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More Effective Metal FormingHigher productivity of servo presses with torque motors, Simotion and Sinamics

The Magazine for the Metalworking Industry

spectrumOctober 2008

METAL FORMING

C o n t e n t

2 spectrum METAL FORMING | 2008

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Screw press with direct drive for precision parts

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Increased dynamics with innovative servo drives and Siemens technology

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Rapid notch pressing with Simotion and Sinamics

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4 Servo for More Effective FormingSchuler AG, Germany

p Screw Presses

7 New DimensionsH&T ProduktionsTechnologie, Germany

10 A German-Italian Success StoryFicep S.p.A., Italy

p Servo Presses

12 One-Stop SolutionAndritz Kaiser GmbH, Germany

14 Servo Gentle and PreciseBurkhardt GmbH, Germany

16 Servo Dynamic for New and Old PressesRaster Technology GmbH, Germany

p Mechanical Presses

18 Faster, More Flexible and More Cost-EffectiveMüller Stanz- und Umformtechnik GmbH, Germany

20 Top NotchMüller Weingarten AG, Germany

p Press brakes

22 Everything Under ControlPress Solution Simotion D and BendingOffi ce

p Hydraulic Presses

24 Quality from Old IronFraunhofer Institute for Machine Tools and Forming Technology, IWU, Germany

p Handling

26 Fast FeederChery Automobile, China

p Solution

28 Fast-lane Press AutomationMetalforming Solution Package

30 A Real Head StartSiemens PLM Software, Germany

PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg,Germany

Division Industry AutomationCEO Anton S. Huber

Division Drives TechnologiesCEO Klaus Helmrich

Editorial Responsibility in Accordancewith the German Press LawPeter Miodek

Title: Wolfgang Geyer

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate PublishingP. O. Box 32 40, 91050 ErlangenTelephone +49 (0) 9131 9192-501Telefax +49 (0) 9131 [email protected]: Gabriele StadlbauerLayout: Bettina Raunecker, Jürgen StreitenbergerCopy editor: Daisy KrausDTP: der Döss, NurembergPrinted by: Wünsch, NeumarktCirculation: 2.000

Jobnumber: 002800 13469Order No: E20001-A640-P620-X-7600

The following products are registered trademarks of Siemens AG: DRIVE CLiQ, ERTEC, ET 200, HMI, Simatic, Simatic Panel PC, Simotion, Sinamics, WinCC

If trademarks, technical solutions or similar are not included in the list, it does not imply that they are not protected.

The information provided in this magazine contains merely general descriptions or

characteristics of performance which in case of actual use do not always apply as describ-ed or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

© 2008 by Siemens AktiengesellschaftMünchen and Berlin. All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

spectrum METAL FORMING 2008

spectrum METAL FORMING | 2008 3

E d i t o r i a l

Dear readers:

Complete automation systems from a single source not only help to eliminate interfaces between system in metal forming but can also increase the productivity and cost-effectiveness of a press or press line in the long term.

“New Beat for the Servo Press” is our slogan for the Euroblech 2008, where we will be showcasing innovative systems, products and solutions for servo presses. One example is SimoPress Servo, the new module in our solution package for metalforming, which covers all essential features of servo presses using Simotion, Sinamics S120 drives and torque motors. By calculating the optimum motion profi le in terms of time and energy, you can achieve considerably more strokes per minute at the same or an even lower draw rate, thereby providing greater profi tability and lower costs per unit. Coordinated feed/recovery units and an intelligent energy management system reduce energy con-sumption.

Another product that will be shown at Euroblech 2008 is the Press Line Simulation software package, which can be used to digitally map and optimize the entire sheet metal forming pro-cess, ensuring there are no collisions. A further highlight will be an automation solution for CNC press brakes, which combines the benefi ts of a CAD/CAM system and motion control system, enabling signifi cant increases in both production and quality.

Curious? We look forward to meeting you there!

Alexandre Bonay

Head of Business Development Converting Solutions


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The Schuler stamping and forming press featuring servo drive technology


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Servo for More Effective Forming

Applying direct drive technology based on servo motors in blanking and forming presses delivers clear benefi ts: the power and time

curve can be confi gured as required via the ram stroke. This means that the press is able to move the tool at high speed until the moment just before it con-tacts the material. The tool then stops in line with speed and power curves that are carefully tailored to the forming properties of the sheet metal and the geometry of the component to be formed. The ram then returns to the uppermost position (top dead cen-ter, TDC) as quickly as possible. For many forming processes, these customized time-distance curves result in time savings of up to 50 percent. This means that productivity can be boosted by between 50 and 100 percent depending on the application. The form-ing process remains reliable despite these reduced time frames, and can even be improved further by the application of optimized time-distance curves. Fur-thermore, the servo drive makes an oscillating stroke possible, which opens up new avenues in relation to forming processes and tools.

Proven components for innovative solutions

The automotive industry and its suppliers are among the numerous users to have recognized these bene-fi ts, prompting Göppingen-based press manufacturer Schuler to develop and launch a complete series of servo presses. The fi rst systems, of various sizes, have already proven their worth in practice. The systems are set apart from conventional mechanical presses by one key feature: they are driven without the aid of a mechanical fl ywheel. Torque motors fi tted at the head of the press drive the crankshaft for the ram stroke directly. These motors feature a high power density, which allows them to develop high torques and thus generate the required stamping force. Of course, the torque motors require converter control suited to their excellent performance capacity.

Schuler’s decision to opt for the Sinamics S120 drive system from Siemens was made with this in

mind. Dieter Reisch, manager of the Automotive Elec-tronics Design department at Schuler, believes that the company’s decision was a good one. He tells us:

“Siemens is an established and respected force within the automotive sector, which is a key target market for Schuler.” Another factor in the purchase decision was the need for good system availability. Siemens sup-plies the components preassembled in electrical cab-inets, which minimizes the wiring and commission-ing work required on site. In addition, the units have proved extraordinarily reliable in other drive envi-ronments, and are now being used as standard world-wide. They combine high speed dynamics with opti-mum positioning and repetition accuracy. Another benefi t of these power control systems is the modular design, which ensures that the right converters are available for all required performance classes: the comprehensive Sinamics S120 program from Siemens has converters in the range of 75 to 1500 kilowatts. If higher performance is required for greater stamping forces, the drives are used in cascade, which means that several torque motors switched in parallel drive the crankshaft via an intermediate gear.

Storing energy in an intermediate circuit

Schuler has developed and patented an energy man-agement system that reduces the high mains supply requirements of servo presses to the levels of conven-tional mechanical presses. The system works by stor-ing the electrical energy generated during braking in a converter DC bus and then reusing it in the next acceleration or forming process. This is done with the help of an additional servo motor that collects excess energy when running in motor mode. In generator mode, it supplies the additional energy required in the DC bus for acceleration and forming operations. Despite the electrical drives having high top perfor-mance levels, servo presses actually help redress the CO2 balance: you will consume less energy for the same operation than you would using a conventional press. And the most important point to note is that

Servo press manufacturers are convinced by the modular design and

global availability of the powerful Sinamics converters.


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Acknowledged standards also in the automotive industry

Sinamics gained further kudos with Schuler by virtue of the extensive standardization work already under-taken. The entire range of servo presses has been given a modular and standardized design in a bid to achieve shorter delivery times. A basic platform is used to produce different presses that are tailored to the user in question and can be delivered to the cus-tomer in the shortest possible time. Dieter Reisch con-fi rms: “The components from Siemens are delivered ready for assembly and are the ideal fi t for our modu-lar machine concept. In addition, they reduce the time required for commissioning and setup considerably. What’s more, we benefi t from global availability in terms of service and spare parts stocks.”

Components from Siemens are well-established, in the automotive industry in particular, and are used today by companies around the globe. This reputation has made acceptance of Siemens components within the industry, even for innovative machine concepts such as the Schuler servo presses, a smooth process. Schuler fi rst started working in this area in 2007, and the factors outlined above will help it continue on the path to servo press success in future. p

S i n a m i c s S 1 2 0 f o r h i g h -p e r f o r m a n c e a p p l i c a t i o n s

Sinamics S120 cabinet units are ideal for use with variable speed drives that need to meet tough requirements in terms of dynamics and speed accuracy, face frequent braking cycles with high braking energy and use 4-quadrant operation.

Highlights:Vector control for the highest degree of 3precisionActive infeed to minimize line interferences 3Simple engineering, simple operation 3Low noise level 3Small footprint 3Easily integrated in higher-level automation 3solutions

there is no longer a need for the ineffi cient clutch/brake technology found in conventional mechanical presses.

Confi gurable drives elevate standardization and fl exibility

Servo presses exhibit numerous other operational benefits not delivered by mechanical presses. For example, the presses can be run in a try-out mode. In this mode, the ram can be precisely positioned for setup speeds using an electronic hand wheel. The various ram forces for distance or position can also be set. In line with stipulations from the supervisory associations and bodies, the press drives also include safety features such as short-circuit protec-tion and redundant brakes, which stop the ram. In setup mode, the press manufacturer uses the “safe torque off” and “safe limited speed” functions, which are an intrinsic part of the Sinamics drive sys-tem. The numerous servo drive functions make servo presses much more flexible than their mechan-ical counterparts. Once tested, time-distance curves for the ram can be programmed into the system and saved, allowing very quick changeovers between various tools and blanking processes. There is no longer any need to manually set and test ram motion: The operator simply calls up a tool data record that contains all the background information about the sheet metal, the time-distance curve for the press ram and the tool. After that, all he has to do is enter the data for the current order – and the press drive is set up at the touch of a button.

Operators use a touch-screen terminal to perform programming, set up and operate the machine. The dialog screens use WinCC. The programmers at Schuler have developed the WinCC-based SMV (Schuler Multi-View) visualization tool to ensure that the Human Machine Interface (HMI) is uniform.

The ram curves can be altered individually using WinCC


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The new multi-servo press with planetary roll thread spindle provides maximum fl exibility

Revolutionary press technology comes from Crimmitschau in Saxony in the East of Ger-many where H&T ProduktionsTechnologie has

developed a new multi-servo press (MSP), which com-bines the speed of a mechanical press and the fl exi-bility of a hydraulic press, as well as including consid-erably increased precision. The unique feature of this press is the planetary roll thread spindle combined with the highly effi cient direct drives. While conven-tional mechanical presses only reach full power when close to the bottom dead center (BDC), the forming capacity is available in every stroke position in the

servo spindle press, providing maximum press force up to zero-speed. Thanks to the skew safe construc-tion and sophisticated readjustments, the MSP can also reach the highest level of precision within a micrometer range at a maximum load. An additional, direct measuring system immediately recognizes the slightest skew resulting from an eccentric load and this is corrected by the drive. “Even during an eccen-tric load, our drive ensures that the plunger always remains parallel to the press bedplate. No other mechanical press has this feature,” emphasizes Jürgen Hauser, leading designer at H&T.

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New DimensionsIdeal combination for unique multi-servo presses from H&T

ProduktionsTechnologie: powerful torque motors and future-

proof Simotion technology.


Perfect power trans-mission in every position – the new spindle press with highly effi cient torque motors

More precise, more productive and gentler on tools

The long-term development partner SIBEA GmbH based in Zwickau implemented the planning and commissioning of the electric automation, opting for an integrated solution from Siemens. The single source automation systems ensure seamless servic-ing, maintenance and technical upgrades. For the spindle drive, SIBEA opted for a highly effi cient Siemens torque motor from the 1FW3 series. It pow-ers the spindle directly, thereby powering the plunger without the need for further mechanical transmission elements. This ensures that a high level of stiffness and precision can be achieved. Dr. Thomas Klärner, man-aging director of SIBEA, explains: “The 1FW3 fulfi lls all the requirements that we set for a press drive –

high torque, high speed, minimum rotor inertia torque and corresponding control effi ciency.” The motors are controlled by Sinamics converters.

The control dynamics are extremely important: In contrast to a conventional mechanical press, the impact velocity of the plunger on the material and the forming rates can be modifi ed in the MSP in every position. This enables even complicated forming pro-cesses to be completed and ensures the tools are not damaged. “This process can be compared to slam-ming your fi st on to the table with all your force, but stopping just before you hit the table and then just pressing down with all your strength,” explains Mike P. Gruner, sales manager for press technology at H&T. “Of course, this ensures less wear and tear and an overall higher quality. By driving the stamp onto the material more gently, a tool that was designed to reach 35 strokes per minute has now been made to achieve 100 strokes per minute.”

By modifying the number of strokes, the adjustable plunger speed ensures that materials are formed in a way that is gentler on the tools, while at the same time reducing noise and vibrations. The plunger’s position and location control enable a catch to be inserted in


» The 1FW3 fulfi lls all the

requirements that we set for a

press drive – high torque, high

speed, minimum rotor inertia

torque and a corresponding control

effi ciency. « Dr. Thomas Klärner, managing director of SIBEA GmbH

O s c i l l a t i n g s h e a r s w i t h d i r e c t d r i v e t e c h n o l o g y

Another innovation at H&T is the oscillating shears, the second genera-tion of which is powered by a 1FW6 torque motor. This driven tool in a press is used to cut high-precision trapezoidal sheet metal that is then made into engine hoods or doors for the automotive industry. In contrast to the conventional servo-motor-powered oscillating shears, the new development enables higher speeds to be used and a more precise positioning.


each plunger position so that peripheral devices can be implemented – such as lasers or cutting devices – that can complement other additional processing steps. This enables extremely precise deep-draw presswork for the electrical, cosmetic and pharma-ceutical industries or stamping parts for the automo-tive industry to be produced during a single process.

Precise control from sheet metal to the fi nished product

Numerous processing steps need to be completed during a transfer or multi-stage operation before a piece of sheet metal becomes a high-precision molded part. SIBEA has implemented the future-proof Motion Control Simotion D445 solution to control this pro-cess, which can also drive several axes without diffi -culty – an important criteria for the modular con-struction of the multi-servo press. In the basic confi guration, at least three motors are connected to the Simotion as ancillary components. The transfer from one level to the next is managed by two linear 1FN3 motors, with the second motor controlling the gripper’s opening and closing mechanism. An addi-tional servo motor (1FT6) is required for the roll feed. There is also an option to attach up to eight servo motors, for example for the feeder swivel axis and the ejector shaft.

Easy and safe to operate and monitor

The presses are operated and programmed through a 15-inch Simatic touch panel. The current plunger position and pressing force can be monitored on the display. The operator can move the plunger with a hand wheel, meaning the plunger can be positioned exactly. There is also an option to stipulate the maxi-mum speed and to test this in a single stroke.

Safety considerations play an important role when it comes to operating the presses since enormous forces are at work. As a precaution, the hand wheel therefore includes an emergency off switch. Addition-ally, the ‘Safety Integrated’ function in Sinamics ful-fi lls the requirements for “safe stop, safe speed, and safe reduction of speed.” Even when at top speed, the plunger will come to a stop after 14 millimeters.

Effi cient energy management

What is particularly impressive about the spindle servo press is its sophisticated energy management system. Any energy that is released when the plunger brakes is stored in a capacitor module developed by Siemens and is then fed back in to the drive system during the next acceleration process. The MSP opera-tor therefore only takes the power from the network that is needed for the forming process, which means that the user does not need high connection rates and the electricity grid is used consistently. The drive is connected to the grid with an Active Line Module from Sinamics S120.

Press technology that is fi t for the future

The collaboration with SIBEA and Siemens has enabled H&T to develop a press that in their words, advances into new dimensions of press technology. “With a multi-servo press, the machine adapts to the tool, the design engineer and the individual. The design engi-neer no longer has to adapt to the constraints of a rigid machine,” explains Mike P. Gruner. Its modular construction has increased its area of application. As well as the MSP 63 prototype with two direct drives and 630 kN pressing force, further models with up to 2500 kN are currently being developed. p

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Ficep S.p.A., Italy p

A German-Italian Success Story

energy from the DC bus and dispense the excess kinetic energy generated when the plunger gear brakes at the end of the lifting cycle. The main com-ponent of the energy management system is the Sinamics S120 drive platform with an Active Line Module, producing a drive system that can obtain energy from the capacitor banks if necessary, thereby decoupling the peak demand of the motor from the mains during the acceleration phase. The line’s power requirements can be projected by implementing capacitor modules in conjunction with the Active Line Module and are similar to the requirements of a con-ventional forging press. To increase the holding capacity of the energy store, several capacitor mod-ules can be linked to one another, enabling numerous multiples of 100 kilowatts in electric energy to be stored temporarily. As a result, the electric power demand is a lot lower and considerably cheaper to implement than conventional solutions.

This solution does not only captivate with its pre-cise design and energy effi ciency but also ensures that the unit containing the spindle and motor are largely insensitive to vibrations and strong braking rates, which regularly occur during the operation of the press.

Tailored electrical cabinets

Due to the fact that the production of the electrical parts of the presses with a direct drive forms an inte-gral part of the machine manufacturer’s success strat-egy, only qualifi ed suppliers were used during the development and implementation stage of electrical components. Since 2006, Siemens has therefore not only been the supplier of automation components, but has also acted as a partner for the implementation of tailored and ready-to-use solutions for all of the machine’s electrical equipment. The electrical equip-ment is manufactured by Siemens in line with the

F icep S.p.A., one of the world’s leading compa-nies in the fi eld of forging systems recognized the potential of the direct drives very early on.

Accordingly, the company manufactures forging screw presses with a pressure force of 64,000 kilo-newton, which are not only much more versatile, user-friendly and faster than conventional friction screw solutions but also save up to 50 percent of energy with the direct drives from Siemens.

Advantages of electric screw presses

In these electric screw presses, the traditional friction screw structure used in conjunction with the fl ywheel during the upward and downward movement, with the corresponding leather binding band to drive the spindle, has been completely replaced by a servo direct drive. In the last couple of years, this type of press has taken a large market share from the tradi-tional friction screw presses. This is due to its improved control l ability and reproducibility of the output using the latest in drive and automation tech-nology and the considerable amount of energy that can be saved. The increased effi ciency also enables the typically high dynamic performance of the linear servo drive to produce a higher impact velocity of the plunger, whereby the wear of the tools is reduced and the cycle time is considerably shortened.

The solution implemented at Ficep consists of linear motors in which the permanent magnets are attached around the spindle, serving as a rotating armature, and the reactor is housed in the base frame of the press. The core of the automation system is the drive and energy management system. Ficep opted for a Sinamics S120 drive system with a DC bus that accesses a capacitor bank as this electric energy stor-age device is equivalent to the fl ywheel of a conven-tional system (“electric fl ywheel”). During the accel-eration period of the plunger, the drives draw their

Innovative forging screw presses with

servoelectric direct drives score points with

their large potential to save energy.



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» The relationship between Ficep and

Siemens is based on close cooperation

and the exchange of knowledge. We

are very pleased that our partners at

Siemens in Italy and Germany are so

fl exible. «Roberto Falcetti, Head of the Electric Engineering Department at Ficep

The “electric fl ywheel“ of the Sinamics S120 converter can produce a high level of energy effi ciency and a comparatively low connection power for the press

exact specifi cations provided by the press manufac-turer so that it corresponds to the individual require-ments and system confi gurations specifi ed by the end customer. During assembly and commissioning, this lightens the load enormously for the press manufac-turer, because the electrical equipment – including all the electric and electronic components – is already tested and ready to be connected when delivered. The machine manufacturer only has to install the machine software and adjust the machine parameters to the mechanics of the press.

Faster certifi cation for press safety control system

Simatic S7-317F controllers are used to manage both the standard and safety-oriented functions of the machine. The high safety standards of the servo screw presses require the control system to have fast response times as well as a defi ned series of safety functions. The certifi ed S7 safety components comply with Category 4 according to EN 954-1 and SIL 3 according to IEC 61508. By ensuring complete press safety functions in self-contained functions, the machine manufacturer can quickly develop an active safety program. The approval of safety functions during the prototype test could therefore be accel-erated. p

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www.siemens.com/sinamicswww.fi [email protected]


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Andritz Kaiser GmbH, Germany p

One-Stop Solution

A whole host of components for electronics, mechanical engineering applications and the automotive industry benefi t from being

manufactured from sheet metal, as it is a productive way to stamp and form special workpieces in large-scale series production. These components include airbag containers, clutch disk housings, bearing cov-ers for household appliances and electrical/electronic plug connectors. In progressive dies, the components are cut, stamped and shaped from a single fl at metal sheet. Andritz Kaiser GmbH in Bretten, Germany

develops and produces stamping and metal forming presses for this purpose, with stroke frequencies of 60 to 450 per minute and pressing forces of 630 to 25,000 kN.

Flexible like hydraulics, productive like mechanics

The company’s current developments include servo presses, which combine the best features of mechan-ical presses with those their hydraulic counterparts. A torque motor on the crown of the press provides direct drive to the eccentric shaft in order to lift and

Stamping and metal forming

presses are equipped with control

and drive technology from

Siemens from top to bottom.

S e r v o P r e s s e s

» The main thing about using a one-stop

shop for control and drive technology

is that it avoids the likelihood of inter-

facing issues. « Stefan Kaiser, authorized signatory and member of the board in Bretten


High-performance torque motor and Simotion control: The servo presses at Andritz Kaiser are ideal for sheet-metal parts in large-scale series production

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Simple touch-screen operation

The press manufacturer is particularly taken by the programming and operation of the stamping and metal forming presses; they use the latest Simatic Panel PC with 19-inch touch screen, which makes it much easier to work with the servo presses. The parameters for the stamping and forming tools are programmed just once and stored as data sets. When the operator sets up the servo press, he calls up the relevant data set on the touch screen. All he has to do to carry out production is enter the order informa-tion, e.g. the quantity required. Apart from changing tools and carrying out mechanical adjustments to stops and guide rails, everything is done at the touch of a button.

As Dr. Ingolf Pappe, who is responsible for sales and engineering at Andritz Kaiser, sums it up: “The best thing about the press servo drive technology is the increased fl exibility it offers. Depending on produc-tion conditions, the servo presses provide renewed access to business areas previously thought to have been lost for a great number of manufacturing shops, most notably in this country.” p

lower the slide. The advantage of this is that both speeds and the acceleration/braking processes can be controlled depending on the stroke. This leads to increased productivity because the speeds for the forming process and the transportation of parts between the individual process stages can be opti-mally tailored to one another. It also allows the form-ing processes to adapt independently to the sheet-metal material and the dimensions. Working with servo presses is therefore much more fl exible than working with mechanical fl ywheel presses.

Harmonized control and drive technology

As the specialists at Andritz Kaiser have already had good experiences with individual components from Siemens in other types of presses, they have outfi tted their servo presses with a complete Siemens system. This complete system offers added benefi ts to the press manufacturer, as Stefan Kaiser (authorized signatory and member of the board in Bretten) explains: “The main thing about using a one-stop shop for control and drive technology is that it avoids the likelihood of interfacing issues. All components are tailored to each other. Plus, we always have just one contact person for both technical and logistical inquiries.”

The servo presses are driven by torque motors from the 1FW3 series and are controlled by power convert-ers from the Sinamics series. The latter also take care of energy management. Andritz Kaiser has managed to counteract that age-old argument that servo drive technology requires too much energy for forming processes. In the DC bus, special high-capacity capac-itors store vast amounts of energy. This is used dur-ing the forming process, which needs higher levels of energy for brief periods.

This means that the servo press can work with a similar rate of power delivery as that required by one of the mechanical presses, producing a comparable forming force and working at a similar rate of produc-tivity. During periods of downtime e.g. while per-forming maintenance on progressive dies, changing a coil or experiencing die problems, the servo drive comes to a standstill and does not consume any energy. There is also no mechanical loss caused by friction wheels and couplings.

The motion paths during the equipment’s forming process are controlled by the Simotion drive package from Siemens. The technicians in Bretten use the PLC S7-300 for monitoring and controlling the various sensors and relays, e.g. for safety circuits and periph-erals. Among other things, this coordinates the drives and movements of the roll feed and the synchro -ni zed transfers in the progressive die. As Stefan Kaiser points out, the integrated electric drive technology makes things much simpler, particularly when it comes to connecting peripherals. And thanks to the extremely reliable and robust components from Siemens, this technology also increases system avail-ability.

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Convinces with high fl exibility: the Burkhardt direct drive servo press

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Servo Gentle and PreciseA direct-drive torque motor makes blanking and

forming presses more fl exible and effi cient.



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The confi guration options and thus the possible applications of a press get increasingly ver-satile with a higher fl exibility of the drive

system. The Burkhardt GmbH company based in Bayreuth, Germany had this principle in mind when the company added an additional servo variant to its patented servo drive concept and developed a direct drive for stamping and forming presses. The solution, which was developed together with Siemens, is based on a high-torque servo torque motor, which drives directly the press’s eccentric shaft. This enables the ram path to be controlled individually along the entire press cycle, which means that it can be adapted fl exibly to the wide-ranging requirements of tools and/or workpieces. This ultimately results in higher productivity and product quality, as well as less stress to the mechanical parts of the machine.

Focus on fl exibility

Almost all press manufacturers offer systems for adjusting the ram path to suit different requirements, for example, by means of drag cranks, non-circular gear wheels or switchover transmissions However, all these solutions only have a limited fl exibility deter-mined by the fi xed relationship between slow and fast eccentric shaft speeds for the working and feed stroke, the generally unalterable changeover points between low and high speed or – on machines with a stroke set-ting – the changeover points that can only be set opti-mally for a small number of stroke lengths.

Direct drive – effi cient and powerful without a fl ywheel

However, in the new solution, a ready-to-install com-plete torque motor from Siemens drives the eccentric shaft of the press using a planetary gear. This means that a whole range of mechanical components are no longer necessary – take, for example, the clutch and the fl ywheel usually required for storing energy. This signifi cantly simplifi es the overall construction of the press and consequently maintenance and stocks of spare parts. In their place, there is now a practi-cally maintenance-free capacitor package that acts as a feed/recovery unit and stores the braking energy in the motor’s generating mode, thereby signifi cantly reducing the required electrical delivery rate and thus the energy/operating costs. Thanks to this energy buffer, it means that the average effective delivery rate can be supplied rather than having to supply the maximum (nominal) rate.

The direct drive means that all aspects of the ram progression can be controlled with the precision and

dynamics of a servo motor, enabling the working and feed stroke and speed to be adapted to practically any conditions. In this way, for example, the impact shock in the tool can be reduced in a targeted way, which increases the life of the tool, puts the press under less strain and minimizes noise emission. In addition, product quality can also be improved due to low, opti-mum forming rates during bending, drawing, stamp-ing and forming, while optimized transport speeds, in combination with transfer units or progressive dies, lead to higher productivity. A constant pendu-lum operation around the bottom dead center (BDC) is even possible, which helps to shorten cycle times.

The crucial advantage of the direct drive: In prin-ciple, all these options are available on one and the same press, which also increases the fl exibility sev-eral times over for the user when making frequent product changes. After die change, the user can call up previously optimized settings virtually at the touch of a button and start production more quickly than ever.

In addition to selecting and designing the suitable control and drive concept, Siemens has developed a simple curve calculation tool for convenient parame-terization of the ram path. The user sets key data such as speeds, changeover points and press forces and the system uses these to calculate an optimized speed/torque profi le for the direct drive in the particular application.

Interchangeability safeguards investments

Throughout all its innovations, the press manufac-turer from Bayreuth always thinks about continuity. The Burkhardt stamping and forming presses have always had a modular construction and the various drive concepts are interchangeable, meaning that even older presses can be retrofi tted at any time with all the latest drive concepts, including the patented servo drive concept right through to the brand-new servo direct drive. p


Raster Technology GmbH, Germany p

Servo Dynamic for New and Old Presses

A fter a successful debut as part of a retrofi t, Raster Technology GmbH of Ötisheim, Ger-many, has launched its fi rst 200-ton press

with servo direct drive to have been designed from scratch: the RST 2000 SM. The key focus of interest is the enhanced opportunities provided primarily by the use of a high-performance standard range 1FW3 torque motor from Siemens. The ultra-dynamic, pre-fi nished complete motor is connected to the press’s eccentric shaft with almost zero play using a single-stage planetary gear and directs its high torque (max. 10,500 N m) to the process in a precisely controlled manner via a Sinamics drive-series converter.

With its new ServoMotion drive concept, the press manufacturer, which is part of Karl Klink Holding, can

achieve maximum stiffness in the drive train by elim-inating the belt drive, continuously variable speed control (since there is no mechanical transmission either) and high dynamics thanks to the small gear

Servo drive technology maximizes the dynamics of

old and new blanking and forming presses alike.

ratio and high torque. The ServoMotion system offers freely programmable ram speed profi les for a wide range of products and tools and fi ne adjustment in hand wheel mode (“Tryout”). This means that the presses are versatile and fl exible – both as fully fl edged production presses and as Tryout presses.

Less is more

The new machine delivers its nominal power of 2000 kN and a maximum working capacity of 15.3 kN m at exactly 26.1° or 7.7 mm before BDC (bottom dead center) and a maximum stroke of 150 mm; the stroke rate can reach up to 170 strokes per minute. The full press force is available from the working stroke of 26.1° or 7.7 mm before BDC and decreases as the working stroke increases. However, the advan-tage of the ServoMotion machine compared to con-ventional flywheel presses is that it is also possible to continue working beyond the operating point, thereby achieving greater working strokes.

The total stroke count (cycle) of the press is deter-mined by the stroke count during the forming pro-cedure. This is reduced in a controlled manner dur-ing the stamping and forming process, though the (longer) residual travel is carried out at maximum cir-culation speed. This generates a signifi cant increase in productivity compared with a fl ywheel press, which grows ever greater as the process-related drop in the stroke count at BDC continues. With current appli cations, the increase in productivity or the in-creased parts production is between 35 percent and 75 percent.


» We are convinced that the servo

drive will quickly become the

standard for press production. «Dr.-Ing. Heiner Lang,Head of Technology and Development at Raster Technology GmbH

The 1FW3 torque motor ensures accurate drive control


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All-in-one complete package

The press is controlled by a combination of Simatic PLC and the drive-based motion control system Simotion D435. For operation and monitoring, a robust Simatic touch panel is installed on site, on which the Raster user interface can run fl exibly using Simatic WinCC. An integral part of the ServoMotion programming functions are the different ram speed profi les for specifi c tasks such as deep drawing or stamping. Profi les can also be generated to match a wide variety of other processes.

Since 2002, Raster Technology has been almost exclusively using Siemens automation technology. Since being aquired by the Karl Klink Holding, a lead-ing provider of high-precision broaching systems, this trend has become even more pronounced. The main reasons for this, besides further harmonization and standardization (including training and mainte-nance), are the global market presence of Siemens and the resulting rapid product availability. Apart from that, an ever increasing number of users prefer presses with automation technology “made by Siemens.”

Full steam ahead, together

Dr.-Ing. Heiner Lang, Head of Technology and De-velopment at Raster, describes the support from Siemens as exemplary: „The initial differences in approach and objectives were quickly resolved to focus on the common goal. Mechanical and electrical interfaces were coordinated, and press and automa-

tion expertise was pooled. An interdisciplinary team with specialists from Raster and Siemens was able to get the most out of the press during initial commis-sioning.“

The response to the ServoMotion system from potential users has also been overwhelmingly posi-tive. Already almost every inquiry regarding a con-ventional fl ywheel press is tied to an optional inquiry regarding the ServoMotion equipment. That is why Raster is fi rmly convinced that servo technology will become the standard for press production. This will also enable a different pricing structure. As the competition increases, however, only the best de-velopments will be able to establish themselves in the market.

“With our previous work and following detailed market research, we at Raster and Siemens are more confi dent than ever that our jointly developed Raster ServoMotion system represents a clear step forward in terms of performance, productivity, operating comfort and energy effi ciency, and will give new dyna-mism to the world of press technology,” concludes Heiner Lang. p

The newly designed Raster 2000 SM with the innovative ServoMotion drive concept. The Simatic control panel ensures convenient operation and monitoring

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The sheet metal blanks are cut to size, then transported to a brush table, where the edges are processed

The Austrian company Tortec Brandschutztor GmbH is the market leader in the production of individual, building-specifi c fi re gates and

doors. In order to ensure a fast turnaround of high-quality products for the extended market in the future too, the company has increased its capacity at the site in Imling with a new, fully automated and highly fl ex-ible production line. The line was developed and con-structed by Müller Stanz- und Umformtechnik GmbH & Co. KG based in Gefrees, who also ensured that the

control technology of the line was fully integrated. Simotion and Sinamics products form the core of the complex system.

From coil to door and gate

In the production of fi re gates and doors, the sheet metal is fed to the line via a moveable decoiler. The squaring shears cut the metal sheet to the relevant blank size, before two grippers position the blank for

Müller Stanz- und Umformtechnik GmbH, Germany p

Faster, More Flexible and More Cost-Effective

Drive-based motion control system and corresponding drive technology for an

effi cient production fl ow, high productivity and precision on a new production

line of fi re gates and doors.

M e c h a n i c a l P r e s s e s


Flexible individual cutting is one of the core functions of the Müller automatic line

the edge trimming process. The next station is a stamping portal, where all cuts for locks, windows, handles, fastenings etc. are made. Here, a slide car-ries the individual stamping tools, which are posi-tioned laterally. The stamping images can be freely confi gured within the scope of the set of tools that is fi tted, while the required axis movements are coor-dinated by the Simotion motion control system. Com-plex stamping images can contain up to 700 individ-ual press cuts. Siemens in Bayreuth has developed a routine that eliminates the need for these to be re-entered for each new gate; the routine automatically generates all traversing records from 20 to 30 basic parameters, and transmits the records to the system controller. This means that once stamping images have been generated, the user can arrange them on the blank almost freely, thereby greatly reducing the programming effort, accelerating the procedure and minimizing retooling times. The line can pro-cess sheet metal up to eight meters long and 1.5 meters wide and, where necessary, the basic raw material can also be split into a maximum of fi ve nar-rower strips.

Complete, consistent automation

The consistent automation technology from Siemens allows the various individual assembly sections to be linked and coordinated without the need for time-consuming interface adjustments. The system com-ponent created by Müller is fi tted with a Simatic Industrial PC, the Rack PC IL 40, which distributes order data that it receives from a higher-level produc-tion planning system. The user interface was created with Simatic WinCC confi guration and visualization software. All axes can also be set up and manually operated via a portable Simatic Mobile Panel 277B, which setup personnel can bring with them to the site.

All told, there are 26 drive axes in the system com-ponent created by Müller, some of which are coupled together electronically via a clock-synchronous Profi bus (12 Mbit/s). The movement is controlled by a drive-based Simotion D445 – the highest perform-ing motion control system in the current Siemens range – integrated directly in the drive line-up. It can coordinate up to 64 axes at a minimum servo/interpo-lator cycle of 0.5 milliseconds. Six of these are coor-dinated directly on the component, while six others are coordinated by another CU320 Sinamics Control Unit linked via fi ve Profi bus interfaces. The primary function of this control unit is to precisely coordinate the movement of blanks (direction X) and tool bars/slide (direction Y) during blanking, and to do so in the fastest possible time. Furthermore, in order to pre-vent slippage, the drives of aligning machines and the structuring via Simotion are electronically synchro-nized. The same applies to the drives of the two grip-pers after the squaring shears, which are synchro-nized to prevent the blanks from twisting and being damaged.

Data is exchanged between the controllers of other assembly sections via a Profi bus interface. Transmit-ter signals, including those from the aligning machine measuring wheel, are fed back to the Simotion via the TM15 terminal module and the decentralized Simatic ET 200S input/output modules. The terminal modules provide drive-specifi c digital inputs and outputs with very low signal delay times.

Tried and tested solution

Müller Stanz- und Umformtechnik has relied almost solely on Siemens automation technology for many years, as this all-inclusive support is available quickly right around the world. The decision to use Simotion and Sinamics proved to be the right step for the machine manufacturer, as there are no unnecessary interfaces and none of the extra cost this would entail. What programmer Florian Hanke values above all is the graphically supported engineering with the Simotion software Scout, which makes even the more challenging motion control tasks such as synchroni-zation and caming easy and convenient. “There was consistently good cooperation between all those involved, which meant that we were able to hand over a perfectly functioning solution in a reasonable time frame,” reports the machine manufacturer’s project

leader, Michael Schmidt. The new line survived its baptism of fi re in practical conditions long ago and since then, individual fi re gates and doors have just been rolling off the production lines. p

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Ergonomically designed, semi-automatic notching press: the production parameters are entered via a Sinamics Multi Panel

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Top Notch

Generators and electric motors require large quantities of notched sheet metal, which is assembled into packets and supports the

coils and magnets in the rotor and in the stator. Demand for these sheets has risen dramatically recently due to the increase in alternative energy pro-duction from wind turbines and the growth in decen-tralized automation systems with electric drives. One company to profi t from this increase in demand is Müller Weingarten AG in southern Germany, now part of Schuler AG. The company manufactures fully and

semi-automatic notching presses with pressing forces of 40 to 200 kN.

With a semi-automatic press, an operator positions the circular blank sheets on a turntable. The tool punches the required number of notches in the sheet while the turntable advances the circular blank by the corresponding angle. In the fully automatic machines, the blank sheets are inserted and removed automati-cally and there is also an alignment mechanism to ensure the sheets are in the right position and at exactly the right angle.

A machine manufacturer from Southern Germany produces faster and more

precise notching presses using drive and control package from Siemens.

M e c h a n i c a l P r e s s e s


State-of-the-art control and drive technology ensures a broad range of blanks are punched in exactly the right places

Highly dynamic and precise positioning

To keep unit costs down, the notching presses need to be as productive as possible. This is achieved by increasing the stroke frequencies, meaning the drives for the turntable have to work extremely dynamically. For example, with a notch sheet that has 60 notches and at a standard stroke frequency of 1200 per min-ute, there are just 0.05 seconds to advance and posi-tion the circular blank to within a few arc seconds. To ensure a high degree of fl exibility, notching presses are all one size but are designed for circular blanks of varying thicknesses and with a wide range of diame-ters. The high degree of positioning accuracy and the required dynamics must therefore also be retained with different moved masses. This places particularly high requirements on the drives.

Universal concept with components from Siemens

With the comprehensive control and drive system from Siemens, Müller Weingarten has succeeded in coming up to the mark. It uses Sinamics together with AC servo motors from Siemens to control the power for the press and turntable drive, and the Simotion Motion Control System to control the fully and semi-automatic notching mechanisms. In the fully auto-matic versions, the peripherals are integrated via ET 200pro interface modules. The company uses Simatic MP377 Multi Panels as the HMI and the spe-cialists have created the dialogs for operating and programming the notching presses using WinCC. These are designed specifi cally for the requirements of the punching processes and the work sequences in notch pressing, and the operator can select menus and functions via a simple touch screen.

Müller Weingarten has implemented the controls required to ensure safe operation during set-up and in production using the Simatic S7-317F controller. Its high calculation and processing speeds mean it can record all data relevant for safety from sensors and drives and link it with safe operation. The fully automatic machines also have integrated inputs and outputs for the peripherals. In the universal control and drive concept, Profi bus connects all components of the motion, power and safety control system. There are plans to use Profi net in the future on account of various benefi ts in terms of signal processing and programming. The complete concept made up entirely of Siemens components cuts assembly and commis-sioning times. For example, sophisticated software tools automatically recognize the connected sensors and actuators. An integrated trace function guaran-tees rapid diagnostics.

Shorter set-up times, greater fl exibility

The comprehensive control concept gives notching press operators greater fl exibility. The presses can be retooled for different notch patterns, blank diameters and sheet thicknesses at the touch of a few buttons, as complete data sets with corresponding tool data are all saved. When a production order comes in, the operator simply has to select the data set and add some order data.

A high-tech image processing system from Siemens ensures that the circular sheet-metal blanks are po sitioned precisely in the fully automatic notching presses from Müller Weingarten. This system enhan-ces the camera-supported detection and position cor-rection of the circular sheets as well as the fl exibility and availability of the notching presses. The position detection functions will of course also be fully integ-rated into the new control and drive concept. p

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W ith its press brakes, shears, punching and nibbling machines, a Turkish machine manufacturer has established itself as a

pan-European supplier of special presses for metal forming. As it plans to expand its current market position with solutions that are individually tailored to customer requirements, the company has decided to equip its CNC press brakes with the Simotion mo-tion control system and the BendingOffi ce software from data M. The fi rst CNC press brakes have now been equipped with the new automation solutions. Release for use in series production is imminent.

New requirements from users

Siemens has optimized its control and drive concept in line with the customer‘s wish to serve the lower-end market segment with reduced requirements and thus be able to cover an even wider range of ma-chines. This allows the user fi ner scalability of the so-lutions while maintaining the same high levels of performance. This in turn results in cost-effi cient machines that are exactly tailored to the respective application. This scalability is based on the Simotion D motion control system, which is available in three

versions. The modules are designed for direct inter-action with the Sinamics S120 drive system and are equipped for different numbers of axes and interpo-lation cycle rates.

Dynamic confi guration

The entry-level version allows the usual four to six axes on a press brake to be controlled precisely and with repeating accuracy, with hydraulic and electric axes being operated in combination. If greater num-bers of axes are to be implemented or if tandem press brakes are to be synchronized with each other, one of the more powerful control modules can be used. Ad-ditional scalability has also been achieved at the Hu-man Machine Interface: A master Simatic Panel PC 477B allows the requirements of both simple and more demanding machines to be covered cost-effi -ciently. The embedded industrial PC with 15-inch TFT display has no hard disk or fan so it can with-stand the higher mechanical strains caused by vibra-tions and impacts in the immediate vicinity of the press brakes, even during continuous operation. The Panel PC is equipped with the Simatic WinCC fl exible 2007 visualization software, which allows machine

Press Solution Simotion D and BendingOffi ce p

Everything Under ControlA leading machine manufacturer will in future be using Simotion D and

BendingOffi ce in its automation systems with a view to bending sheet metal

more effi ciently and cost-effectively.

P r e s s b r a k e s


3D simulation of the bending process on the Panel PC 477B

manufacturers to create individual, freely confi gu-rable user interfaces for commissioning of the press and diagnostics.

Shorter cycle time, less waste

Together with data M Software GmbH, Siemens has developed a solution that allows sheets to be bent more effi ciently and cost effectively. Using the Bend-ingOffi ce user interface, users can, for example, cre-ate the sheet pieces themselves by designing 2D cuts. In addition, users can defi ne the bending sequence manually or automatically, set up collision monitor-ing and select the required tools from a database. The bending process can be simulated in real time on a 3D model of the machine and displayed on the screen. Moreover, the open software structure in Simotion gives machine manufacturers suffi cient free rein to develop their own innovations. Similarly, the hardware of the solution is open in many re-spects: communication between the Panel PC and Simotion takes place via an Industrial Ethernet inter-face. Connection to master systems (such as central production planning/order management) is also pos-sible via Industrial Ethernet. The modular drive line-up can be extended with additional motor modules in a single axis or two-axes design, as required. Force sensors and the Copra LaserCheck laser-based bend-ing angle measurement system from data M can be integrated directly into the automation solution via the USB 2.0 ports on the Panel PC to achieve high-precision bending results.

The laser measurement system reduces the number of bending faults by recording the springback online and sending corrections directly to the Simotion con-trol system. This saves cycle time for each workpiece

while also reducing the amount of waste; this in turn helps reduce costs – particularly in the case of exten-sively pre-machined sheets.

High precision, extreme smoothness

The machine manufacturer was impressed both by the reproducibly high bending quality and the ex-treme smoothness of the machines. Both are the re-sult of the high quality of control offered by Simo-tion: the synchronization deviation of the hydraulic axes when pressing is less than 20 micrometers. And the repeating accuracy is better than 10 micrometers in both directions. This is important for correct alle-viation when measuring the springback using Copra LaserCheck and is fundamental to ensuring a very high level of precision in the bending angle. These factors enable the Simotion system to quickly, accu-rately and reproducibly implement the BendingOf-fi ce instructions. The motion control via cams can be set as required during commissioning. During oper-ation, seamless switching between characteristic curves or operating modes is possible.

This enables dynamic yet soft movements and leads to signifi cantly smoother operation, which not only enhances the quality of the metal sheets, but also the service life of the machine, as there is less strain on the mechanics. p

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H y d r a u l i c P r e s s e s

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Quality from Old Iron

Together with the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz, Siemens has piloted a new kind

of control and communications environment for multi-axes hydraulic presses, and has now made it fi t for industrial use. The distinguishing feature of this solution is its control cycle of just 0.25 milliseconds with 16 hydraulic axes on one controller. A double-sided press from „Zeulenroda“ (now Raster Zeulen-roda) with a clamping force of 2500 kilonewtons was used for the pilot project. The special feature of this machine is its die cushion, which is made up of 16 hydraulic axes. As there is no common cushion plate, the die cushion axes are mechanically decoupled from one another. This construction places particular demands on the control accuracy of position synchro-nization and pressure regulation. It is, however, pos-sible to tackle very challenging technical forming jobs, since the pressure can be applied around the part in a very specifi c way. This in turn means that a targeted material fl ow can be generated during the forming operation.

New press control increases the speed and

availability of a hydraulic press.

„Before the retrofi t, this machine was no longer acceptable from a technical point of view,“ reports Michael Hoffmann, group leader for drive controls at the Fraunhofer Institute. Not only was the control technology outdated, but the documentation was also unavailable, meaning that there were very few people who knew how to operate the press.

Clear targets

The IWU opted for a complete retrofi t of the hydraulic press. “The target of the retrofi t was not only to ensure permanent availability of the machine, but also to cre-ate a reference project for a new type of press control,” explains Michael Hoffmann. It was also important to achieve a high speed, or in other words, a short pro-cessing time. And the required degree of precision still had to be maintained when controlling all axes. The IWU decided on a collaboration with Siemens – fi rstly in order to implement the tough demands in the best possible way, and secondly, because based on previous projects, it already had faith that Siemens

The press was equipped with new safety tech-nology; thanks to WinCC fl exible, it is easy to operate

Work space with a confi gured die and inserted workpiece


could supply all necessary components from a single source and would subsequently be able to take on service and maintenance activities for industrial cus-tomers.

Quality through speed

The Simotion motion control system with a very fast peripheral was the only option to achieve control cycles of far less than a millisecond that provide addi-tional reserves for the controller. With this system, the user no longer has to work with different types of controls, as the PLC and technology functions are combined in one control unit. This makes it possible to carry out complex motion control and simple, motion-related PLC functions in the same system. The

necessary fast peripheral (less than one microsecond) was initially found in the Drive-Cliq components of the electric drives.

Two-stage retrofi t

The fi rst retrofi t took place in 2006 using Simotion D, the Drive-Cliq peripheral (analog I/O module TM31) and a Profi bus connection for the measuring systems. This verifi ed the use of the technology objects (Simo-tion architecture). As this retrofi t did not fulfi ll all of the objectives, a second stage was carried out in 2007. Simotion D was replaced with Simotion P 350 V3. The peripheral modules were replaced with the new inter-face module IM 151-3 PN High Speed for Simatic ET 200S and the corresponding high-speed modules. In addition, the peripheral connection was converted to Profi net. By switching to ET 200S with the interface module IM 151-3 PN HS and Profi net with IRT, it was possible to reduce the cycle time to 250 microseconds with a terminal to terminal reaction time of a mini-mum of 600 microseconds. Using this package, it was

now possible to operate 16 hydraulic axes including a virtual leading axis (to ensure the required synchro-nization) on a Simotion P350-3 control system with a 250-microsecond control cycle. This was the break-through. The researchers and developers at the IWU can now use these high speeds to overlay the basic pressure of the die cushion axes with an additional vibration for instance. “This reduces the stick-slip effect between the holder and the sheet and means that the material can fl ow continuously, which in turn leads to a higher degree of deformation,” explains Michael Hoffmann. The press has also been equipped with new safety technology using a fail-safe Simatic S7-317F programmable logic controller. This new technology includes two light curtains (at the front and back of the press) and 2-handed operation. The

user interface was developed with WinCC fl exible, the HMI system from Siemens.

Prognosis for the future

The project has now come to an end. “The press is equipped with state-of-the-art technology and is therefore 100% fi t for industrial use,” sums up Michael Hoffmann. “It is safer and more user-friendly. Among other things, we are now able to save the mea-sured values and create a log book of the completed forming process.” The experts at the IWU also greatly appreciate the fact that they can transfer the software they have developed using technology objects – an interesting aspect for the automotive industry, for example, where it is becoming increasingly common to produce smaller lots. p

» 16 axes with differential pressure measurement

and seamless alternation between pressure and

position control with a 250-micro-second control

cycle on one control unit show what they‘re

made of. «

Michael Hoffmann, group leader for drive controls

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Feeder automation with an orientation station – each press has a load and unload feeder as well as a deposit or orientation station

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Car manufacturer Chery Automobile Co. Ltd. in Wuhu, China, is going its own way. While most of the company’s competitors in the booming

Chinese automotive industry have entered into joint ventures with Western manufacturers, Chery has remained an independent producer since its incep-tion in 1997.

The company is very successful in its home country, having now risen to fourth place in terms of sales fi g-ures for passenger cars in China. Its comprehensive range includes everything from small cars to sedans and sports coupés and right up to minivans. Chery vehicles are already enjoying great success in emerg-ing automotive markets in South America and Asia and, in an unusual step for a Chinese OEM, the com-pany has already opened CKD plants around the world. The self-assured management team at the Wuhu headquarters is already working toward its next goal: entry into the US and European markets.

Modern production in Wuhu

The new markets are to be conquered from the pro-duction facility in Wuhu, where state-of-the-art tech-nical standards are employed. Future models to be produced here include a new small car and a compact sedan in the C segment.

For this purpose, the Chinese-manufactured trans-fer press line is to be upgraded. To increase the throughput of the press line, the management decided on an innovative solution for the automation of the feeders between the individual press stages: Profi net with integrated safety.

Safe Profi net for the press

This represents the fi rst ever universal adoption of the Profi net automation standard with integrated per-sonal safety in Chinese car manufacture. The plant

Chery Automobile, China p

Fast FeederSimotion and Profi net with IRT ensure throughput

increase on press line.

W . S t r o t h m a n n G m b H , S c h l o ß H o l t e - S t u k e n b r o c k

W. Strothmann GmbH has made a name for itself with effective mechanical engineering and handling solutions for many industries, particularly for the automotive industry. The specialists from Northern Germany plan and inte-grate the complete automation of press lines. This includes the entire blank loading area, blank washing station, press linking with linear robots and transfer equipment, removal of com-pleted parts, as well as integrated control and information systems. The company continues to set benchmarks with inno-vations, making it an industry partner in great demand.

www.strothmann.com

H a n d l i n g


infocontact

www.siemens.com/profi [email protected]

construction company appointed to carry out the upgrade, Strothmann, supplied an automation solu-tion for the feeders featuring the secure Simatic S7-317F PN/DP for the safety-specifi c functions (guard door, shutdown etc.). The controller communicates with the Simotion P350 control system via the only remaining Profi bus connection in the installation.

The Simotion panel PC is the platform for the run-time software that controls all ET 200S und ET 200F peripheral devices as well as the Sinamics S120 drive system with CU320 control unit. The drives transmit the relevant commands to the Simodrive 1FT7 servo motors.

WinCC fl exible also runs on the Simotion panel PC as the SCADA system for the entire feeder system. MP 177PN mobile panels are used for the on-site opera-tion and setup of the system.

Synchronization in real time

The Profi net profi le IRT (isochronous real time) is employed to enable virtual real-time communication within the system and synchronization of the feeders at all stages within one millisecond. The CBE 20 com-munication processors with integrated ERTEC switch (Enhanced Real Time Ethernet Controller) ensure that the Sinamics converters respond equally quickly.

With a high bus speed of 100 megabits per second, the system meets the strict European safety require-ments of SIL 3 (Safety Integrity Level 3).

One bus for all jobs

With the new, Profi net-based bus architecture, no sep-arate bus structures are required for the safety-spe-cifi c and standard logic functions or for the drive syn-chronization. Thanks to the uniform bus structure of the system controller, drives and peripheral systems, Chery is able to reap considerable savings. The whole system runs on a single platform, resulting in signif-icant cost reductions for engineering, commissioning, maintenance and ongoing production.

Another important aspect for this dynamically growing manufacturer is that the Profi net basis re presents a state-of-the-art, open system that can be enhanced at any time.

The system has proven itself to be stable and highly productive and, according to the operators, has increased throughput by 15% over manual process-ing. p

Feeder upgrade safety confi guration for Chery in Wuhu


Developing highly productive press systems to a high degree of reliability and within a tight timeframe requires innovative automa-tion solutions

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Metalforming Solution Package p

Fast-lane Press Automation

Special solutions from Simotion drive

simplicity and cost-effectiveness in the

fi eld of press automation.

S o l u t i o n

When designing and developing mechanical and hydraulic presses and handling equip-ment, a largely modular approach ensures

maximum flexibility and fast turnarounds when it comes to configuring and assembling customer-spe-cific machinery. Standard components from Siemens bring their full potential to bear during the process of automation. Sinamics drive components in con-junction with the Simotion motion control system facilitate integrated concepts that provide the required degree of flexibility in the design, construction and individual assembly of machine components.

Adapted to the press automation

The Metal Forming Solution Package (comprising SimoRoll, SimoTrans, SimoFeed and SimoPress) has been designed specifi cally with press automation in mind and offers the full range of functions required to automate presses. The package supports press manu-facturers in implementing their specifi c press concepts within a tight timeframe. Tried-and-tested sample applications perfectly demonstrate the functions that


infocontact


can be achieved and use of the individual software modules. The scalability of each of the applications offers a real advantage: users can select the software modules from the extensive product range that repre-sent the most cost-effective solution for their applica-tion. These out-of-the-box software modules can then be confi gured in just a few steps and integrated into the machine-specifi c software. Independent testing of individual software modules prior to integration into the overall concept ensures minimum development times and maximum reliability when programming the complete applications. Technically mature diag-nostic tools from Simotion reduce the time between concept and a ready-to-use automation solution to a minimum. Once all modules, including their integra-tion into the existing operation system (e.g. WinCC fl exible), have been proved to be stable and reliable, they can be incorporated into the machine software using a modular approach. This process allows even complex, customer-specifi c presses and peripheral functions to be automated quickly and effi ciently. The structure of the machine software remains clear and provides scope for modular expansion – giving press

H i g h l i g h t s o f t h e M e t a l F o r m i n g S o l u t i o n P a c k a g e

manufacturers optimal fl exibility while reducing development times to a minimum.

Platform-independent solution

The Metal Forming Solution Package is designed to be hardware platform-independent in order to meet the requirements of press manufacturers. Simotion can be used in conjunction with the topology of SPS, IPC or even intelligent drive modules. Any number of modules for monitoring and controlling presses and press peripherals can be combined with the standar-dized automation platform Simotion and the Metal Forming Solution Package to create customized auto-mation solutions. All Simotion applications in the Metal Forming Solution Package are based on ready-to-use and proven modules that can be confi gured in line with individual requirements. p

Simotion SimoRollMaster axis coupling/cam disks 3Online feed length compensation 3Flexible feed programs 3Freely selectable feed angle 3Transparency through extensive 3diagnostic toolsEnd-of-line monitoring 3

Simotion SimoFeedManual, automatic and single-step 3operating modesCost-optimized solution through fi ne- 3tuned performance and number of axes“Teach-in” functions 3Adjustable infeed and outfeed positions 3Master value coupling 3User interface to connect customer- 3specifi c transformations

Simotion SimoTransHighly dynamic and non-abrasive motion 3controlAccelerated tool changeover 3Simple confi guration of motion path 3Coupling of motion system to press 3master valuePlausibility check of the motion profi le 3data

Simotion SimoPressOperating modes for servo presses and 3conventional mechanical presses Static and dynamic position and feed 3control, and frame counterPress force monitoring and tool protection 3Dynamic braking angle calculation for 3OT stopMain drive controller with specifi cation 3of stroke rate

Simotion SimoPress ServoAutomatic calculation of energy- 3optimized motion for the press ramSimple generation of ram kinematics 3through entry of working area, draw rate, number of strokes and downtime at bottom dead centerHand wheel operation for trial operation 3Pendulum stroke 3


Siemens PLM Software, Germany p

A Real Head Start

People automatically associate UGS – now Siemens PLM Software since the takeover by Siemens – with the company’s CAD/CAM sys-

tem. What is less known, however, is that Siemens PLM has a development center in Berlin where it developed the “Press Line Simulation” software. Using this software, it is possible to digitally map and then simulate the entire sheet metal forming process in the automotive industry, thereby optimizing it and eliminating collisions. This saves a great deal of time later in the workshop when setting up and running the press lines.

First, Siemens PLM maps the press line precisely in the software. Next, the customer data (CAD data

Software to simulate and optimize tools and press lines in the automotive

industry speeds up car body production.

for the tools and auxiliary equipment) is entered. Together with the basic production conditions, this forms the complete scenario, which can be simulated on the computer.

The customer can view his plant on the screen and can set and test all parameters. All errors are detected virtually and can also be rectifi ed virtually. This is much quicker and simpler than in a real environment and means that the parts can go into casting without any errors.

Two main CAD/CAM systems are used in body de velopment within the automotive industry: “NX” and “Catia” from Siemens PLM. The simulation sys-tem features interfaces to both systems.V

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» Using our software, it is possible to digitally map and then simulate the entire sheet metal forming process in the automotive industry, thereby optimizing it and eliminating the risk of collisions. «

Dr. Ulrich Lorenz, product manager for press line simulation at Siemens PLM in Berlin

Different press models

Presses vary greatly and experience has shown that a generalized model never produces the desired degree of simulation precision. For this reason, the simula-tion models developed in Berlin correspond to real models – an expense that pays for itself. Each and every Siemens PLM customer is supplied with an exact model to which he can then add his own data. This enables him to predict exactly what will happen later during the actual production process. According to Siemens PLM, the match rate of the simulation results with the subsequent actual results is over 90 percent. In this way, for instance, one German vehicle manufacturer was able to detect 99 percent of all tool errors thanks to the software.

Simulation of the sheet metal cycle

During the simulation, all kinematic processes such as feeder movements or parts lifters are mapped. In addition to the sheet forming and shaping at the moment of forming and the deep drawing optimi-zation, all processes are factored in, meaning that at the end, the sheet metal part runs smoothly through all stations – at the desired speeds and without any collisions. Furthermore, sheet warpage during trans-portation is also observed. Using a special module in the simulator, the warpage can be determined under specifi c constraints, such as the suction cup positions. This enables the user to anticipate the vibration volume during the passage through the plant and react accordingly.

The collision calculation is crucial for the accuracy of the simulation. This is understood to be the contact or penetration of infi nitesimally small surfaces. How small these surfaces are depends on the faceting of the model. A large number of facets produces greater accuracy but increases the time required for calcula-tion. The algorithm fi nds all collisions and indicates them on the screen.

It is impossible to generalize regarding when the simulator will have paid for itself. However, one of the

company’s customers was able to shorten the set-up time on the press lines for its latest vehicle model by around 70 percent. This means that production can begin much earlier, and the resulting savings ensure that the simulation pays for itself in under six months. Siemens PLM Software offers basic training in “Press Line Simulation.”

A look at the future

Siemens PLM Software can defi nitely see itself serv-ing further markets beyond the automotive industry, one example being the “white goods” sector. However, the simulator can also be used to resolve problems of a completely different nature, basically in any situa-tion involving motion and where the potential for col-lisions exists. The current trend is for retrofi tting existing presses as well as continuing to enhance the technology of parts transport per se.

A further trend is concerned with the increasingly complex press controls, which are designed to maxi-mize the number of strokes (= parts production per minute). Such controls can only achieve the desired result in coordination with an accurate simulation, i.e. manual optimization of the forming process is un realistic.

For the fi rst time, a version of “Press Line Simu-lation” has been unveiled that is capable of exchang-ing data with a control unit. Slide movement profi les, die cushions and transfers are taken from Simotion and fed into the simulation. These are then synchro-nized and the machine parameters are returned to the control unit. The aim is to further increase the accuracy of the simulation and simplify the transfer of data to the actual press. p

How to combine the flexibility of hydraulic presses with the speed of mechanical presses, maximizing your energy efficiency at the same time? With our complete package for servo presses. This is based on proven standards, particularly the motion control system SIMOTION® and the SINAMICS® drives. It not only increases your output but also optimizes the movement profile for the plunger, ensuring long-term energy savings. To find out more, go to: www.siemens.com/metalforming.Setting standards with Totally Integrated Automation.

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