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

Isgec Solution g for Hot Forming Line

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 End of Line (EOL) Station with Racking (Cell # 4) 5. End of Line (EOL) Station with Racking (Cell # 4)

Hot Forming Line Layout

Oven 4 Stacks of 4 Ovens (4 load and unload locations, highest at 12’)

Pa P

Load/Unload Load/Unload

Con P

• alletized

Parts 1 Press Cycle Time = 8 sec ntainer 1 Pick from 1

• r 2

Centeri ng table Containe r2 1 Palletiz Parts

Load/Unload

zed 2

Load/Unload After Pick-up Stamp part with date and time stamp

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 ll ) (total 16 cells)

• 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 tit 6 Axes quantity 6 Maximum Static Load on Wrist 100 kg(220.46 lb) Additional Maximum Load on Axis #3 50 kg (110.23 lb) Total Maximum Load 150 kg (330.69 lb) T A i 4 638 N Torque on Axis 4 5 6 638 Nm 638 Nm 280 Nm Axes Stroke (Speed) 1+7 2 3 ± 180° (120°/s)

• 49° to +95 °(108 °/s)

222° t 68° (120 °/ ) 3 4 5 6

• 222° to -68° (120 °/s)

± 200° (190 °/s) ± 120° (190 °/s) ± 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 C5G 125 Kg g (C5G base only) g

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

: 2000 mm (78 7”)

• Daylight

: 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

: 2 nos.

• No. of Moving Bolster

: 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

: Siemens / ABB Main Motor : 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

Responsible for Project

Supplier of Hydraulic Press Supplier of Robotic Automation

Responsible for Project

Supplier of Furnace

(After Sales Support) (Line Integration, Prove Out & Component Trial)

Isgec Customers : g

Comau Robotics Customers :

Thank You