pressemappe. press release. - foam expo pres… · pressemappe. press release. elisabeth steuber...

PRESSEMAPPE. PRESS RELEASE.

Elisabeth SteuberMarketing Director Phone: +49 2734 289 220E-mail: [email protected]

Albrecht Bäumer GmbH & Co. KG Asdorfer Str. 96 - 106 | D-57258 Freudenberg

The company Albrecht Bäumer GmbH & Co. KG We are the leading manufacturer of machines and plants for the foam industry. Through customer-specific engineering and intelligent services, we assure the future of our customers in the foam industry. As market leaders, we offer not only a comprehensive range of foam cutters and transportation systems, but also tailor-made, comprehensive and intelligent concepts for your production. Turnkey systems, control systems for complex process sequences and optimization of your production – we are your partners in the foam industry.

Albrecht Bäumer is an international, medium-sized and value-based family-run business which for generations has undertaken to do everything possible to maintain its competitive edge in the market.

We carry out our day-to-day work with a high degree of personal commitment and impetus. Professionalism and determination best describe how we act in many different situations. We can claim to be able to provide the “best-in-class” solutions using cutting-edge technologies. Because we know what we are doing and how we are doing it.

Together with our customers, suppliers and colleagues, our actions are deliberate and always in complete conviction that we are able to provide the best possible solution.


Bäumer 4.0: New networking platform upgrades Bäumer’s digital services

We assure the future of our customers by deploying customized engineering and intelligent services, and amalgamating information systems with the production level.

We aim to incorporate all of the people, machines and processes involved in the value-added chain into one network through digitalization and automation.

The networking of machines is a basic condition for the development of digitalized, automated processes in modern production. Production plants become more intelligent and have smarter control functionalities allowing more effective and more flexible reactions during the production process.

For many years, Bäumer has been developing and upgrading a variety of automation and control modules for use at various corporate levels of the foam production industry in the control and networking of many different processes.

The automation circle – the so-called system highway - shows how information is passed on. The digital Bäumer portfolio is represented at various levels:


When our customers network their machinery and operative functions with digital Bäumer products, they can reckon with higher value at all points along the value-added chain. Foam producers and foam processors have been battling for many years with increased pressure on efficiency, higher throughput times and reduced costs. In order to reach the required rates and to maintain a leading position in the industry, a trouble-free production process is essential. Simplified and quick processes which control production are elementary. The following diagram shows how Bäumer products are networked in the customer’s day-to-day business.

The portfolio has been upgraded with the new networking platform B+ Connect which affects and connects all levels.


B+ Connect: The new networking platform from Bäumer Bäumer is taking the next steps towards digitalization with the B+ Connect driver (Bäumer Plus Connect), which will result in a new platform for future product lines to bring digitally networked machinery and operative functions to a new level. Four modules to support customer processes With initially four modules Bäumer will be supporting its customers in their direct day-to-day business. Modul 1: B+ Focus Not only the production and maintenance staff but also the product manager and management must keep an eye on the machines, plants and production in real time. The preparation of key figures creates a rapid overview of daily business and facilitates control – wherever and whenever necessary, via smartphone, tablet or laptop. The current condition of the machines can be optimally monitored and visualized. The capacity and efficiency of the machines are shown as well as the complete picture of all machines on an international level in all locations in Germany and abroad.

Identification of OEE (overall equipment effectiveness) Display of dead times and causes Monitoring of technical assemblies Retrievable maintenance log for each machine Available information on the state of each machine

Modul 2: B+ Support Customers with a problem can now be helped even more quickly now. The machine operator uses B+ Support to send a service message manually or, as an alternative in certain pre-defined cases, the machine triggers an alarm independently. Both reach the Bäumer Service immediately. The specialists at Bäumer are connected directly with the customer, either to provide a service or to defuse a critical situation. For example, the settings in the machine control can be checked by means of remote maintenance and problems can be remedied online. Customers can also chat with the Bäumer specialists or hold a webcam conference. If the machine operator puts on his head-mounted display, the Bäumer specialist is able to see exactly what the machine operator sees and can look “directly into the machine”.


This means that on-the-spot support rules out any misunderstanding when describing the defects orally, faults can be identified and qualified solutions quickly found.

Fast reaction time Reduction in number of machine downtimes Time savings at machine start-up Reductions in process costs

Modul 3: B+ Maintain Maintaining and servicing machinery is now even easier. All of the maintenance activities required are sent directly to the operator via a role concept (access control) or registered with the central maintenance department. The customer has a constant overview of which activities are due at a certain time or perhaps are already overdue. Each item of maintenance work is documented and can be tracked at all times. Instructions are displayed for certain maintenance jobs so that the operator not only sees what he must do, but also how he must do it – without having to leaf through any documentation.

Condition-based, predictable maintenance Improved information on the requirements situation Plannable maintenance measures

Modul 4: B+ Shop Relevant parts can be procured automatically at the touch of a button. The Customer Cockpit easily recognizes wearing parts and spare parts, which can then be ordered directly. The B+ Shop can be used via a role concept at different levels with various rights in the ordering system. Orders can be placed directly at the machine or centrally in the Procurement department.

Simplified identification of spare parts minimizes incorrect orders Automated ordering process Complete price transparency

With the B+ Connect as a further milestone in digitalization Bäumer is assuring the future of its customers.


Bäumer’s new nesting program - mattress nest When using high-quality materials in a sophisticated and expensive manufacturing process, it is essential to make the best possible use of resources. Nesting programs therefore have been standard for some time now; in cases where, for example, short blocks must first be split horizontally and then, using nesting software, vertically contoured. Bäumer has now developed a new software for horizontal contour cutting machines which automatically put different mattress programs together, nesting them in a foam block (short and long blocks). Fully automated nesting of daily mattress production – promptly planned and true to quantity Up until now, the daily production from importing to finishing had to be planned manually. Manual nesting, however, is not true to quantity because the machine operator nested only one type of mattress from the block until the complete block was full. This inevitably resulted in overproduction and warehousing. Bäumer Mattress Nest makes it possible to carry out nesting true to quantity and fully automatically by planning the complete daily production in one go. Less manpower is required for planning and machine operation. Manual intervention in production is not necessary, but still possible. The complete production is quicker and more cost efficient.


Automatic creation of cutting programs and cutting jobs Bäumer Mattress Nest imports the order data into the system every day or for several days and first sorts automatically them according to the required qualities. Then programs for different mattresses which can be cut out of a short block or long block are optimally nested automatically, and the cutting programs created in this manner are executed in one continuous process on the BÄUMER horizontal contour cutting machines. Because the cutting program executes the main program (e. g. the mattress contour) and the side programs (e. g. cutting the mattresses to length) in one continuous process, different mattress types (e. g. children's mattresses and overlengths) can be processed in one single short block. In addition, the program automatically detects during nesting whether different mattresses have to be processed without any interval between cuts or whether an interval must be maintained. The remaining capacity of a residual block is also identified and factored into the calculations allowing for a freely selectable, tolerable waste quantity. In case of larger residual blocks, the order list can be filled with standard sheet dimensions or other orders.


OFS-HE3, 3400 mm block width for 100% more efficiency

Bäumer is now offering the OFS-HE3 with circulating knife for cutting cushions and mattresses, the fastest and most efficient horizontal contour cutting machine solution, that handles a 3400 mm block width. Now it is possible to cut instead of 2 blocks up to 4 blocks at the same time. With the new size, the machine is especially suited for companies that produce large quantities of the same mattress types or for mattress cutters who offer the entire range of mattress widths. Increasing the working width significantly improves machine efficiency. For example, it is possible to process mattresses with a width of 800 mm in 4 blocks at the same time, or mattresses with a width of 1.600 mm in 2 blocks simultaneously. A second center support stabilizes the knife and ensures precise cutting results. A fully automatic sheet holding-down device holds the block in place.

Quick bulk production of mattresses made of PU flexible foam, visco or latex Flexibility in the production of a wide variety of mattress widths


Increased efficiency, since up to four mattresses can be produced at the same time

Highest possible dynamics thanks to the design principle of separated table and cutting unit drives

High productivity and quality when cutting simple to complex mattresses composed of materials such as PU flexible foam, PU cold foam or latex

Two center supports for improved knife support and greater accuracy Hold-down system to secure the block and ensure superior cutting accuracy Fully automatic horizontal contour cutting machine design available with

automatic turntable and transport conveyors for loading and unloading Using a micro-toothed knife prevents regrinding and guarantees a constant cut

quality


Bäumer Cube: 3-D nesting software for cuboids – optimum workflow for vertical cutting machines Although a vertical cutting machine may seem to be a straightforward device, it is quite a complicated tool to operate. The machine operator is confronted with the task of optimally nesting various sizes of rectangular blocks from many different orders in diverse blocks while producing as little waste as possible. Then these cuboids have to be cut from the block in a time-saving sequence. The job also includes sorting the orders according to different material qualities, colors, etc. as well as marking any residual blocks that are produced.

Complicated nesting from many different orders, as shown in the example here with Cube, can only be performed by an operator who has an excellent capacity for spatial thinking and can anticipate the next steps as in a chess game. Therefore not only good planning but also an outstanding capacity for spatial thinking and logics is required for processing a daily production on the vertical cutting machine. The efficiency and quality of the process depend heavily on the operator. The solution for fast, forward-looking planning, constant quality, and minimum expenditure of

time is Bäumer Cube software, which nests the orders three-dimensionally with a special nesting algorithm and ensures optimum block utilization. Usually this step is performed by work preparation staff. The special challenge our software programmers had to meet with Cube is the combination of automatic and manual processes. Compared to a CNC machine where cutting programs are sent to the machine and are processed fully automatically, only sub-processes can be automated with PLC control on a vertical cutting machine. For example, partial blocks have to be manually removed from the machine now and then or rotated around an axis before the workflow is continued or, in other words, the next step is done.


On the machine, Bäumer Cube specifies the optimum workflow for the operator. The software guides the worker step by step. First Bäumer Cube specifies which block to use and how to position it on the machine. Then the block is cut. Initially, all the cuts which are possible according to the current orientation of the block are carried out. Afterward, Bäumer Cube indicates whether the created partial blocks are finished parts, residual blocks, waste, or temporary blocks for further processing. Finished parts are assigned by Cube to orders or commissions so that the operator can remove, label, and store them. Residual blocks are provided with a clear identifier and back posted to the stock. Temporary blocks are still required in the further course of the cutting program. They are also provided by Cube with a clear identifier, stored temporarily, and repositioned for the next steps according to the specification from Bäumer Cube. Every instruction from Bäumer Cube must be confirmed by the operator by pressing the button on the touch screen before the next step is specified. The purpose of Bäumer Cube visualization is to provide clear instructions to the operator. In a simplified model of the machine, the position of the knife and the stop as well as the positioning of the block are shown in relation to the machine. In addition, the edges of the block are measured and it is clearly indicated whether the edges need to be trimmed. Features at a glance:

Preparation of cutting jobs in the work preparation department Optimum block utilization thanks to clever nesting algorithm Operator-specific parameters can be stored Feature for estimating the cost of the individual cut part Bäumer Cube is network-compatible – cutting jobs can be selected by the

operator via a client PC at the machine via a large screen Specification of optimum workflows Clear instructions to machine operator thanks to clear visualization Marking and debiting of finished parts and finished messages Integration into the control of vertical cutting machine IS-M for automatic

processing of instructions from Cube, such as stop positioning, setting quantity and cutting thicknesses, or performing the cutting job

Cutting errors can be communicated to the system, and parts planned from the (partial) block are automatically sent back to the order pool

Identification of identical finished parts within a block and request to remove entire layers


Consideration of block edges (side, upper and lower skin or untrimmed edges) Label printing for marking finished orders, residual, and temporary blocks Integrated residual block management Log data as MDE data (BDE)

Highest possible efficiency increase thanks to integration of Cube into the control Basically, Cube can be provided for any vertical cutting machine. The operator enters the dimensions specified by the software manually and individually in the control, adjusts the stops, etc. It is, however, a quantum leap in efficiency enhancement when the work steps specified by Cube are automatically performed by the machine. This total integration of Cube is now available in the new generation of vertical cutting machines IS-M, on sale starting in May 2017. The cutting process takes place automatically, allowing for material-dependent cutting parameters such as cutting speed. Cutting progress and, finally, cutting end are displayed on the IS-M. Finished parts are visualized and labels can be printed.


New Split-HE 500 splitting machine: faster, more accurate and more versatile

The successor to the BSR-1 allows utmost precision in splitting sheets and block material with densities of up to 450 kg/m³ depending on the material and cutting thickness. It is the perfect splitting machine for the packaging and automobile industries, as well as other technical applications. This all-purpose horizontal splitting machine for splitting flexible materials and materials that are difficult to split offers new features: At the top of the list of new advantages are versatility in use, greater cutting accuracy, extremely clean cutting surfaces, less waste and shorter cycle times. Variety of applications The new splitting machine has pushed the limits of hard splitting much further, and can now split significantly harder materials with high densities and hardness levels of over 40 shore A.


It can split a wide variety of materials such as PU and PU rebond, polyethylene (PE, XPE), cellular rubber, Basotect®, Baynat®, rubber and rubber rebond, cork, foam rubber, neoprene and comparable materials, reticulated foams, EVA and latex. Particularly with PE, we were able to split densities of over 100 kg/m³ in the course of comprehensive tests. More stability and greater holding forces With respect to ever-growing demands concerning the materials to be split, an innovative knife guide system was developed in cooperation with major PE producers and manufacturers. The result is a knife bar with a new geometrical shape, which combines the properties of greater stability but also reduced friction with an exact cutting guide! The more stable suspension of the press roller and the resulting rigidity of the guide, as well as the significantly more stable press roller with an increased diameter, result in very good cutting tolerances. The more sturdy material support table also has a supporting effect. The optimized table width and a new vacuum system that provides 40 % more power underline the convincing cutting result. The foam block does not lift, and the cut is guided absolutely precisely. And that is not all. Bäumer has developed some new technical improvements that will impress the foam processing industry: Improved knife technology for more power and accuracy Compared to its predecessor, the knife tension of the Split-HE 500 has been increased, thus offering greater resistance to the cutting forces. The knife glides more firmly and more cleanly through the material. Even with very abrasive materials and materials with high compression hardness, for example rubber rebond materials, the results are impressive. Maximum cutting quality and limit of accuracy are achieved.

A further innovative feature of the new machine is the maintenance of the position of the knife tip in relation to the material thanks to optimized automatic knife readjustment. In the event of changes in cutting thickness and the associated automatic angle adjustment of the cutting unit, the press roller is also automatically adjusted. The result is a very good limit of accuracy of the cut sheets, low strain and thus extended knife durability.

Two knife drive systems, one for each knife track wheel, provide more power for cutting. Difficult materials can easily be split.


Less waste The reduction of the remaining sheet thickness to 2 mm reduces the volume of waste to a minimum. This is made possible by the new height adjustment measuring system. Shorter set-up times The travel speed of the vertical axle is very high. This leads to short set-up times, for the loading position is reached very quickly. This allows you to produce faster and more efficiently, thus increasing your throughput. Effective grinding In the very sturdy and powerful grinding unit, large grinding wheels with diameters of 150 mm are used. The knife is thus sharpened extremely quickly, which means a great improvement in effectiveness and also meets the constantly increasing demands on the precise splitting of difficult materials. Quality assurance through automatic grinding Traditionally, the grinding stone must be adjusted by hand. This is a purely manual job, which requires a lot of experience and competent know-how on the part of the operator in order to adjust the grinding stone optimally. Good cutting results depend on this to a significant extent. The new, camera-monitored system of the Split-HE 500 automatically detects dimensional deviations on the knife edge, and corrects them immediately. Manual intervention is not necessary. High constant quality is achieved, independent of the operator. Easy operation Usability is rounded off by the intuitive touch system.


Lamit-HRB-PUR

Lamit-HRB-PUR is a bonding machine for processing polyurethane hot-melt adhesives for the foam industry will be presented, together with an assembly and press section. In this rapidly evolving branch of industry, the Lamit-HRB-PUR sets new standards through its usability for a large number of materials and applications in the flexible foam sector, through extremely good bonding with minimum bonding agent application, as well as perfect full-surface adhesion. Flexible for changing products in the foam processing industry This machine meets the need for flexible production with changing materials and different applications. It is intended for all manufacturers who require the full-surface adhesion of foam materials, either with each other or with a different substrate, for their end product. Through the great strength of the bond and the high heat resistance of the PUR hot-melt process, it is ideal for insulation sandwiches, sponges of all kinds, packaging materials etc. This machine is also being used in different production line concepts in the production of sandwich mattresses, since the process allows not only the above-mentioned properties but also a soft and permanent bond seam as well as highly economical application quantities (from approx. 40 g/m2). High level of automation Through the adjustable roller gap, the quantity of adhesive applied can be adjusted product-specifically and very precisely. The automatic thickness detection system with


almost simultaneous set-up of the roller application system as well as an adhesive level monitor with automatic adhesive filling, programmable transportation and application speeds, simple width adjustment, programmable penetration depth as well as automatic length detection, are further features of the standard unit. Comfortable cleaning Bonding machines are not easy to clean. The procedure is time-consuming. The Lamit-HRB-PUR has a comfortable, large opening door. A new feature is that the complete bonding unit can also be moved laterally out of the bonding line, so that it is accessible from all sides. Further bonding processes and production lines Besides the above-mentioned production line, comprehensive information and product examples of other Bäumer bonding machines and processes will be available. This applies particularly to the roller bonding system as well as the hot-melt bead and spray application system for various applications in foam tailoring. In the field of automatic mattress production for medium and high capacities, Bäumer production lines, consisting of the bonding machines in conjunction with installation and press stations as well as diverse handling systems for the automatic infeed and stacking of finished products etc. have set new standards in the industry.


TURN OLD INTO NEW: MODULAR STANDARD CONVERSION IS-M VERTICAL CUTTING MACHINE

Technology, in particular control technology, is progressing at an ever-increasing pace. Yesterday’s computer is old today, and tomorrow it will already be out of date. After a certain time, spare parts are no longer available, dramatically jeopardizing production reliability. Control engineering and mechanical systems are improving from generation to generation, offering new opportunities for improving efficiency and quality. A new retrofit concept for older IS-M vertical cutting machines is available and in stock now for machines from the year 1984. Retrofit solutions bring your machine back up to date and make your units even more powerful. The investment pays off within a short period of time, since retrofits improve the productivity and operational reliability of the machines. The new IS-M modification is split into four partial retrofits that are available individually or as a complete conversion package. Your technicians can install the retrofits themselves. Benefits: - Reduced machine downtime - Renewed access to replacement parts - Ability to take advantage of retrofitting, i.e. maximize utilization of existing material that does not have to be replaced (e.g. control box)


- Excellent value for your money - Latest Siemens technology (TIA components) - Depending on your need and budget, replace only the faulty part - Customers can install the retrofit themselves at low cost - In stock and available for optional overnight delivery - Low shipping costs - Remote maintenance possible via B-Con (from step 3 partial retrofit) - Regain access to support and servicing - Continue to use pre-existing retrofits (partial retrofits) - Maintenance-free motors - Intuitive operation, no reorientation or training required FROM PARTIAL TO COMPLETE RETROFIT Step 1: Stop drive replacement The old DC controllers are no longer available as replacement parts and are replaced by a frequency controller with a maintenance-free asynchronous motor.

Step 2: Unit drive replacement The old and no longer available DC controllers in this case are also replaced by a frequency controller with a maintenance-free asynchronous motor.


Step 3: SPS replacement If your IS-M is still controlled by a type A0444 or A120 AEG SPS, replacement parts have not been available since 2015, and faulty parts will result in the machine downtime. An IS-M retrofit includes a new and updated SPS S1200 by Siemens.

Step 4: Panel replacement A new panel with touchscreen controls is installed on the existing or a new stand. Operation very much resembles the old system, meaning that no training is required after the retrofit.


B-TRACE: RELIABLE FAULT DIAGNOSTICS

Continuous monitoring of process and operating data Reliable cause determination Avoidance of costs and machine downtimes Access with high safety standards possible using remote maintenance


Detect the fault, determine the cause, rectify the fault: in simple structures, the reason for a defect in or even failure of a machine can generally be quickly found and operational capability restored immediately. In complex, integrated systems, however, a technical cause often cannot be immediately assigned to a fault. Particularly in the event of faults that occur irregularly or do not occur at all over longer periods of time, diagnosis is frequently complicated and difficult to predict.

B-Trace is a Bäumer service product that facilitates the diagnosis of your system even in difficult cases, avoids costs when searching for the cause of a problem and helps to minimize machine downtimes. Tracking down the fault: continuous monitoring using a data logger The core of B-Trace is an industrial box PC, which is equipped with special software and installed in the control cabinet of the machine you wish to monitor. The computer is connected to the machine control system by means of a PLC interface, and records all process and operating data of the machine permanently and if necessary over a longer period of time, and saves these data. As soon as the fault you are looking for occurs, the data measured at that point in time can be valuated and the cause reliably determined. Fast help with B-Con remote maintenance Machines fitted with the B-Con remote maintenance system allow a service technician access - directly and at any place in the world. This means that when the fault is found, either it can be rectified immediately or its rectification can be prepared specifically, so that the full performance of the machine is restored as quickly as possible.


For data transmission using B-Con, Bäumer complies with the same high security standards that are implemented by banks or professional online shopping sites. Using an external key switch on the machine control cabinet, you as the customer can initiate the creation of the VPN tunnel. Your network is only used as a transport route; undesired access to the factory network is completely blocked. An integrated firewall and encryption of data provide added security for the connection. The https connection is detected automatically by your system. The security settings in your customer network do not have to be changed. Time-consuming configuration is not necessary. Can be used for many brands of machines B-Trace can be connected to almost any Bäumer machine delivered since 1998, as well as to almost every Lamit machine, but data streams from the machines of other manufacturers can also be recorded.

pressemappe. press release. - foam expo pres… · pressemappe. press release. elisabeth steuber...

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