Isgec Solution for Hot Forming Line

Transcription

1 Isgec Solution for Hot Forming Line

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

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

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

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

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

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

8 Floor Mounted Heating Elements, Bottom Access

9 Heating Elements

10 Common wired elements to rear

11 Multi Chamber, Atmosphere,Development Unit

12 Proto Unit,3 chamber, Atmosphere Side

13 Atmosphere Flow Stand, Control Panels

14 7 Chamber System, 2 Piece Sections

15 Fork Load Chambers

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

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

18 Robots : MAIN TECHNICAL FEATURES AXIS / PART DATA Robot model COMAU SMART NJ Structure Articulated Parallelogram Axes quantity 6 Maximum Static Load on Wrist 100 kg( lb) Additional Maximum Load on 50 kg ( lb) Axis #3 Total Maximum Load 150 kg ( lb) Torque on Axis Nm Nm 280 Nm Axes Stroke (Speed) ± 180 (120 /s) -49 to +95 (108 /s) to -68 (120 /s) ± 200 (190 /s) ± 120 (190 /s) ± 200 (250 to 275 /s) Repeatability ± 0,20 mm Maximum Reach Horizontal 3209 mm (10.53 ft) Weight Robot 1250 kg ( lb) Programming language COMAU PDL2 Control unit weight C5G 125 Kg (C5G base only)

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

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

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

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

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

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

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

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

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

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

29 Isgec Customers :

30 Comau Robotics Customers :

31 Thank You