Hot Forming Line Isgec Solution for g Hot Forming Line - PDF document

Hot Forming Line Isgec Solution for g

Hot Forming Line Composition : g p 1. De-Stacking and Marking Station (Cell # 1) 2. Furnace Loading and Unloading (Cell # 2) 3. Press Loading (Cell # 3) 4. Hydraulic Press (Isgec) 5 5. End of Line (EOL) Station with Racking (Cell # 4) End of Line (EOL) Station with Racking (Cell # 4)

Con ntainer Containe 1 r2 locations, highest at 12’) Oven 4 Stacks of 4 (4 load and unload Cycle Time = 8 sec Press Ovens Load/Unload Load/Unload Load/Unload Load/Unload Hot Forming Line Layout Centeri After Pick-up Stamp part with date ng table Pa alletized Palletiz zed Parts 1 P Parts 2 and time stamp P Pick from 1 1 o or 2

Hot Forming Line details : g � Cycle time of Press : 8 sec. without Hold (Dwell) time � Press sequence : Fast Closing Fast Initial Pressing Final Pressing Hold (Dwell) Fast Return � Blank Material : Steel coated Hot Stamp Material � Single blank dimensions - Width (Flow direction) : 1220 mm (48”) - Length : 1830 mm (72”) � Twin blank dimensions - Width (Flow direction) : 1220 mm (48”) - Length : 1830 mm (72”) � Blank thickness : 0.635-2.54 mm (0.025”-0.10”) � Single Blank weight : 20 kg Maximum � Twin Blank weight : 10+10 kg Maximum

De-Stacking and Marking Station (Cell # 1) : g g ( ) Consist up of : � 1 no. Robot for De-Stacking � 2 nos. Moving Carts on Rails / Tables (both options available) � Magnets to avoid Double blank pick up � 1 no. Conveyor with Centering station (Vision system) � � Cart Transfer speed : 0 25 m/s with Positional Cart Transfer speed : 0.25 m/s with Positional accuracy of +/- 3 mm Options : � Marking Machine � Automatic Positioning system for Magnets

Furnace Loading and Unloading (Cell # 2) : g g ( ) Consist up of : � 4 nos. Electric Heated Furnace suitable for Batch System with 4 Cubicles each one (t t l 16 (total 16 cells) ll ) � Suitable for heating blanks upto 920 Deg.C and Blank Size 2200 mm x 2200 mm x 3 mm (86.6” x 86.6” x 0.11”) � Maximum load per cycle per chamber : 35 Kg � Opening and Closing by Pneumatic cylinders automatically operated p g g y y y p � 2 nos. Robots for Loading and Unloading blanks Options : � Fifth Chamber

Temperature Profile of Furnace Temperature Profile of Typical Chamber � Blank is 1.2 mm � Heats up to 950 Deg. C � Approx. 200 sec. Chamber Uniformity � Better than +/- 10 Deg. C

Floor Mounted Heating Elements, Bottom Access

Heating Elements

Common w ired elements to rear

Multi Chamber, Atmosphere,Development Unit

Proto Unit,3 chamber, Atmosphere Side

Atmosphere Flow Stand, Control Panels

7 Chamber System, 2 Piece Sections

Fork Load Chambers

Chamber Interior � Removable Roof � Multiple Zones-Frt-Rear � Atmosphere Capability � � Piers selected based on Piers selected based on automation � Modular Design for maintenance

Press Loading (Cell # 3) : g ( ) Consist up of : � � 1 no Robot for Loading blanks inside the Press 1 no. Robot for Loading blanks inside the Press � Pyrometer inside press measure blank temperature � Interact with Press for checking blank temperature � If blank temperature low, Robot pick the blank and put it in garbage container

Robots : MAIN TECHNICAL FEATURES AXIS / PART DATA Robot model COMAU SMART NJ 100-3.2 Structure Articulated Parallelogram A Axes quantity tit 6 6 Maximum Static Load on Wrist 100 kg(220.46 lb) Additional Maximum Load on 50 kg (110.23 lb) Axis #3 Total Maximum Load 150 kg (330.69 lb) T Torque on Axis A i 4 4 638 N 638 Nm 5 638 Nm 6 280 Nm Axes Stroke (Speed) 1+7 ± 180° (120°/s) 2 -49° to +95 °(108 °/s) 3 3 -222° to -68° (120 °/s) 222° t 68° (120 °/ ) 4 ± 200° (190 °/s) 5 ± 120° (190 °/s) 6 ± 200° (250 to 275 °/s) Repeatability ± 0,20 mm Maximum Reach Horizontal 3209 mm (10.53 ft) Weight Robot 1250 kg (2755.77 lb) Programming language COMAU PDL2 Control unit weight g C5G 125 Kg g (C5G base only)

Smart IP : � A powerful software with a “user-friendly” interface and “Windows-like” icons. � It reduces the robot start-on-production time and manages the line production parameters, calculating the cycle-time of the robots and synchronizing them with the press line during loading/unloading and transfer of the parts. � Immediate productivity display � Total parameterization of the performances.

Hydraulic Press (Isgec) : y ( g ) Major Technical parameters of the Press : � Capacity : 12000 kN (1330 US Ton) � � Daylight Daylight : 2000 mm (78.7 ) : 2000 mm (78 7”) � Stroke : 1500 mm (59”) � Slide/Bolster Size : 3000 mm x 2200 mm (118.1” x 86.6”) � Fast Approach : 800 mm/s � Pressing @ 6000 kN : 250 mm/s Pressing travel : 250 mm (9.84”) � Pressing @ 12000 kN : 75 mm/s Pressing travel : 10 mm (0.39”) � Fast Return : 800 mm/s � No. of Moving Bolster No. of Moving Bolster : : 2 nos. 2 nos. � Direction of Moving Bolster : Center to Left & Center to Right

Hydraulic Press (Isgec) : y ( g ) Major Bought-outs used in the Press : � Main Pumps : Parker / Rexroth � Major Hydraulic Valves : Parker / Rexroth / Oilgear � Pressing & Safety Module : Rexroth � Seals & Packing : Merkel -Simrit / Parker / Buchak Shamban � Pipe & Pipe Fittings : Parker / Legris / Hyloc � Main Motor Main Motor : : Siemens / ABB Siemens / ABB � PLC & HMI : Allen Bradley / Siemens � Lubrication System : Woerner / Voegel

End of Line (EOL) Station w ith Racking (Cell # 4) : ( ) g ( ) Consist up of : � � 1 no Robot for Unloading of blank from the Press and place it in container 1 no. Robot for Unloading of blank from the Press and place it in container. � 2 nos. Racking Containers � 2 nos. Automatic roll doors

Isgec Reference Installations : g 12000 kN (1330 US Tons) Hydraulic Hot Forming Press installed at MARTINREA FABCO, Detroit, USA (Formerly Thyssen Krupp Fabco)

Isgec Reference Installations : g 25000 kN (2780 US Ton) Hydraulic Hot Forming Press installed at AXLE INDIA LIMITED , India

Isgec Reference Installations : g 20000 kN (2220 US Ton) Hydraulic Hot Forming Press installed at BHARAT FORGE LIMITED , India • First machine supplied in 1991 • Repeat order received in 1999 • Repeat order received in 1999 • Used for Calibration & Padding Application • In 24 x 7 continuous operation with CLAMA robot

Comau Robotics Reference Installations : Hot Forming Press Line installed in Cassino Italy

Comau Robotics Reference Installations : Hot Forming Press installed in Clinton, TN

Project Organisation : j g Supplier of Supplier of Hydraulic Press Robotic Automation Responsible for Project Responsible for Project Supplier of Furnace (Line Integration, Prove Out & (After Sales Support) Component Trial)

Isgec Customers : g

Comau Robotics Customers :

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