher coil thickness range. They are the ideal solution when space is at a premium. Our product range includes coil feed lines in various high-performance basic versions, and is adapted to all press types. The modular concept permits flexible configuration of the lines. With our extensive package of options, you can react to new requirements at any time while keeping control over your investments.
REFERENCE Data OF tHE BasIC VERsIONs

Coil feed line in short design.
Coil width [mm] Coil thickness [mm] Coil weight [t] up to 1850 up to 12 up to 27
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COIL FEED LINEs IN LONg DEsIgN Compact Line product line The Compact Line from Schuler has been specially developed for small coil widths and tonnages. It covers coil widths up to 800 mm and tonnages up to 7.4 tons for requirements with a straightforward level of automation. Power Line product line As an expansion of the Compact Line product line, Power Line coil feed lines are available for large coil widths and tonnages. These Schuler coil feed lines do full justice to the requirements of the automotive and components industry for material feed with the option of a high level of automation for high-speed, prog-die and transfer presses. Coil widths up to 1850 millimeters and coil weights up to 27tons make it possible to prepare coil material for structural and skin panels as well as blanks.
Schuler Power Line.
TECHNICaL Data OF tHE COMPaCt LINE

COMPaCt LINE Coil weight max. [t] Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Leveling rolls [mm] Loop radius [mm] L-BS 0450 3 110 [40] 450 0.5 4 70 1,000 L-BS 0650 5.5 110 [40] 650 0.5 4 70 1,000 M-BS 0800 7.4 110 800 0.5 6 70 1,300
TECHNICaL Data OF tHE POwER LINE

BasIC VERsIONs OF COIL FEED LINEs IN LONg DEsIgN Coil data for Light weight class POWER LINE Coil weight max. [t] Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Leveling rolls [mm] Loop radius [mm] 650 L-BS 0650 5.5 110 [40] 800 0.5 4 53 1,000 1,050 L-BS 0800 12 L-BS 1050 12 L-BS 1300 14.5 110 [80] 1,300 1,600 L-BS 1600 17
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Coil data for Medium weight class POWER LINE Coil weight max. [t] Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Leveling rolls [mm] Loop radius [mm] Coil data for Heavy weight class POWER LINE Coil weight max. [t] Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Leveling rolls [mm] Loop radius [mm] 8 96 1,600 650 H-BS 0650 10 120 800 0.5 6 1,050 H-BS 0800 15 H-BS 1050 15 H-BS 1300 17 205 1,300 1,600 H-BS 1600 23 6 70 1,300 M-BS 0650 13.5 110 650 800 0.5 4 4.5 M-BS 0800 11.5 M-BS 1050 12.5 120 1,050 M-BS 1300 13.5 160 1,300 M-BS 1600 16 205 1,600 1.850 M-BS 1850 22
ADVaNtagEs Flexibility: Systems and components available on short notice Scalable weight classes>Light>Medium>Heavy Wide range of options can be retrofitted Can be configured for manufacturing structural and skin panels Implementation of customer-specific requirements Rapid retrofitting Flexible attachment to existing price systems Variable level of automation: Manual or motor-driven adjustment of the setup axes Visualization User-friendly machine operation: Intuitive operating concept Online diagnosis Attractive price/performance ratio: Significant cost advantage by modular line configuration and preconfigured components Energy-efficient by optimum drive configuration Very straightforward maintenance
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ROLL FEED UNIt
POwER FEED ROLL FEED UNIt The Power Feed roll feed unit shortens the automation time, especially with highly dynamic presses. ServoDirect drives provide greater dynamics and system accuracy, as do the low-play and maintenance-free planetary gear units. In the long term too, this makes it possible to achieve a system accuracy of 0.05 millimeters. Furthermore, there is an optimally configured roll coating which transfers the high acceleration values to the material. The Schuler Power Feed is divided into different weight classes depending on the mass to be moved: Weight class L (Light) with movable mass up to 100 kilograms, M (Medium) with movable mass up to 180 kilograms or H (Heavy) with movable mass up to 300 kilograms.
Power Feed.
FEED PERFORMaNCE DIagRaM, POwER FEED (EXaMPLE)

Feed time [s]
Stroke rate [spm]
400 350 300 250 200 150 100 50 0 0 100 200 300 400 500 600
0,40 0,35 0,30 0,25 0,20 0,15 0,10 0,05 0,00 Feed time 240,0 180,0 120,0 60,0
Feed length [mm]
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MODeL VarIants
COIL DATA POWER FEED Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Coil cross section max. [mm] Loop radius [mm] POWER FEED Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Coil cross section max. [mm] Loop radius [mm] POWER FEED Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm] Coil thickness max. [mm] Coil cross section max. [mm] Loop radius [mm] L-BP 0300 40 300 0.5 4.0 750 1,000 M-BP 0300 40 300 0.5 6.0 1,350 1,300 L-BP 0450 40 450 0.5 4.0 1,125 1,000 M-BP 0450 40 450 0.5 6.0 2,025 1,300 L-BP 0650 40 650 0.5 4.0 1,300 1,000 M-BP 0650 40 650 0.5 6.0 2,600 1,300 H-BP 0650 40 650 0.5 8.0 3,250 1,600 L-BP 0800 40 800 0.5 4.0 1,600 1,000 M-BP 0800 40 800 0.5 6.0 2,800 1,300 H-BP 0800 40 800 0.5 8.0 4,000 1,600 L-BP 1050 40 1,050 0.5 4.0 2,100 1,000 M-BP 1050 40 1,050 0.5 6.0 3,150 1,300 H-BP 1050 40 1,050 0.5 8.0 5,250 1,600 L-BP 1300 80 1,300 0.5 4.0 2,600 1,000 M-BP 1300 80 1,300 0.5 6.0 3,900 1,300 H-BP 1300 80 1,300 0.5 8.0 6,500 1,600 L-BP 1600 80 1,600 0.5 4.0 3,200 1,000 M-BP 1600 80 1,600 0.5 6.0 4,800 1,300 H-BP 1600 80 1,600 0.5 8.0 6,400 1,600 M-BP 1850 80 1,850 0.5 6,0 7,200 1,300
ADVaNtagEs Connection to all press types Ideally usable within highly dynamic processes ServoDirect drive System accuracy of 0.05 millimeters Scalable in weight class and performance Available on short notice Low maintenance requirement Can be retrofitted at any time
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TRI-AXIs tRANsFER sYstEMs
PRO TRaNs With its three motor versions L (Light), M (Medium) and H (Heavy), Schuler Pro Trans covers low, medium and high part weights and stroke rates. The heavy version has twice the performance capability of the light version, while the medium variant is situated in between. All the transfers owe their significantly improved output performance to having motor systems with direct advance drive, featuring highly dynamic servo drives. Overall, the Schuler Pro Trans has a modular principle: The three defined standard models AT1, AT2 and AT3 can quickly and easily be adapted to changed requirements. Schuler offers a wide selection of options for this. POwER TRaNs Schuler offers a high-end transfer solution for highperformance presses in the form of Schuler Power Trans
Schuler Pro Trans transfer.
and the S (Speed) motor system, the use of which permits productivity to be increased even further and by a significant amount. For example, the output rate with Power Trans is up to 30% higher than with Pro Trans motor systems. This additional performance is achieved in particular by using newly developed carbon rails with aluminum profile functions combined with the ServoDirect drive. The rails are very light and rigid, which means the vibration levels are extremely low. As a result, they are ideal for use in highly dynamic production processes.
The new modular transfer generation is a high-performance addition to sheet metal forming presses. Designed with three sizes, the transfer system covers a wide range of applications. In all transfer solutions, active vibration damping AVD also guarantees reliable parts transport with the highest level of dynamic properties and at full load.
ADVaNtagEs Can be retrofitted regardless of the press Optimally adaptable to different applications Simple and cost-effective performance increase High output performance High rigidity in the overall system Low tendency for vibration Short changeover times Large clearances for attaching components for material feed and material unloading Left-over strip processing regardless of material
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INtRa TRaNs The Schuler Intra Trans can be equipped with all motor variants from L (Light) to S (Speed), which means it is suitable for use in presses ranging from conventional to high-performance. In Intra Trans, the transfer rails do not operate through the press window, but are installed between the press uprights. Parts feed in the working direction is performed by movable slides mounted on the transfer rails, with servo drives integrated in the rail. Each carriage of the Intra Trans can be moved individually so the central joining of parts or even different distances between stations are possible. Using this compact transfer makes it possible to manufacture larger parts with the same transfer press. The new transfer solution is also a genuine alternative to progressive die manufacturing. Conventional transfers require a larger press for the same maximum part size but the compact design of the Intra Trans means it needs only the same space as the progressive die. The transfer exploits its full benefit: less material is consumed, because the parts are transported by the slides and not by the coil material itself. Additional material is required in combined sequential production, and the material has to be cut off the finished pressed part as scrap. Intra Trans is ideal for retrofitting to existing combined sequential presses as a means of reducing unit costs. Access to the die and the die change are possible without restrictions as before, and as far as the operator is concerned there is no difference from the Schuler transfers in the Pro Trans and Power Trans series.
OVERVIEw OF tHE sIZEs

Size AT1 AT2 AT3 Support width [mm] 3,000 6,000 10,000 Press window/drive unit width [mm] up to 1,600 up to 2,500 up to 5500
MODULaR sYstEM All models in the Pro Trans, Power Trans & Intra Trans series have gripper rail drive units that can be attached in the press (1), between the press uprights (2) or on the outside of the press uprights (3). Furthermore, they can be installed above (hanging) or below (standing) the transport level, resulting in the highest level of flexibility both in project planning and for retrofitting to existing presses.
Slide
3 Gripper rail drive units 3
3 Gripper rail drive units
Moving bolster
Attachment variants of the transfer drive housings of the Schuler transfer system on the press upright.
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PREss LINEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
PREss LINEs
The future starts with Schuler: with high-quality implementation and the technology of tomorrow, we are taking measures today to ensure the greatest possible productivity in mass production for the automotive industry. Our results satisfy the most exacting requirements and win over our customers worldwide. Flexibility and quality are what we stand for. Our innovations are unusual and practical. we create change for the market, time and time again. Groundbreaking new developments such as ServoDirect technology, press automation with the crossbar feeder or crossbar robot ensure the best component quality, high availability and output.
HYDraULIc press LInes HYbrID press LInes MecHanIcaL HIgH-speeD press LInes SerVO press LInes
54 56 57 59
SCHULER ONLINE Would you like to find out more about our automotive press technology? You can find our complete selection at www.schulergroup.com/automotive. In addition, the highlight on the page provides direct information about the important aspect of High-Speed in the Stamping Plant.
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Press LInes
HYDRAULIc PREss LINEs
Fully automated hydraulic press line.
Loading station with robot automation.
RELIaBLE, FLEXIBLE aND ECONOMICaL Hydraulic press lines are mainly used to manufacture a wide variety of parts in small to medium batch sizes. Depending on the forming operations, the lines consist of four to six single presses. The production process is fully automated from the blank to the finished component. Depending on requirements, automation is provided by conventional robots or crossbar robots developed by Schuler. The control and graphic display for hydraulic press lines offer the operator uniform, user-friendly operation, efficient fault diagnostics and the management of all process and die data for all presses and automation systems.
ADVaNtagEs Flexibility in the forming process Ease of maintenance and installation thanks to block hydraulics Dynamic cylinder mode switching and ring valve technology increase production rates Automation for tooling and dies to ensure fast changeovers Precise slide guiding and rigid press frame Uniform control concept User-friendly operation and efficient fault diagnostics Fast startup of new die sets
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HYDRAULIC PRESS LINES
IN PRActIcE
CUstOMer: TRUCK MANUFACTURER, FRANCE
Existing and newly-developed dies will be used.
Automation with crossbar robot, one destacker and two outfeed belts.
THE REQUIREMENts: When the Euro-6 exhaust standard comes into force on January 1, 2014, permitted nitrous oxide emissions from trucks with a weight of more than 3.5 tons will be reduced by 80%. Our customer took this opportunity to thoroughly revise all of their models. In the future, important components of the new trucks will be produced on a high-performance hydraulic press line from Schuler. High productivity combined with high flexibility proved to be convincing arguments.
THE sOLUtION: Hydraulic lead press with 20,000 kilonewtons press force Three hydraulic follow-up presses, each with 10,000kilonewtons press force Destacker Press automation with crossbar robots Unloading with crossbar robot Two outfeed belts
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Press LInes
HYbRID PREss LINEs
LEaD PREss HYDRaULIC FOLLOw-UP PREssEs MECHaNICaL Hybrid press lines consist of a hydraulic lead press and mechanical follow-up presses. They are a cost-effective alternative when single-action and double-action dies will be used on the same line. Modern hydraulic slide drives put the output rate of hybrid lines in the region of mechanical press lines. The slide cycle of hydraulic lead presses is user-programmable, and the nominal press force of the press is fully available at any time throughout the press stroke.
Hybrid press line with hydraulic lead press and mechanical follow-up presses.
ADVaNtagEs One forming system for single and double-action dies Flexible production alternative Suitable for complex drawn parts because of the hydraulic lead press Quick and easy startup of new die sets
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Press LInes
MEcHANIcAL HIGH-sPEED PREss LINEs
CROssBaR FEEDER IMPROVEs OUtPUt PERFORMaNCE To increase the cost-effectiveness of mechanical press lines, Schuler developed the crossbar feeder. In press lines with crossbar feeder automation, the components are transported directly from press to press without intermediate stations. If required, the components can also be repositioned before placement into the die. As compared to mechanical press lines with robot or feeder automation, it is possible to achieve production rates as high as 15 strokes/minute. In mechanical press lines with crossbar feeder automation, both the loading of press 1 as well as unloading the finished parts can be performed with the crossbar feeder.
Mechanical high-speed press line with crossbar feeder automation.
ADVaNtagEs Output rate up to 15 strokes/minute Crossbar feeder with seven degrees of freedom No intermediate stations required One set of tooling for each press opening Short distances between presses Rapid die and tooling changes
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MecHanIcaL HIgH-speeD press LInes
IN PRActIcE
CUstOMer: AUtOMObILe ManUfactUrer, PeOpLe's RepUbLIc Of CHIna
Mechanical high-speed press line.
End-of-Line-System.
THE REQUIREMENts: Delivery of a fully-automated mechanical high-speed press line.
THE sOLUtION: Schuler high-speed press line. Destacker Loading press 1 with crossbar feeder Fast die change Crossbar feeder press automation End-of-Line-System with crossbar f eeder and robot Control station
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Press LInes
SERVO PREss LINEs
QUICK, COMPaCt aND FLEXIBLE Equipped with a Schuler destacker, crossbar feeder and End-of-Line-System, servo press lines offer the greatest possible flexibility, high output rates with a wide range of parts as well as short die and tooling change times. Using innovative drive technology, the slide movements of all presses can be individually adapted for each component, the forming process, the die and the parts transport. In identical processes, this leads to higher output rates for single, double or four-fold parts in steel, aluminum and components made from higher-strength materials. The combination of high output, short change times and high flexibility contributes to reduction of part unit costs and improvement to the productivity of press shops.
Six-stage servo press line with crossbar feeder automation.
ADVaNtagEs Output rate up to 23 strokes/minute High level of flexibility Reduction in part unit costs Slide movement freely programmable Optimum adaptation to various forming processes Automation with destacker and crossbar feeder Compact design of the press line Fully automatic die and tooling change in three minutes One set of tooling per press opening Die tryout possible with hand wheel function User-friendly user interfaces Ergonomic parts outfeed Easy-to-maintain technology, because the flywheel, clutch and brake are dispensed with
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SerVO press LInes
IN PRActIcE
CUstOMer: AUtOMObILe ManUfactUrer, GerManY
Servo press line with six die stations.
Destacker.
Control station.
THE REQUIREMENts: Delivery of three servo press lines for large-scale mass production of a wide range of parts in three plants. Output performance: 17 strokes/minute. THE sOLUtION: Fully automated servo press line with six die stations. Destacker with lubricating unit and optical centering station Loading press 1 with crossbar feeder Crossbar feeder press automation End-of-Line-System with robot and crossbar feeder Control station Hand wheel function for die startup Crossbar feeder simulator Die change in three minutes
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Press line with ServoDirect technology. 61
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AUtOMatION OF PREss LINEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
AUtOMAtION OF PREss LINEs
From the single press to the complete press line: As a system supplier, we automate your forming systems intelligently and practically. We boost the performance of your production efficiently and economically. Whether it comes to a broad portfolio of parts, high productivity or the need for a compact space, automation solutions from Schuler guarantee high efficiency and reliable production processes. When it comes to modernizing existing lines, we offer tried-and-tested practical solutions for efficient production of components in the highest quality. Automation solutions from Schuler deliver convincing performance in all aspects of forming technology.
DestacKer fOr press LInes bLanK wasHers anD LUbrIcatIOn UnIts RObOts CrOssbar rObOt CrOssbar feeDer Part racKIng sYsteMs
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SCHULER ONLINE Would you like to find out more about our stamping plant? You can find our High-Speed in the Stamping Plant focus at www.schulergroup.com/automation. In addition, you can download the Performance along the line Automation from Schuler brochure as a PDF.
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AUtOMatIOn Of press LInes
DEstAcKERs FOR PREss LINEs
Modular designed destacker concepts for mechanical and hydraulic press lines are designed to suit downstream forming systems. Schuler offers a selection of models adapted to the required part size and contour, the type of material, the blank weight and the loading speed. From the simplest loader with one robot without centering station for small parts and simple operations, up to destackers with two destacking stations, optical or mechanical centering station, blank washers and lubrication units for large and/or heavy blanks we have it all. The blank destacking is performed by the robot or feeder. To help make full use of the capacities of large press lines, two or even four blanks can be processed at the same time. For press lines with crossbar automation, loading the first die station can be performed by a crossbar robot or crossbar feeder. In addition to handling conventional steel sheet, these destackers can also process blanks
Crossbar robot automation.
in aluminum, steel-aluminum mix, and higher-strength steels.
THE BLANK COMPONENTS One or two destacking stations for separating blanks with a double blank monitor Optical or mechanical centering station Wash unit Lubricating unit Loading unit with robot, crossbar robot or crossbar feeder
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BLANK WAsHERs AND LUbRIcAtING UNIts
Blank washer, lubrication unit and loading robot in front of a hydraulic press line for manufacturing aluminum components.
Blank washers provide a high and consistent component quality.
Destacker with optical centering station, loading robot and blank washer.
BLaNK wasHER aND LUBRICatINg UNIt Superior quality for outer skins and structural parts requires blank washing prior to processing to remove any dirt and deposits, and a final application of a defined amount of oil. The effect of systematic washing and a consistent application of oil prevents downtime for the entire process.
In addition, blank washers also provide significant reductions in downstream reworking and costs when it comes to body-in-white assembly and painting. Blank washers are an integral part of modern destackers and can, if required, be retrofitted to existing lines.
Depending on requirements, the blank washers are designed to suit variable blank lengths and widths. A defined amount of oil provides optimum preparation of the blank for subsequent forming processes. Flexibly programmable spraying heads in the lubrication unit ensure superior part quality for forming involving high drawing forces.
ADVaNtagEs Superior, consistent surface quality of the components Best possible part quality, even with high drawing forces Increased productivity levels Cost-savings for entire process Longer intervals between die cleaning
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RObOts
Press line with robot automation.
Loading robots position the blanks accurately in the die of the first press.
In addition to advanced automation solutions, such as crossbar technology, there is still a place for conventional solutions with robots. Robots are flexible since only one robot is required per press opening. Automatic changeover of robot tooling is easy.
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CROssbAR RObOt
The crossbar robot combines proven robot technology with the advantages of crossbar technology. This application uses a conventional industrial robot. The robot is then expanded by one feed axis and the crossbar beam provides a second axis. The horizontal motion takes place along the x-axis that is mounted on the press uprights. Programming is done at the operator's panel for the robot. The crossbar robot can be delivered with new lines or integrated into existing press lines.
CROssBaR ROBOt
AXR90 Max. loading crossbar robot [kg] (part and tooling) Max. throughput rate with press [strokes/min] Turning horizontally Swiveling at right angles to the transport direction 90 1215 10 25 25
The crossbar robot combines the advantages of robot technology and crossbar technology.
Swiveling in the transport direction
ADVaNtagEs Direct parts transport from die to die Press spacings from 5 to 10 meters No intermediate station Flexible parts orientation from die to die No turning of components from die to die User-programmable change in parts orientation Simple programming Adapter permits takeover of the crossbar feeder tooling Complete solution including destacker and End-of-Line Can also be used as destacker and unloader Flex, double and four-fold parts production possible Suitable for steel and aluminum One set of tooling per opening Rapid automatic tooling change Ease of maintenance due to free access to the press opening
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CROssbAR FEEDER
Crossbar feeder within the press line.
Three rotating and four linear axes.
The crossbar feeder is the automation technology for high-speed mechanical and servo press lines. It increases the line and process efficiency of mechanical press lines. The crossbar feeder offers seven degrees of freedom, three rotating and four linear axes, increasing the
productivity of the stamping plant. The components are transported from die to die without intermediate stations and can also be repositioned. The short, compact design makes the feeder extremely rigid.
ADVaNtagEs Seven degrees of freedom Output rate up to 23 strokes/minute No intermediate stations required Optionally available with feed-direction rail for large distances between presses One set of tooling per press opening Variable press spacings Free access to the press opening Compact construction possible Fast die changes
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PARt RAcKING sYstEMs
Press line with ServoDirect technology and automatic part racking system.
Part racking systems are reliable and fast, while ensuring maximum part quality. A special suction-cup technology protects the highly sensitive surfaces of outer skin panels for downstream processing and preparation for subsequent body-in-white assembly. AUtOMatIC PaRt RaCKINg sYstEM FOR sERVO PREss LINEs The newly-developed, automatic, flexible part racking system from Schuler operates with hanging robots, which can also be moved on a track. The position of the finished parts is detected visually by a camera system.
Then the correction data is transferred to the robots. The robots pick up the finished parts in the correct orientation and stack them in parts containers. The automatic racking system allows single, double and four-fold parts to be stacked with a stroke rate up to 17 strokes/minute. Up to four robots are used with single parts, while there are up to eight used with double and four-fold parts. The robots operate in pairs and alternately stack the parts in the same container in order to ensure a high output rate. The part racking system may also be equipped with an automatic quality control function.
ADVaNtagEs Stacking of single, double and four-fold parts Four-fold racking performance up to 68 parts/minute Compact, short design Automatic quality control can be integrated
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TRYOUt sYstEMs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
TRYOUt sYstEMs
Tryout systems offer the highest level of flexibility for die making and stamping plants. Depending on the requirements, they contain various hydraulic or mechanical press types, die turnover devices and turntables. The time-consuming job of manually reworking the dies is carried out outside the tryout presses. The individual components of the tryout system are connected by moving bolsters on a rail system.
HYDraULIc DIe-spOttIng anD trYOUt presses HYDraULIc MULtIcUrVe presses TrYOUt centers TrYOUt presses wItH SerVODIrect tecHnOLOgY DIe tUrnOVer DeVIces anD sIMULatOrs
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SCHULER ONLINE Would you like to find out more about our tryout systems? You can find our complete offer at www.schulergroup.com/hydraulic_press. There you can find a complete overview of all our system solutions.
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TrYOUt sYsteMs
HYDRAULIc DIE-sPOttING AND tRYOUt PREssEs
DIE tRYOUt BEFORE tHE PRODUCtION staRtUP To keep the startup costs of new die sets low, it is important to prepare them optimally for series production. Hydraulic tryout presses ensure short startup phases under near-to-production conditions. They are suitable for use in die tryout and startup prior to production getting underway. The line operator has the full press force available at any time, and can lower the upper die sensitively onto the lower die if required. In terms of sizes, performance data and equipment details, die-spotting and tryout presses are designed to meet the requirements of die tryout and pilot-series production.
Tryout center with hydraulic tryout presses.
ADVaNtagEs Programmable speeds and forces Slide return possible at any point Precise slide movements using a joystick Maximum force available over the entire stroke Simple adjustment for varying die heights For double-action presses: operation possible in singleaction or double-action modes Rigidity like production presses Bed cushion technology like in production lines ensures optimum startup results
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TrYOUt sYsteMs
HYDRAULIc MULtIcURVE PREssEs
PRECIsE sIMULatION OF FORMINg PROCEssEs Hydraulic multicurve presses are used for starting up die sets in the die shop, in tryout centers and in the stamping plant. Equipped with a hydraulic accumulator drive, they simulate the slide motion characteristics of various hydraulic and mechanical production presses. To properly represent the forming processes of mechanical production lines, the hydraulic multicurve press achieves working speeds up to 500 millimeters/second. Various user-programmable slide motion curves are available to the user at any time, with any desired adjustable stroke rate. The four-point drawing cushion in the press bed is identical to that in the production press and ensures optimum startup results.
Multicurve presses with moving bolster and die turnover device.
ADVaNtagEs Precise simulation of the slide movement curves of all press types Drawing speeds up to 500 millimeters/second User-friendly management of the programmable motion curves Reduction in startup times on production lines Bed cushion identical to that on the production press
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TrYOUt sYsteMs
TRYOUt cENtERs
FLEXIBLE sYstEM sOLUtION IN tHE DIE sHOP Tryout centers with a number of different press types offer an extremely high degree of flexibility in the die shop. Depending on the design, these centers may include mechanical and hydraulic die-spotting and tryout presses, die turnover devices and turntables. The time-intensive manual die rework mainly takes place outside of the tryout presses. The various pieces of equipment within the tryout center are connected by moving bolsters on a rail system. The dies can be moved into the optimum position for the required work.
Tryout center with die-spotting and tryout press.
ADVaNtagEs High level of flexibility Die startup on moving bolsters outside the presses Turning the upper dies with die turnover devices for ergonomic reworking from above Use of simple die-spotting presses for die-spotting work Optimum utilization of the equipment
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HYDraULIc DIe-spOttIng anD trYOUt presses In tHe DIe sHOp
IN PRActIcE
CUstOMer: AUtOMObILe ManUfactUrer, GerManY
Tryout center with hydraulic tryout presses.
The slide can be moved sensitively up and down using a joystick.
THE REQUIREMENts: Tryout center for die startup of series production dies. THE sOLUtION: Tryout center with a total of twelve hydraulic tryout presses. Bed and slide dimensions: 4,500 2,500 millimeters Each press with moving bolster to the front, hydraulic drawing cushion, hydraulic slide cushion and hydraulic impact shock dampening
A hydraulic multicurve press, press force: 25,000kilonewtons With multicurve accumulator technology Drawing cushion in eight-point design Three hydraulic multicurve presses, press force: 21,000kilonewtons each With multicurve accumulator technology Drawing cushion in eight-point design Four hydraulic tryout presses, press force: 16,000kilonewtons each Four hydraulic tryout presses, press force: 12,000kilonewtons each
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TrYOUt sYsteMs
TRYOUt PREssEs WItH SERVODIREct tEcHNOLOGY
INCREasINg tHE aVaILaBILItY OF PRODUCtION PREssEs Tryout presses with ServoDirect technology are configured as a duplicate of mechanical production lines. The bowing and deflection properties of the line are consistently simulated for the slide drive, connection point arrangement, spacings between uprights and bed cushions. This means the availability of production operation can be increased even further. The hand wheel function in particular offers the press operator new possibilities when starting up new dies. The servo drive allows optimum simulation of the movement properties of an extremely wide range of presses.
Tryout presses increase availability in the press shop.
ADVaNtagEs Simulation of the production conditions of mechanical presses Increased availability in production Reduced parts costs per stroke Slide tilting is identical to production presses Takeover of die data
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TrYOUt sYsteMs
DIE tURNOVER DEVIcEs AND sIMULAtORs
Die turnover device for easy turning of upper dies.
Simulator device for crossbar feeder.
DIE tURNOVER DEVICE ERgONOMICaL DIE REWORK For ergonomic rework of upper dies in the tryout phase, it is preferable to turn them to an ergonomically favorable position. Die turnover devices are used for safe opening and turning, and can be connected to the tryout presses using moving bolsters. Die turnover devices simplify die handling, so that the dies are subsequently available to the production presses more quickly. THE ADVANTAGES Simple opening and turning of the dies Ergonomic rework of the turned dies Integration into tryout centers using rail systems and moving bolsters
SIMULatORs PRECIsE sEtUP OF aUtOMatION EQUIPMENt At the interface between the die shop and stamping plant, tryout presses and simulators both play a role in preparing dies and automation devices for series production while the production continues without interruption. The component transport is simulated and optimized in order to reduce cost-intensive setup phases on the production presses. THE ADVANTAGES Simulation of the automation while production continues Shortening of changeover and startup times Increased press uptimes Training of employees while production continues
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LIgHtwEIgHt tECHNOLOgIEs / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
LIGHtWEIGHt cONstRUctION tEcHNOLOGIEs
Nowadays, it is technically feasible to build a light and safe car, but the manufacturing costs are a factor. Some particularly light and low-consumption car models did not attract enough buyers in the past, because they were too expensive for customers. In the future, there cannot be simply one basic approach to achieving greater efficiency. What are called for are different concepts according to individual customer requirements and vehicle categories. It is only through the interplay of several processes and the use of different materials that the required success can be achieved in lightweight construction. Each material has specific strengths, and is therefore suited to different installation areas in the car.
Press HarDenIng wItH PCH tecHnOLOgY Press HarDenIng tecHnOLOgY center COLD fOrMIng Of HIgH-strengtH steeLs ALUMInUM fOrMIng FOrMIng Of fIber-reInfOrceD pLastIcs HYDrOfOrMIng
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SCHULER ONLINE Would you like to find out more about pressure-controlled hardening (PCH) in the forming process? You can find further information at www.schulergroup.com/forming_systems. In addition, you can download various brochures on the topic from there, or view an explanatory film.
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LIgHtweIgHt cOnstrUctIOn tecHnOLOgIes
PREss HARDENING WItH PCH tEcHNOLOGY
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SUstaINaBLY sUCCEssFUL Schuler makes cars lighter. The results are: lower fuel consumption and CO2 emissions. The greatest saving potential available in today's passenger cars are to be found in the bodywork and running gear, which together comprise about 65 percent of the vehicle's mass. Perfectly built, quality components for the chassis, engine and bodywork not only make cars look attractive, they also guarantee safety and comfort. Press hardening with Pressure Controlled Hardening (PCH) technology is the basis for higher body rigidity significantly improving crash behavior. In press hardening, high-strength safety components are manufactured by heating the blank, then forming in a hydraulic press with rapid cooling in the die. Steels with initial strengths of 500 to 700 newtons/ square millimeter achieve ultimate strengths of 1300 to 1600newtons/square millimeter.
Press hardening of safety components in large-scale production.
THE COMPONENt sPECtRUM OF PREss HaRDENINg: Side impact elements and B-pillars Side sill plates Roof frames Support parts Tunnel Door frame reinforcements Bumpers
ADVaNtagEs Higher strengths with reduced component weight Higher rigidity of the bodywork Improved crash behavior New possibilities in component design Good repeat accuracy without spring-back Less expensive material compared to high-strength steels No high press forces required
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PREss HaRDENINg
Yesterday Simple press technology Presses without cushion technology Functions integrated in the die Part quality mainly dependent on the die Only limited process control Long cool-down times Max. production rate 2 parts/stroke Robot or feeder automation Average production rate 4 to 6 parts/minute High cost for dies Today Innovative press technology Presses with cushion technology Functions integrated in the press Part quality can be improved Control of important processes possible Short cool-down times Max. production rate up to 4parts/stroke High-speed transfer automation Average production rate 12 to 24 parts/minute Lower cost for dies
Press hardening die for series production.
THE PREss HaRDENINg PERFORMaNCE RaNgE Forming simulation Die design and construction System engineering and installation - Destacker - Hydraulic press technology - Centering station - Robot or transfer automation - Integration of furnace technology - Blanking presses and dies - Soft-Shock technology - Laser equipment - Finished part handling - Master controller
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PREss HARDENING tEcHNOLOGY cENtER
Test stand for further development of the press-hardening process.
Fast twin-feeder automation.
CENtER OF COMPEtENCE FOR PREss HaRDENINg The center of competence is where Schuler brings together its entire process and machine expertise relating to press hardening, offering not only machine construction but consulting across the entire process. Here, the process is continuously developed by experts from process engineering, press construction, die and automation technology for applications in automotive series production. The current developments in modern steel materials are also incorporated into creating future-oriented system solutions. Development goals include shortening cycle times, optimizing the process and thus reducing the costs per component. Furthermore, the specialists are working on continuous improvements to component quality and increasing the flexibility of system solutions.
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COLD FORMING OF HIGH-stRENGtH stEELs
Innovative lightweight vehicle manufacture is now inconceivable without high-strength steels, and applications in mass production will increase in coming years. It is possible to achieve further reductions in sheet thicknesses by using new, high and extra high-strength steels while maintaining the same component properties. This means a lighter weight and reduced costs. SERVODIRECt tECHNOLOgY Is POINtINg tHE waY tO tHE FUtURE Press lines, transfer and prog-die presses as well as blanking systems with ServoDirect technology have significantly changed stamping plants. They are characterized by maximum flexibility, high output and short die change times. The slide movement of each press for each component can be individually adapted to the forming process, the die and the automation. This
ServoDirect press for cold-forming high-strength steels.
is opening up new possibilities for cold forming of high-strength steels. NEw PROCEssEs NEw POssIBILItIEs Using the advantages of ServoDirect technology, Schuler is developing new production concepts for manufacturing lighter components. For example, interdisciplinary teams are looking into the possibility of integrating follow-on processes or adopting new approaches for manufacturing hybrid components. The objective is to develop new production processes that can meet all the requirements of series production despite the conflicting objectives of reduced component weight, efficient production and high safety requirements.
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ALUMINUM FORMING
Aluminum has now become a standard material in the area of hang-on parts in many vehicle types. The material can significantly reduce the weight of a body-in-white, even if it is only rarely entirely made by forming aluminum. Nowadays, about 40 percent of the overall weight of a car is accounted for by the body. The trend for an increasing variety of materials means aluminum is being used to an increasing extent in automobile production. From the skin through to the front wing and bonnet aluminum is being used more and more frequently in modern, reduced-weight vehicle manufacture because these applications are often selected as a means of replacing heavier materials. Thanks to its unique energy absorption ability, it can also save lives in case of a collision. Lower fuel consumption, greater comfort and performance are further arguments alongside that of
Hydraulic press lines for manufacturing aluminum components.
increased safety for the use of aluminum as a material. Schuler develops mechanical and hydraulic press lines as turnkey solutions for processing aluminum skin panels. We order suitable retrofit solutions for existing production systems. Our turnkey machines have all of their components designed for the materials they will process, from automation through to the press and die.
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FORMING OF FIbER-REINFORcED PLAstIcs
Fiber-reinforced plastics offer a great deal of design freedom and a wide range of functions with minimum component weight. They represent new, lightweight concepts in vehicle architecture and in bodywork manufacture. Schuler builds fully automated hydraulic press systems for efficient and reliable series production of fiber-reinforced components, that can withstand even the most demanding component and production requirements. Hydraulic press systems from Schuler are suitable for series production of SMC (sheet moulding compound) components, GMT (glass mat thermoplastics) components, LFT (long fiber-reinforced thermoplastics) components and RTM (resin transfer moulding) components. Different systems are used for these, depending on the component requirements and the production process.
Robot-automated production of fiber-reinforced plastic components.
The result is: Best parts quality and highest production reliability for greater efficiency and maximum productivity.
HYDRaULIC PREssEs FOR FIBER-REINFORCED PLastICs

Press force [kN] 12,500 Press force with max. parallel 10,500 control force [kN] Bed size [mm] 2,8001,800 Slide stroke [mm] 1,600 Shut height [mm] 2,200 16,000 14,000 2,8001,800 1,600 2,200 21,000 18,000 3,0002,000 1,800 2,600 25,000 22,000 3,2002,200 1,800 2,600 30,000 26,000 3,4002,400 1,800 2,600 36,000 32,000 3,6002,400 1,800 2,600
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HYDROFORMING
Fully automatic tubular forming machine at a German automobile manufacturer.
Tubular hydroforming of longitudinal members.
Tubular hydroforming offers a wide variety of opportunities. Above all, however, it is used in series production of automobiles, since this is where particularly high requirements in terms of component composition and component design need to be met. The process is used for, among other things, forming exhaust, chassis and structural parts.
Schuler offers its partners not only elaborate systems and integration solutions but also component analyses, feasibility studies, prototype and die construction all from a single source.
ADVaNtagEs High component rigidity and strength Low component weight by optimized design without material duplications Best exploitation of material Integration of additional functions in the components Maximum repeat accuracy High component quality and long service life by avoiding welds and having a geometry optimized with regard to function High freedom of design for complex components
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PROCEss tECHNOLOgY / THe entIre wOrLD Of MetaL fOrMIng
PrOcess tecHnOLOgY
CONsIstENt PERFORMANcE
TaRgEtED sUPPORt To be prepared for the challenges of the future, we tackle them with efficient structures. By establishing our own Process Technology department, we have reoriented ourselves strategically, and are now capable of supporting you in an even more targeted and consistent way. For example, we are excellently prepared to expand our range of services and products to include new ideas and innovative concepts. That is the basis for future success together: after all, your success is our success! The product development process is our key area of expertise. Whether you are looking for a complete solution or a partial one with our knowledge of the entire process cycle, we can offer you inestimable advantages for your production.
Set of consecutive steps.
SUCCEssFUL tOgEtHER wItH aLL SCHULER tECHNOLOgIEs
Automotive Press Technology
Stamping & Cutting Technology
Forging Technology
Hydraulic Press Technology
Highspeed Technology
Automation Technology
Process Technology
Feasibility & simulation
Method & production concepts
Design
Model making
Mechanical processing
Assembly
Tryout
Stamping plants
Training & Startup support
Equipment in Quality
Multi-disciplinary technological process team
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Success can be programmed. After all, perfectly matching processes are required for producing components in the best quality and with maximum output rates.
Transfer die for manufacturing disk carriers.
ENgINEERINg PERFORMaNCE sPECtRUM Method planning/simulation Feasibility analyses Creation of methods and drawing systems Process layout creation Deep-drawing simulation including simulation of the follow-up stations Springback calculation Active surface creation Crowning and overpressure points Design Simulation of dies and press sequences Drawing and forming dies Trimming/perforating dies Progressive dies, Transfer dies Folding dies Mechanization systems Model making Drawing system production Casting models for die making Casting models for general engineering
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RaNgE OF DIE sERVICEs Body dies for Skin panels Structural parts Press hardening dies for structural parts Powertrain dies for Disk carriers Spiders Guide disks Thrust washers Modular dies for Welding modules Friction modules Piercing nut modules Laser modules Solid plate forming module Progressive/transfer dies for Structural parts for prototype and ultra-small batch production
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PROCEss tECHNOLOgY / THe entIre wOrLD Of MetaL fOrMIng
New press generation TST TwinServo Technology at the UmformCenter Erfurt.
Gppingen stamping plant.
PaRts PRODUCtION PERFORMaNCE RaNgE Gppingen stamping plant Skin panels Structural parts Schuler Forming Center Erfurt Disk carriers Guide disks Spiders Structural parts
At our stamping plants in Gppingen and Erfurt, we offer the following services: Startup as well as process and quality optimization, temporary part pressing operations, small-series production and series production.
FROM sIMULatION tHROUgH tO sERIEs PRODUCtION Thanks to our core expertise in engineering, method, model and die making as well as tryout, we meet the ever increasing needs of the automotive and components industries with intelligent, complete solutions.
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SYstEMs FOR LaRgE PIPE MaNUFaCtURE / THe entIre wOrLD Of MetaL fOrMIng
AT A GLANCE
SYstEMs FOR LARGE PIPE MANUFActURE
With Schuler, you lay the foundations for success with economic, efficient and high-output production of spirally and longitudinally welded large pipes. On your behalf, we develop turnkey production lines for large pipes whether pipelines for crude oil, natural gas, water or large pipes in the petrochemicals industry, for use in wind turbines or in the construction industry. Not only do we offer the necessary experience, we also provide the appropriate worldwide service for any required solution and projects of all scales. We ensure that we maintain our position of leadership in quality by permanent innovations and investments in research and development. At Schuler, we regard turnkey solutions for manufacturing large pipes as a highly integrated overall concept: From innovative layouts and designs through to intelligent production principles. Our goal is for you to be able to produce in an environmentally friendly way, minimizing your use of resources. In this way, you can benefit during every phase from our extensive, groundbreaking expertise in large pipe manufacture and from our competence.
SPIRAL PIPE PRODUCTION SYSTEMS SYsteM sOLUtIOns fOr LOngItUDInaLLY weLDeD LARGE PIPES
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SCHULER ONLINE Would you like to find out more about our system solutions for large pipe manufacture? You can find our complete selection at www.schulergroup.com/large_pipes. In addition, you can download the System Solutions for the Manufacture of Large Pipes brochure as a PDF file.
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SYsteMs fOr Large pIpe ManUfactUre
SPIRAL PIPE PRODUCTION MACHINES
ONLINE PROCEss Combined forming and welding machine The pipe forming is directly followed by submerged arc welding from the inside and outside. OFFLINE PROCEss Separate forming and welding machine After pipe forming and subsequent tack welding, the submerged arc welding process is performed from the inside and the outside on separate welding stands; speeds up to 12 meters /minute MODERNIZatION Conversion of existing online machines to the offline process The objectives of such a conversion of existing machines are to increase quality and productivity as well as
Spiral pipe production machine.
improving safety at work and energy efficiency. TECHNICaL Data
We plan and implement complete production plants for manufacturing spirally welded large pipes, making them turnkey for you. The machines meet the most demanding requirements in terms of diameter tolerances or welding gap, as well as impressing with maximum availability and productivity. Schuler offers progressive and highperformance solutions, precisely adapted to your requirement profile and tailor-made to your specific requirements from planning and consulting through to startup.
Suitable for spiral pipes with Length up to 24 meters Diameter from 450 to 3500 millimeter (18"140") Wall thickness from 6 to 25 millimeters (1/4"1") Other dimensions possible on request. tHE aDVaNtagEs Automation of important working steps Increased safety at work Low downtimes High process reliability Reproducible, high product quality Planning and implementation of complete production lines
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Hydrotester.
Coil preparation stand.
End beveling machine.
HYDROtEstER Ball head mounted inside sealing or face sealing Water hydraulic control system Variable holding time Connected to PID data system Automatic pipe positioning Automatic test sequence Visualization with database for all pipe parameters Full automatic pipe feeding
COIL PREPaRatION staND Schuler ensures a significant simplification in handling during the coil change at the same time as improving quality and optimizing procedures. Not only does this enable you to reduce unproductive downtimes, it also ensures consistently higher efficiency throughout the production process. Furthermore, you sustainably increase the safety of work on the stand.
END BEVELINg MaCHINE Automatic clamping with correct force according to the diameter Infinitely coverage for all diameter ranges Short changeover time Concentric clamping Energy recovery by using the latest inverter technology
Pipe diameter [inch] Pipe length [m] Closing force [kN] Water pressure max. [bar] High-pressure control range [liter/min]
18140 824 max. 50,000* 400 33300
Coil weight max. [t] External coil diameter [mm] Internal coil diameter [mm] Coil width [mm] Coil thickness [mm] Speed [m/min] Coil unwinding Plasma cutter
45 1,3002,200 720800 1,0002,050 625.4
Cutting speed max. [m/min] Face plate feed speed [mm/min] Face plate drive servomotor max. [kW AC]
90 550 200
* Higher closing forces on request.
0.36.0 0.13.0
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SYsteMs fOr Large pIpe ManUfactUre
LONGITUDINALLY WELDED LARGE PIPES
formed either using a bending element or with a broad bending shoe. This ensures fast and efficient production. PROCEss FOR HIgH PRODUCtION OUtPUt U-O-presses primarily represent a solution when the highest possible production output of a particular pipe dimension range is to be achieved. As with the bending presses, the C-press is also configured as the crimping press for pipe forming; together with the tacking press it ensures consistent pipe forming, while this concept provides optimum passage through all the individual pipe production stations. MODERNIZatIONs Presses and machines from Schuler are particularly suitable for complete modernization concepts or exchanging individual system components in existing
Large pipe production machine.
pipe plants. TECHNICaL Data
Regardless of whether your machine should be designed for longitudinally welded large pipes with a bending press or with U-O-presses Schuler provides you with the innovative and forward-looking production technolgy. We adapt and individually tailor our presses to your product dimensions. Not only are we your expert for efficient modernizations in order to optimize the performance of existing pipe plants, we are also the ideal technology partner for complete turnkey solutions. Whichever approach you take the best idea is to get the expertise and experience of Schuler on your side right from the outset. StEP PROCEss FOR FLEXIBLE PRODUCtION Schuler bending presses (step process) are universally applicable for pipes with diameters from 406 mm to 1625mm (16"64"). Pipes in this dimension range can be
96
Suitable for longitudinally welded large pipes with Length up to 18.3 meters (60') Diameter from 406 to 1625 millimeters (16"64") Wall thickness 12 to 70 millimeters (0.48" 2.76") Other dimensions possible on request. tHE aDVaNtagEs Planning and implementation of complete production lines Matching processes and process sequences High process reliability Reproducible, high product quality High level of automation Safeguarded high availability Energy-efficient hydraulic drives EHF Global service network Security of investment by turnkey solutions
TABLE OF CONTENTS
LFJ-pipe forming press.
U-O press.
LFJ PIPE FORMINg PREss The modular LFJ pipe forming press is a further development of the conventional pipe forming press. This unique development means that Schuler has an exclusive and attractive product highlight in its portfolio. It is characterized by an almost direct sheet feed, and bowing compensation is not required. The modular structure ensures straightforward transport and input into the press without difficulty. tHE aDVaNtagEs High productivity because the panel is loaded at the same time as the open-seam pipe is unloaded High productivity because bending shoes can be used High flexibility by using the bending element High process reliability by simplified press design Simple transport and trouble-free integration into existing production lines because of modular structure Simple structure with scope for future uprating by extension for bending longer pipes Automatic die change and die adjustment available as an option
U-O PREssEs The particular advantage of the U-O process is its high production output of pipes with one set of dimensions. The individual forming steps are adapted to this in order to produce a good quality open-seam pipe. In this way, the subsequent production steps can be carried out optimally. tHE aDVaNtagEs High productivity for set pipe dimension Optimized die setting Simple integration into existing production lines Modernization option for existing machines Comprehensive, tried-and-tested operating concept
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11
FORMING THE FUTURE
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SItes anD ScHULer serVIce
At a gLance
SItEs AND ScHULER sERVIcE
Technologies, systems and machines from Schuler are at home in the following sectors: automotive, tier 1-3, appliances, minting, packaging, drives & generators, railway, aerospace and large pipes. Developing solutions for these industries requires us to do the following: reduce good concepts to a common denominator. With the objective of coming even closer to our customers and taking account of different industry requirements. Therefore, we supply you with not only press technology but also intelligent system solutions which meet the requirements of the global competitive environment. The individual requirements of users in the particular market environment are the center of our attention. In this way, we convert technological leadership into specific customer benefits, and together with you we wish to take advantage of technological and growth opportunities. For this purpose, the Schuler Group employs about 5,500people and has its own sites/agencies in 40 countries. We are your reliable partner who supports you worldwide. Benefit from the extensive expertise of our project teams in installations all over the world. We are there for you.
Partners fOr sHeet MetaL fOrMIng ScHULer SerVIce
100 102
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ADDresses
PARTNERS FOR SHEET METAL FORMING
15
Schuler Group headquarters, Gppingen.
13
Schuler AG Bahnhofstrasse 41 73033 Gppingen Tel. +49 7161 66 -0 Fax +49 7161 66 -233 info@schulergroup.com www.schulergroup.com Schuler service www.schulergroup.com/service
GERMANY
10
Schuler service and production sites Schuler Service
SCHULER ONLINE We employ about 5,500 people worldwide at our own sites and agencies in 40 countries, so we are always in your vicinity. How to contact us. For an overview of all our sites and the most important address information, refer to the Internet at www.schulergroup.com/plant_locations.
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ADDresses
9 3 5 2 6 4 8 11 7
1. Germany 2. France 3. United Kingdom 4. Italy 5. Poland 6. Switzerland 7. Slovak Republic 8. Spain 9. Russian Federation 10. Brazil 11. People's Republic of China 12. India 13. Mexico 14. Thailand 15. USA
12 14
SOCIaL MEDIa Current information about Schuler is available on Facebook, YouTube, Xing, Twitter and LinkedIn. The footer at the bottom right of our webpage www.schulergroup.com contains links to our activities. You can visit us on the Internet. We are looking forward to seeing you.
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SCHULER SERVICE. OPTIMUM SERVICE FOR MORE PERFORMANCE.
Schuler Service offers a tailored portfolio of services covering the entire life cycle of your equipment.
Schuler Service Customer-oriented, efficient, worldwide.
TABLE OF CONTENTS
Over 900 service employees worldwide provide expert support 24/7 in close cooperation with you our partners. Our main priority is always to ensure the ultimate productivity and safety of your production equipment in order to secure your companys continued success. With over 170 years of experience and expertise, we can guarantee the best possible support for the operation of your machines and not only those supplied by Schuler, but by all other manufacturers. Whatever the situation, Schuler Service has the right solution for your specific needs.
Components and Accessories: Spare parts and spare part packages Maintenance kits Repair parts Replacement parts Project Business: Modernization Retrofits Refurbishment Machine relocations Special Services:
OUR SERVICES FOR YOU. Technical Customer Support: Machine inspections Safety inspections Preventive maintenance Repair Repair welding Production support
Service contracts Hotline and remote service Training Tailored customer training Optimizing plant & processes Consulting Used Machinery: Purchase and sale Evaluation
SCHULER SERVICE ONLINE Want to know more about our full range of services? Simply scan the QR code with the camera of your smartphone or tablet. www.schulergroup.com/service
www.schulergroup.com Find out more. Simply scan the QR code using the camera of your smartphone or tablet.
www.schulergroup.com/sheetforming
Schuler AG Bahnhofstrae 41 73033 Gppingen | Germany Phone +49 7161 66 -0 Fax +49 7161 66 -233 info@schulergroup.com service@schulergroup.com www.schulergroup.com
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THE ENtIRE WORLD OF MEtAL FORMING

Components for sheet metal forming.

TaBLE OF CONtENts / THe entIre wOrLD Of MetaL fOrMIng

TABLE OF CONTENTS. THE ENtIRE WORLD OF MEtAL FORMING.

WeLcOMe tO tHe staMpIng pLant. WeLcOMe tO ScHULer. 01 | BLanKIng LInes

turnover devices and simulators.

08 | LIgHtweIgHt tecHnOLOgIes 02 | HYDraULIc sIngLe presses

09 | PrOcess tecHnOLOgY 03 | MecHanIcaL sIngLe presses

From simulation to series production.

10 | SYsteMs Large pIpe ManUfactUrInG

04 | AUtOMatIOn Of sIngLe presses

42 11 | LOcatIOns anD ScHULer serVIce

used machines on your doorstep, worldwide.

06 | AUtOMatIOn Of press LInes

Subject to technical modifications and amendments to content. 3

WELcOME tO tHE stAMPING PLANt. WELcOME tO ScHULER.

Transfer press with ServoDirect technology. 4

WELCOME tO SCHULER / THe entIre wOrLD Of MetaL fOrMIng

BLaNKINg LINEs / THe entIre wOrLD Of MetaL fOrMIng

INDIVIDUAL sOLUtIONs, FLEXIbLE APPLIcAtIONs

BLaNKINg LINEs / THe entIre wOrLD Of MetaL fOrMIng

Blanking line with cross-cut shear.

Blanking line with laser cell.

BLANKING LINE WItH PREss

OUtPUt RatE OF BLaNKINg LINE wItH sERVO PREss

BLaNKINg LINEs / THe entIre wOrLD Of MetaL fOrMIng

BLANKING LINE WItH cROss-cUt sHEAR

OUtPUt RatE OF BLaNKINg LINE wItH 4-COLUMN CROss-CUt sHEaR

BLANKING LINE WItH LAsER cELL

Blank shapes when using laser cutting heads.

BLaNKINg LINEs / THe entIre wOrLD Of MetaL fOrMIng

BLanKIng LIne wItH SerVODIrect tecHnOLOgY

HYDRaULIC sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng

HYDRAULIc INDIVIDUAL PREssEs

HYDraULIc InDIVIDUaL presses

FLEXIbLE APPLIcAtION WItH HIGH PRODUctION RELIAbILItY

HYDRaULIC sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng

HYDraULIc press wItH a press fOrce Of 4000 KILOnewtOns

10. Impact shock dampening cylinder

MODEL OVERVIEw HYDRAULIC PRESSES 1,600 tO 16,000 KILONEwtONs

HYDraULIc DrawIng press fOr ManUfactUrIng sIDe sILL pLates

Maximum output rate of the line: 12strokes/minute.

Semi-automatic die change in 15 minutes.

HYDRaULIC sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng

HYDraULIc InDIVIDUaL presses

PREssEs FOR tHE NON-AUtOMOtIVE INDUstRY

HYDraULIc press fOr ManUfactUrIng Heat eXcHanger pLates

Hydraulic coining press. Press force: 25,000 kN.

Fully automatic production system for manufacturing heat exchanger plates.

Heat exchangers of various sizes.

HYDRaULIC sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng

HYDraULIc InDIVIDUaL presses

HYDRAULIc tRANsFER PREssEs

Hydraulic transfer press. Press force: 25,000 kN.

Feeder loading station with blank singling.

MECHaNICaL sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng

MEcHANIcAL INDIVIDUAL PREssEs

MecHanIcaL InDIVIDUaL presses

allow the presses to be adapted to individual customer requirements.

MODEL OVERVIEw OF C-FRaME PREssEs

* Maximum stroke down, slide adjustment up, without clamping plate. 24

MECHaNICaL sINgLE PREssEs / THe entIre wOrLD Of MetaL fOrMIng

MecHanIcaL InDIVIDUaL presses

2 Press upright 3. Drawing slide