Machine and plant manufacture for stamping and forming technology. HR and HRM STAMPING AND FORMING AUTOMATIC PRESSES.

Transcription

1 Machine and plant manufacture for stamping and forming technology HR and HRM STAMPING AND FORMING AUTOMATIC PRESSES ,000 kn

2 Precision and flexibility Proven by practice and innovative QUALITY AND PRECISION Presses with follow-on composite tools are version for large series production. The stamping and forming automatic presses of the HR series from RasterZeulenroda are specialized in this field. The parts are kept together in sheet metal strips until finally detached in the follow-on composite and moved through the various tool stations in the strips. HRM Another alternative is forming technologies at several stages with transfer of parts. The stamping and forming automatic presses of the HR series are remarkable for the precision of all movements and long-term accuracy. This ensures that the quality of the products is on the same high level throughout a large series. HR 400 with 3-D transfer and integrated scrap transport system

3 HRM 160 with complete strip system CHARACTERISTICS AND OPTIONALLY SELECTABLE FEATURES > Press frames in monobloc design as welded steel construction connected to form a structure of high resistance to bending and torsional forces, stress relieved and FEM calculated, little table sag, exact parallelism between table and ram and high precision of the angular run of the ram along the full stroke length > Multi-part welded steel construction > Optional: heat-treated multi-part special casting design connected to form a particularly flexurally rigid frame by use of hydraulically prestressed steel anchors > Coupling and braking system with extremely short braking angle > Bearings located directly at force transmission points > Special connecting rod mounting points on the outside of the ram for absorbing any eccentric loads occurring, connecting rod supported in half shells (standard), ball spindle with hydraulic clamping (optional) > Ram of welded steel construction (standard), of heat-treated special casting (optional), application-oriented with sliding or roller guides, efficient guide ratio > Pneumatic ram and overhead tool weight balancing, counteracts the mass acceleration occurring during cutting processes especially during tooling-up > With automatic ram adjustment > With automatic stroke adjustment > Press control by Beckhoff or Siemens > Drive design adapted to the application of the machine > Adaptation of the machine s working space to customized tools > Optionally with separate creep speed drive > Optionally as link version Accessories/optional equipment > Strip line equipment > Coilers, recoilers > Roll feed > Transfer equipment > Toll carrier arms > Tool change plates > Roll block lifters > Hydraulic sliding clamps > Ram blockage > Oil collection pan 3

4 CONSTRUCTION FEATURES Press frame Monobloc Welded steel construction of high resistance to bending and torsional forces, stress relieved and FEM calculated. > Nesting of welded walls ensures that force is not only transmitted through welds > Little table sag > High parallelism between table and ram > High accuracy of angular run across the ram stroke > Table sizes up to 2,500, pressing forces up to 5,000 kn Optional: Tie rod design / steel or special casting versions, torsionally resistant 4-part special-casting press frame. The robust, 3-part cast frame absorbs the fine vibrations produced by cutting and/or punching. High and consistent work quality is guaranteed by the stability and rigidity of the table, ram and press frame. Hydraulically prestressed steel anchors connect the frame components, effectively compensate any press forces occurring and prevent expansion of the press frame. This results in long tool service life at a consistently high part quality. Ram and ram guide Eight-fold sliding or 16-fold roller guides are provided to suit the dominating application conditions. The 8-fold sliding guides, which are especially recoended for punching operations, have extremely stable, adjustable guide rails. Very closely located adjustment keys ensure lowdeformation support of the guide rails. For higher-speed presses, or for increased accuracy requirements with respect to ram guidance precision, we recoend a zero-backlash prestressed 16-fold roller guide system. The precision roller-guidance system available as an option, combined with the exceptionally rigid press frames, ensures the highest possible output of parts between two sharpenings of the tool at guaranteed working quality. Besides, high off-center loads are possible. Eccentric shaft, eccentric shaft bearings The design and dimensioning of the eccentric shaft and shaft bearings play a considerable part in the long-term static and dynamic stiffness of the entire system, in addition to the press frames, and affect the long-term accuracy of the dimensional working space relationships. The eccentric shaft, made of high-strength tempered high-alloy forged steel, is supported in four multi-row roller bearings or plain bearings in the iediate vicinity of the connecting rods in order to be stiff against warping. Reduced bearing clearance and pressure points located at the outside extremes ensure lowest possible central deflection und therefore the greatest possible dimensional consistency at ram end positions even under extreme loads. Ram guide plan view (left) and section of guide (right) Eccentric shaft with SERVO drive 4

5 Connecting rod ram force transmission Highly wear-resistant and optimally dimensioned force transmission joints located at the outside extremes of the ram are extremely important for the long-term accuracy of working space geometry under load. The tried-and-tested compression joint (of pressure shell design) consisting of the hardened and precision-ground cylinder contact face on the connecting rod and the counterbearing in the height-adjustable spindle made of high-quality bearing metal, ensures safe, low-wear transmission of the very highest forming and cutting forces. Hydraulic overload protection It reliably protects the machine and tools from overloading. A prestressed high-pressure hydraulic cushion is placed in the direct force flux in the ram underneath each connecting rod. If the preset press force is exceeded, the machine is shut down by the automatic high-speed shut-down system. Jaing of the ram is prevented by synchronizing both hydraulic cushions. Overload travel 20 Response time < 10 ms Ram adjustment The ram height is adjusted synchronously by motor within an accuracy of 0.01 via two threaded spindles. The height can be set in the tool data as part of the press control. Position clamping is hydraulic and fully automatic. Ram weight compensation The weights of the ram and the overhead tool are compensated sufficiently. The required air pressure is set manually at a controller or in the user surface (tool data). This facilitates the setting up process and improves the tool service life. The ram weight compensation is designed as bellows and in direct connection with the reservoir. There is no restriction, e.g., due to temperature, large strokes or high stroke frequencies which, ensures a large open cross section between the bellows and the reservoir. In addition, there is also no restriction of the degrees of freedom. Ram weight compensation Connecting rod bearing half shell Alternative: Supporting the connecting rod (pressure points) in a ball spindle design with hydraulic clamping (zero-backlash and low-wearing). Ram integrated adjustment Working capacity Stroke adjustment Stroke adjustment is fully automatic. The new type of pneumatically powered and mechanically synchronized stroke adjustment avoids jaing of the ram because all 4 stroke discs are moving synchronously. The sensitive adjustment enables variable latched positions: Standard = 10 strokes, up to 40 strokes are possible, adjustment time: max. 2 min The system is locked mechanically. The adjustment process is monitored electrically. Working capacity in knm Intermediate gear Strokes per minute Direct drive Stroke adjustment with SERVO drive: The presses with SERVO drive support free prograing of ram strokes (pendulum mode) under stroke parameters. Fixed stroke can be selected for simple applications. Connecting rod bearing in a ball spindle design 5

6 DRIVE AND CONTROL Possible drive concepts > Conventional with intermediate gear > Complete drive > Link drive > SERVO drive (as direct drive or with intermediate planetary gear) DESCH-SERVOX -planetary gear Inverter drive This drive can be varied steplessly by remote adjustment of the speed from the operator console. The working capacity is always designed according to the customer s part range. Power train Motor belt pulley belt complete drive crankshaft connecting rod ram Complete drive The complete drive of the press replaces the complete spur-type intermediate gear or one or two gear stages at the stamping and forming automatic press, for which the energy required by the machine is obtained from the flywheel running at high speed. Link drive The link drive substantially reduces the impact speed of the ram, including that of the overhead tool, in comparison with conventional drive solutions. The additional articulation in the drive system has a positive effect on the ram movement. In addition, the tool service life is increased considerably. Benefits: > Longer tool life > Fast upward travel > Increased part output The link system ensures that forces generated by the punching process, which act on the eccentric shaft, are not transferred into the drive system. SERVO drive with/without intermediate planetary gear This drive is implemented with hightorque motors which depending on the application are connected to the eccentric shaft or by a low-backlash planetary gear. The SERVO motor is the power source of the machine. The intelligent control supports prograing different speed profiles, which makes the machine highly flexible and suitable for different applications. The machine output can also be increased with this configuration. The speed of the steplesscontrol torque motor is adjustable at the operator panel. Features of the SERVO drive: > High torque with compact design and small construction volume > Optimized mechatronic solution > Highest rigidity > High speeds possible > Improves productivity and product quality > High dynamic action (fast acceleration) > Excellent true running > The suitable motor for low-energy solutions Benefits: > Gentle cutting > Difficult contours are produced very exactly > Long tool life > Low noise emission > Fast upward travel > High output of parts > Reduced auxiliary process times Energy management: > Based on capacitor modules; or electro-mechanical storage motor > The generator energy is stored in the intermediate circuit in such a way that the total connected load of the stamping and forming automatic press is similar to or lower than that of mechanical machines The press control Optimum for the press operator: > Complete information on the press and the job at any time > Automatic operator prompts Optimal for the machine setter: > Simple, function-oriented prograing of tool data, notepad and photo album for every tool > Reference function to prior tool settings or other tools Optimum for maintenance: > Extensive press diagnostic function with link to on-line help (Beckhoff) > On-line help with photos of all sensors for quick localization to speed up problem resolution (Beckhoff) > Maintenance interval with reminder function (for machine, peripherals and tool) Optimum for production planning: > Automatic recording of job-specific data > Automatic update of the job history Optional: > Web server for remote monitoring of the machine via the intranet Comprehensive remote service: > User support > Program updates Control from Beckhoff or Siemens: > TFT color screen control on basis of Beckhoff PC control with soft PLC > PC-integrated operating hours counter; Raster-Zeulenroda visualization under Windows > PLC with Simatic S7-300 and 15 touch panel with color display; prograing with structured text (SCL + SCL-Petri nets); visualization based on WinCC flexible > Simotion control for machines with SERVO direct drive; Raster-Zeulenroda- visualization under Windows 6

7 HR 800 with transversal shaft drive Overview of control versions Control, field bus Visualization system Comprehensive comfortable RasterZeulenroda visualization based on Windows XP Pro Simple visualization based on Siemens WinCC flexible Visualization based on Siemens WinCC Beckhoff TwinCAT, EtherCAT SIMATIC S7, Profibus SIMOTION Profinet Photo credits: Beckhoff Automation GmbH 7

8 TECHNICAL SPECIFICATIONS 1,000 kn 1,600 kn HR 100 / 800 HR 100 / 1,100 HR 100 / 1,400 HR 100 / 1,700 HR 125 / 800 HR 125 / 1,100 HR 125 / 1,400 HR 125 / 1,700 HR 160 / 1,100 HR 160 / 1,400 HR 160 / 1,700 Press force 30 bbdc kn 1,000 1,250 1,600 Working strokes, stepless Ram stroke setting in steps of approx. 10 Distance between table and ram at largest stroke down ram adjustment at top (tool installation height) Fixed ram stroke, max. * Ram height adjustment min Table area 900 1,100 1,500 1, ,200 1,500 1,800 1,200 1,500 1, Table opening ,200 1, ,200 1, ,200 1, Ram area 800 1,100 1,400 1, ,100 1,400 1,700 1,100 1,400 1, Passage between columns at side (W x H) Width between oil collection pans Strip feeding height above table surface, adjustable 420 x x x ,110 1,410 1, ,110 1,410 1,710 1,110 1,410 1, Drive power kw Total machine weight, approx. kg 13,000 15,500 19,000 21,500 15,500 19,000 22,000 25,500 19,500 23,000 28,000 * other fixed ram strokes on request High-speed stamping and forming automatic presses and stamping and forming automatic presses with back gear on request. All versions also available as monobloc frame. 8

9 2,000 kn 3,150 kn HR 200 / 1,100 HR 200 / 1,400 HR 200 / 1,700 HR 200 / 2,000 HR 250 / 1,300 HR 250 / 1,600 HR 250 / 1,900 HR 250 / 2,200 HR 250 / 2,500 HR 315 / 1,600 HR 315 / 1,900 HR 315 / 2,200 HR 315 / 2,500 Press force 30 bbdc kn 2,000 2,500 3,150 Working strokes, stepless Ram stroke setting in steps of approx. 10 Distance between table and ram at largest stroke down ram adjustment at top (tool installation height) Fixed ram stroke, max. * Ram height adjustment min Table area 1,200 1,500 1,800 2,100 1,400 1,700 2,000 2,300 2,600 1,700 2,000 2,300 2, Table opening 900 1,200 1,500 1,800 1,100 1,400 1,700 2,000 2,300 1,400 1,700 2,000 2, Ram area 1,100 1,400 1,700 2,000 1,300 1,600 1,900 2,200 2,500 1,600 1,900 2,200 2, ,000 Passage between columns at side (W x H) Width between oil collection pans Strip feeding height above table surface, adjustable 520 x x x 300 1,110 1,410 1,710 2,010 1,310 1,610 1,910 2,210 2,510 1,610 1,910 2,210 2, Drive power kw Total machine weight, approx. kg 28,000 31,500 35,000 37,000 38,500 42,500 47,000 51,000 57,000 47,000 51,000 57,000 62,000 * other fixed ram strokes on request High-speed stamping and forming automatic presses and stamping and forming automatic presses with back gear on request. All versions also available as monobloc frame. 9

10 TECHNICAL SPECIFICATIONS 4,000 kn 5,000 kn HR 400 / 1,600 HR 400 / 1,900 HR 400 / 2,200 HR 400 / 2,500 HR 400 / 2,800 HR 500 / 1,600 HR 500 / 1,900 HR 500 / 2,200 HR 500 / 2,500 HR 500 / 2,800 HR 500 / 3,600 Press force 30 bbdc kn 4,000 5,000 Working strokes, stepless Ram stroke setting in steps of approx. 10 Distance between table and ram at largest stroke down ram adjustment at top (tool installation height) min Fixed ram stroke, max. * In these versions are not available. In these versions are not available. Ram height adjustment Table area 1,700 2,000 2,300 2,600 2,900 1,700 2,000 2,300 2,600 2,900 3,600 1,200 1,300 1,400 Table opening 1,400 1,700 2,000 2,300 2,600 1,400 1,700 2,000 2,300 2,600 3, Ram area 1,600 1,900 2,200 2,500 2,800 1,600 1,900 2,200 2,500 2,800 3,600 1,000 1,100 1,200 Passage between columns at side (W x H) 900 x x 500 1,000 x 500 Width between oil collection pans Strip feeding height above table surface, adjustable 1,610 1,910 2,210 2,510 2,810 1,610 1,910 2,210 2,510 2,810 3, Drive power kw Total machine weight, approx. kg 60,500 65,000 70,500 77,500 85,00 64,000 68,000 74,000 80,000 87, ,500 High-speed stamping and forming automatic presses and stamping and forming automatic presses with back gear on request. Monobloc frame available up to press force of 500 tons and 2,500 table. 10

11 6,300 kn 8,000 kn HR 630 / 1,900 HR 630 / 2,200 HR 630 / 2,500 HR 630 / 2,800 HR 800 / 2,800 HR 800 / 3,200 HR 800 / 3,600 HR 800 / 4,000 Press force 30 bbdc kn 6,300 8,000 Working strokes, stepless min Ram stroke setting in steps of approx Distance between table and ram at largest stroke down ram adjustment at top (tool installation height) ,000 Fixed ram stroke, max. * In these versions are not available. 500 Ram height adjustment Table area 2,000 2,300 2,600 2,900 2,900 3,300 3,700 4,000 1,400 1,500 Table opening 1,700 2,000 2,300 2,600 2,600 3,000 3,400 3, Ram area 1,900 2,200 2,500 2,800 2,800 3,200 3,600 3,900 1,200 1,300 Passage between columns at side (W x H) Width between oil collection pans Strip feeding height above table surface, adjustable 1,100 x 500 1,600 x 950 1,920 2,220 2,520 2,820 2,620 2,920 3,520 3, Drive power kw Total machine weight, approx. kg 110, , , , , , , ,000 * other fixed ram strokes on request High-speed stamping and forming automatic presses and stamping and forming automatic presses with back gear on request. 11

12 TOOLS Table surface Coil feeding Ram surface 12

13 Tool installation dimensions 1,000 kn 8,000 kn Model A B C D E F H J K L M N O HR 100 / , ,040 8 HR 100 / 1,000 1, ,380 1,100 1, HR 100 / 1,400 1,500 1,200 1,680 1,400 1, HR 100 / 1,700 1,800 1,500 1,980 1,700 1, HR 125 / , ,040 8 HR 125 / 1,100 1, ,380 1,100 1, HR 125 / 1,400 1,500 1,200 1,680 1,400 1, HR 125 / 1,700 1,800 1,500 1,980 1,700 1, HR 160 / 1,100 1, ,380 1,100 1,340 8 HR 160 / 1,400 1, , ,680 1, , HR 160 / 1,700 1,800 1,500 1,980 1,700 1, HR 200 / 1,100 1, ,380 1,100 1,360 8 HR 200 / 1,400 1,500 1,200 1,680 1,400 1, , HR 200 / 1,700 1,800 1,500 1,980 1,700 1, HR 200 / 2,000 2,100 1,800 2,280 2,000 2, HR 250 / 1,300 1,400 1,100 1,640 1,300 1, HR 250 / 1,600 1,700 1,400 1,940 1,600 1, HR 250 / 1,900 2,000 1, , ,240 1, , HR 250 / 2,200 2,300 2,000 2,540 2,200 2, HR 250 / 2,500 2,600 2,300 2,840 2,500 2, HR 315 / 1,600 1,700 1,400 1,940 1,600 1, HR 315 / 1,900 2,000 1,700 2,240 1,900 2, , , HR 315 / 2,200 2,300 2,000 2,540 2,200 2, HR 315 / 2,500 2,600 2,300 2,840 2,500 2, HR 400 / 1,600 1,700 1,400 1,940 1,600 1, HR 400 / 1,900 2,000 1,700 2,240 1,900 2, HR 400 / 2,200 2,300 1, , ,540 2,200 1,000 2, HR 400 / 2,500 2,600 2,300 2,840 2,500 2, HR 400 / 2,800 2,900 2,600 3,140 2,800 3, HR 500 / 1,600 1,700 1,400 1,940 1,600 1, HR 500 / 1,900 2,000 1,700 2,240 1,900 2, HR 500 / 2,200 2,300 1, ,000 2,540 2,200 1,100 2, HR 500 / 2,500 2,600 2,300 2,840 2,500 2, HR 500 / 2,800 2,900 2,600 3,140 2,800 3, HR 500 / 3,600 3,600 1,400 1,000 3,300 3,800 3,600 1,200 3, HR 630 / 1,900 2,000 1,700 2,400 1,900 2, HR 630 / 2,200 2,300 2,000 2,700 2,200 2, ,400 1, , HR 630 / 2,500 2,600 2,300 3,000 2,500 2, HR 630 / 2,800 2,900 2,600 3,300 2,800 3, HR 800 / 2,800 2,900 2,600 3,140 2,800 3, HR 800 / 3,200 3,300 2,900 3,540 3,200 3, ,600 1, ,400 1, HR 800 / 3,600 3,700 3,300 3,940 3,600 3, HR 800 / 4,000 4,000 3,700 4,340 4,000 3, Other dimensions on request. 13

14 PRINCIPAL DIMENSIONS Front view Side view Hydraulic unit 14

15 Principal dimensions 1,000 kn 3,150 kn Model A B B* C D E F G H L M HRM 100 / 800 1,050 1,850 2,150 1,840 HRM 100 / 1,100 1,200 2,000 2,300 2,140 3,100 3,800 1,100 1,400 2,340 HRM 100 / 1,400 1,450 2,150 2,450 2,440 HRM 100 / 1,700 1,600 2,300 2,600 2,740 3,200 3,900 HRM 125 / 800 1,050 1,850 2,150 1,840 HRM 125 / 1,100 1,200 2,000 2,300 2,140 3,150 3,900 1,100 1,400 2,540 HRM 125 / 1,400 1,450 2,150 2,450 2,440 HRM 125 / 1,700 1,600 2,300 2,600 2,740 3,250 3,950 HRM 160 / 1,100 1,230 2,200 2,500 2,200 HRM 160 / 1,400 1,480 2,350 3,650 2,500 1,100 1,500 2,600 3,300 4,000 HRM 160 / 1,700 1,630 2,500 2,800 2,800 3,400 4,100 HRM 200 / 1,100 1,230 2,200 2,500 2,200 3,350 4,100 HRM 200 / 1,400 1,480 2,350 2,650 2,500 1,100 1,500 2,800 HRM 200 / 1,700 1,530 2,500 2,800 2,800 3,450 4,150 HRM 200 / 2,000 1,680 2,360 2,660 3,100 3,550 4,250 HRM 250 / 1,300 1,450 2,250 2,550 2,230 HRM 250 / 1,600 1,600 2,400 2,700 2,530 3,600 4,600 HRM 250 / 1,900 1,750 2,550 2,850 2,830 1,200 1,700 3,000 3,700 4,700 HRM 250 / 2,200 1,900 2,700 3,000 3,130 3,800 4,800 HRM 250 / 2,500 2,050 2,850 3,150 3,430 3,900 4,900 HRM 315 / 1,600 1,450 2,250 2,550 2,530 3,700 4,900 HRM 315 / 1,900 1,600 2,400 2,700 2,830 3,800 4,900 1,200 1,700 3,000 HRM 315 / 2,200 1,750 2,550 2,850 3,130 3,900 5,000 HRM 315 / 2,500 1,900 2,700 3,000 3,430 4,100 5,100 B* with back gear Principal dimensions with drive unit (planetary gear, flywheel, coupling, brake) 4,000 kn 8,000 kn Model A B B* C D E F G H I J HRM 400 / 1,600 2,400 2,000 2,500 2,900 HRM 400 / 1,900 2,550 2,150 2,650 3,200 4,600 5,550 HRM 400 / 2,200 2,700 2,300 2,800 3,500 1,300 2,000 3, HRM 400 / 2,500 2,850 2,450 2,950 3,800 4,700 5,650 HRM 400 / 2,800 3,000 2,600 3,100 4,100 4,800 5,700 HRM 500 / 1,600 2,400 2,000 2,500 2,900 HRM 500 / 1,900 2,550 2,150 2,650 3,200 4,600 5, HRM 500 / 2,200 2,700 2,300 2,800 3,500 1,300 2,000 3,300 HRM 500 / 2,500 2,850 2,450 2,950 3,800 4,800 5, HR 500 / 2,800 3,000 2,600 3,100 4,100 5,000 5, HR 500 / 3,600 3,400 3,200 3,700 4,900 6,200 5,900 HR 630 / 1,900 2,050 3,350 3,850 3,300 HR 630 / 2,200 2,200 3,500 4,000 3,600 5,900 6,600 1,700 2,000 3,500 HR 630 / 2,500 2,350 3,650 4,150 3, HR 630 / 2,800 2,500 3,800 4,300 4,200 6,000 6,700 HR 800 / 2,800 3,210 3,210 5,000 2,200 3,400 4,000 8,400 9, HR 800 / 3,200 3,410 3,410 5,400 2,400 3,400 4,000 8,400 9, HR 800 / 3,600 3,610 3,510 5,900 2,400 3,400 4,200 8,800 9, ,000 HR 800 / 4,000 3,810 3,810 6,300 2,400 3,400 4,200 8,800 9, ,000 B* with back gear Other dimensions on request. 15

16 Machine and plant manufacture for stamping and forming technology Hamburg 600 km Hannover 460 km Berlin 300 km Leipzig 110 km Köln 530 km Dresden 180 km Zeulenroda Frankfurt 380 km Prag 300 km Wien 650 km Nürnberg 180 km Stuttgart 400 km München 340 km > TRANSFER FORMING AUTOMATIC PRESSES > STAMPING AND FORMING AUTOMATIC PRESSES > TOOL TESTING AND PRODUCTION PRESSES > HYDRAULIC OPEN-FRONT AND DOUBLE-SIDED PRESSES > SPECIAL-PURPOSE PRESSES AND SPECIAL CONSTRUCTIONS > SERVICE AND GENERAL MAINTENANCE > JOB ORDER PRODUCTION Raster-Zeulenroda Werkzeugmaschinen GmbH Triebeser Straße 5 D Zeulenroda-Triebes Tel.: + 49 (0) / 42-0 Fax: + 49 (0) / info@raster-zeulenroda.de Date: 10/ Photos: fotolia