Common cause Levelling and deburring A new strip levelling line from KOHLER A slitting unit for automotive suppliers A zig-zag strip levelling line

Transcription

1 NEWS ISSUE 1/2015 Common cause Levelling and deburring A new strip levelling line from KOHLER A slitting unit for automotive suppliers A zig-zag strip levelling line

2 EDITORIAL KOHLER writes company history! Dear Readers, After our move in the fall of 2014, a new chapter in the history of the company was already started in January: The PAUL ERNST Maschinenfabrik in Eschelbronn was integrated into the WINTERSTEIGER Group. With PAUL ERNST on board, we have a partner on our side that fits perfectly to our company: because basically every part levelling machine customer also needs a deburring machine. This results in powerful sales synergies that have already been showcased at joint presentations at trade fairs. Read more about this on page 3. Another step in development has been made towards internationalization: the KOHLER subsidiary in Shanghai, China, with an emphasis on part levelling and deburring machines has successfully taken up operation. A very new branch is the contract levelling and deburring offered in the Competence Center for Levelling Technology in Lahr, Germany. This service is tailored for those customers who would like to enter the world of levelling and deburring technology but do not need the capacity provided by a system of their own. In addition, we perform levelling and deburring tests for and with customers in order to determine the right machine for their specific application. Dipl.-Ing. Arnd Greding, Technical Director at KOHLER On the technical side, we inform you about two special projects in this issue: on the one hand, we present a report about the new strip levelling line for an international automotive supplier. This system demonstrates the high degree of individualization, the robust construction and the comprehensive concept and design that are possible to achieve with KOHLER systems. A "zig-zag strip levelling line" in a compact design has also been realized. It is mounted on a transverse mechanism that forms a zig-zag movement together with the simultaneous forward feed. Written reports cannot replace personal experience and contact, which is a good reason to visit us at the Blechexpo from November 3rd to 6th in Stuttgart, Germany the perfect opportunity to get to know KOHLER and ERNST machines and discuss questions in depth with us personally. We are pleased to invite you and look forward to your coming! Yours faithfully, Dipl.-Ing. Arnd Greding Technical Director

3 COMMON CAUSE 2 3 A symbiosis of two specialists The integration of PAUL ERNST Maschinenfabrik GmbH into the WINTERSTEIGER Group has created the best conditions for advancing and expanding the technological leadership of both companies in levelling and deburring technology. The motto is "Sheet metal deburring and levelling from a single source." In terms of organization, the sales of strip levelling lines has been separated from that of part levelling and deburring machines so the two departments can work the market with independent sales teams. ERNST's network of retailers and representatives will also help cultivate the market for the part levelling business. The ERNST demonstration center has moved to Lahr, and the machines there can now be used by customers and other interested parties for testing and training purposes. Trade fair in Poland The first synergetic presentation took place from June 9th to 12th, 2015, at the ITM (a trade fair for industrial technology and capital goods) in Poznan, Poland. In-house exhibition at KOHLER On June 23rd and 24th, 2015, customers and other interested parties were invited to an in-house exhibition held at KOHLER's premises. Volker Ihling Head of Sales at KOHLER, Artur Biedka Head of Sales for Eastern Europe at KOHLER (Parts Department) and Markus Lindörfer CEO at PAUL ERNST Maschinenfabrik GmbH KOHLER and ERNST have also joined forces for sales. Presently, both companies are jointly presenting the advantages that this constellation provides for customers in diverse trade journals, reports and at in-house exhibitions and trade fairs. The responsibility for the sales of the part levelling and deburring machines lies in the hands of Markus Lindörfer, CEO at ERNST. The responsibility for the sales of the strip levelling lines will be carried by Volker Ihling from KOHLER. Visitors were given the opportunity to meet experts in person and to immerse themselves in every aspect of the world of levelling and deburring technology. Product tests were also carried out on various models, and visitors could bring their own material to be levelled or deburred. Expert lectures and tours of the premises were also featured at the exhibition. Another highlight of the in-house show presented the services offered by a contract levelling and deburring center to the visitors. The customers and interested visitors were impressed by the professional expertise and engineering options. Impressions of the in-house exhibition.

4 LEVELLING AND DEBURRING Two steps to ensure clean results Deburring and levelling are two processes that harmonize perfectly in sheet metal processing: levelling rollers do not appreciate burrs, which lead to increased wear. Therefore, the sheet metal parts must first be deburred before they are introduced to the levelling machine. However, many deburring machines on the market work with traditional, usually inflexible grinding units that must be aligned precisely within +/- 0.2 mm. That may sound like an impossible task when it comes to workpieces that can have warpage on the scale of several millimeters. But not so for the ERNST company from Eschelbronn, Germany: their machines utilize a floating, highly flexible deburring roller that can also compensate for warpage of several millimeters. Deburring and levelling belong together. First deburr, then level. The levelling machine specialist KOHLER Maschinenbau in Lahr, Germany, is the perfect match for ERNST; after all, practically every part levelling machine customer also needs a deburring machine. For this reason, KOHLER and ERNST have merged their sales departments and will now cooperate jointly with retailers and representatives in all markets. The companies have also merged their demonstration centers at the newly established KOHLER facility in Lahr in the Black Forest in Germany, directly on the A5 Karlsruhe-Basel motorway. They will demonstrate their expertise in both fields here on a floor space of 400 m². The deburring and levelling steps follow directly after the flat sheet processing. There are many reasons for deburring and levelling sheet metal parts before further processing. Pros for deburring: reduction of the risk of injury on sharp sheet metal parts (particularly with stainless steel parts) improved coatability and durability of the coating (by removing oxidation and rounding the edges of the workpiece) compliance with standards (like DIN EN 1090) technical specifications (such as R 0.3 mm) Machines from ERNST remove up to 25 mm of oxide: left before and right after treatment. This is how added value is created. Right: level and with hand-friendly rounded edges. Left: warped and with razor-sharp edges as the part leaves the stamping machine or laser unit.

5 4 5 Pros for levelling: significant reduction of tension in favor of subsequent processes such as edge folding or machining ability to automate subsequent processes (laser welding, robot welding) technical requirements for flatness "There is an increasing awareness of the fact that both of these steps provide real added value," says Markus Lindörfer, CEO at PAUL ERNST Machinenfabrik GmbH. He adds: "If you compare a warped and razor-sharp part as it comes directly from the stamping machine or laser side-by-side with one that is perfectly flat and has rounded edges and then hold both of them in your hands, it quickly becomes clear just what added value is created." An important factor in the decision to acquire the PAUL ERNST Maschinenfabrik GmbH for the WINTERSTEIGER Group was the fact that ERNST provides a complete portfolio of deburring machines. ERNST offers both wet processing machines for greasy sheet metal parts and aluminum and dry processing machines. Among other things, these are used when no mix of materials will be processed. For customers whose capacity requirements would not or would not yet justify an investment, both companies offer contract levelling and deburring in their joint Competence Center for Levelling Technology in Lahr. Facts about KOHLER KOHLER has been on the market for more than 50 years. The company manufactures strip feeding lines for presses and automatic stamping machines. This includes levelling machines for strips and parts, camber levelling machines, decoilers and recoilers, as well as systems for the process automation of presses. In addition, they also manufacture systems for the automotive and steel industries, cut-to-length and slitting units and solutions for special applications. More than 6,000 systems have been produced and sold worldwide. The special feature of the part levelling machines is the electromechanical levelling gap control that operates very fast and above all without hydraulics. Facts about ERNST ERNST is the technological leader in sheet metal deburring and offers modular solutions. These provide flexibility for customers that do not process a product of their own and must frequently adapt to changing requirements. Modules are offered for the following process steps: deslagging, deburring, oxidation removal (up to 25 mm), edge-rounding (up to R2) and surface finishing with abrasive belts and brushes. Your contact partner for part levelling and deburring machines: Markus Lindörfer, CEO at PAUL ERNST Maschinenfabrik GmbH. KOHLER Maschinenbau GmbH Einsteinallee 7, Lahr, Germany Tel.: info@kohler-germany.com PAUL ERNST Maschinenfabrik GmbH Alte Meckesheimer Landstraße Eschelbronn, Germany Tel.: info@ernst-maschinen.de

6 A NEW STRIP LEVELLING LINE FROM KOHLER Machines for maximal flexibility Shorter product cycles and the desire for shorter delivery times have led to the development of the new strip levelling line. The task was to develop a modular machine: diverse modules can be integrated via standardized interfaces. We have developed a machine that fulfills the high demands stipulated in the product concept catalog. The coiler, the strip leading-in device and the strip guidance have been modularized and subjected to the value management process, as has the levelling machine. If the levelling or supporting rollers are to be removed, only the front bearing rail needs to be dismantled. This procedure can also be done within a few minutes and no readjustment is needed after remounting. Thus changing rollers or a thorough cleaning of the levelling cassette also become tasks that are easily completed. The safety and operation concept has been designed for the future, as was the drive technology. For the SPS control and its respective visualization, the types S and KP 700 have been chosen. The machine will of course continue to be equipped with the tried and tested features that customers appreciate, such as the quickchange device for levelling and supporting rollers. For this, the lower or the upper half of the levelling cassette can slide out of the machine. This can be done in a largely automated process directly beside the machine without any extra tables or supports. In this way, the levelling rollers and the spaces under the supporting rollers can be cleaned from oxide scale. Finally, we have given the machine a new visual design and it carries the unmistakable look of the new generation of KOHLER machines. It provides the customer with perfect accessibility for operation and maintenance. Franz Müllerleile, Technical Manager We have succeeded in developing an intelligent modular concept for strip levelling lines!" Franz Müllerleile, Technical Manager at KOHLER Maschinenbau GmbH Here a schematic drawing of the new strip levelling line to be presented live at the Blechexpo in Stuttgart, Germany.

7 A SLITTING UNIT FOR AUTOMOTIVE SUPPLIERS 6 7 International automotive supplier orders a slitting unit from KOHLER Exceptional flexibility in production through maximal individualization: the automotive and component supplier industry relies on maximal precision and efficiency in all stages of fabrication and production. This is naturally also true for the entire process of machining and processing sheet metal that comes directly from the coil. For decades KOHLER has been one of the most reliable partners in the industry for the entire levelling process including the required peripherals, with more than 6,000 levelling machines built. This is one reason why one of the leading full-service suppliers for the global automotive industry has decided to rely on a slitting unit from the Competence Center for Levelling Technology. The entire system consisting of a decoiler, levelling machine, strip loop, slitting shears, dancer roller and recoiler will be used to produce ventilation and speaker covers made out of stainless steel. Maximum precision thanks to a 21-roller levelling machine The decoiler with a maximum capacity of 1,500 kg will be loaded with coils of expanded metal in thicknesses between 0.5 and 1 mm and widths between 80 and 1,000 mm. The coil will be pulled off by a 21-roller levelling machine with a roller diameter of 30 mm and carried forward to a strip loop. A PI-controller ensures that the strip is continuously advanced to maintain a predefined loop height. The slitting unit then pulls the material automatically from the loop. It is the master and always operates at line speed. The shear is equipped with five pairs of blades and can cut strips in six stripes of different widths. The width can be varied and thus guarantees great flexibility for production. The strip is supported and the material conveyed by rubberized ejector rings. Recoiling side Side view of the slitting unit

8 The dancer roller as a compensating factor There is a dancer roller between the slitting shears and the recoiler that can be freely positioned as needed. In addition to the coiler winding tension, the speed is also controlled by the weight and position of the dancer roller. The interchangeable counterweights and the position of the dancer roller make it easy to adjust the coiler winding tension and speed. Beyond that, the dancer roller can compensate for small differences in the length of the individual strips. Separator discs attached to the dancer roller aid in winding up the strips on one common coiler despite differing lengths. The large diameter of the discs prevents neighboring strips from colliding with each other.

9 8 9 Robust construction for high speed The strips are transported over metal rollers and separated by discs when taken up on the recoiler. The unit is equipped with a measuring wheel. This serves to measure the length of the processed material and calculates both the target position and the material, shift and annual production levels. The entire construction of the slitting unit is built in the typically robust KOHLER way and can be operated at a maximum speed of 50 m/min. The unit is also designed for the direct coiling mode of operation in which the strip is recoiled directly by dancer or tension control with no strip loop or slitting. Comprehensive design and layout After the unit had been assembled, the engineers at KOHLER took up the task of preparing it for the industrial production process. One of the most complex aspects in this was the correct adjustment of the levelling machine. The expanded metal that the customer wished to process was found to have great inner tension and a transverse camber. The levelling experts therefore had to find a precise point at which enough tension was removed from the material without creating edge waves. Thanks to the broad expertise and the comprehensive concept and layout, the system could be readily integrated into the customer s variable and interconnected production process. This results in very high-precision expanded metal strips of different widths that are wound up on a common coil and ready for further processing.

10 A ZIG-ZAG STRIP LEVELLING LINE KOHLER builds a zig-zag strip levelling line for an automotive specialist When it comes to levelling machines with extremely high levels of individualization including very special layouts, KOHLER is sought after as a partner for industry around the world. This is confirmed by the fact that an order has been placed by a leading manufacturer of systems and components for vehicle drivetrains that delivers its products worldwide. KOHLER has been commissioned with the development and construction of a zig-zag strip levelling line in a compact design with a downstream scrap shear. With this machine, cold or hot-rolled steel and stainless steel with a strip thickness from 1 to 7 millimeters and widths up to 620 millimeters can be levelled and fed to a downstream stamping press. Thanks to an oscillating levelling machine, the blanks can be stamped out of the strip optimized for material use and cost effectiveness. This boosts efficiency and reduces costs KOHLER therefore often speaks of "the Baden art of engineering." Master of the periphery KOHLER not only stands for exceptional specialist expertise in the area of levelling technology, the levelling experts are also masters in the entire complex of coil handling. This has been clearly demonstrated by the zig-zag strip levelling line that was built recently. "Coil handling made easy" was one of the requirements expected of this project. Thus a coil loading car ensures that the coil can be placed on the coiler quickly and easily. The coil loading car is adjustable in height and with the help of its transverse mechanism it transfers the coil to the coiler mandrel. A hydraulic sliding wedge system and a lateral coil retainer fixate the coil and prevent the windings of the coil from sliding out sideways. The pressure arm provides added safety and prevents the coil from simply springing open when the strapping bands are removed. The material is moved smoothly and safely over the infeed table with the help of a pressure roller and pinch rollers to the precision 21-roller levelling machine. Levelling machine in zig-zag operation Lead-in device for the levelling machine

11 10 11 Overall view of the zig-zag machine An impressive zig-zag course Those who only think of the sophisticated technical football skills of the Barcelona striker Lionel Messi when approaching the opponents goal are making a mistake: in the field of levelling technology, zig-zag also stands for technical sophistication. It describes the capability of a levelling machine to move sideways simultaneously to the forward feed, resulting in a zig-zag motion that makes it possible to optimize stamping processes for material use and cost-effectiveness, as can be done with this machine. During the stamping process, the levelling machine and the pinch rollers are opened repeatedly with a hydraulic lifting function. This intermittent release ensures that the strip is loose and can be freely positioned to center the punching tool optimally. Incidentally, the transverse mechanism of the levelling unit is made possible by a play-free drive with a planetary transmission and roller screw drive. All's well that ends well The entire system from the Competence Center for Levelling Technology is not only convincing because of its very robust construction, but it also stands out with its uncomplicated controls and operation. Whether its coil handling, levelling unit or the scrap shear at the end of the line for cutting up the stamping scrap and removing the outer layers of the coil, the entire production line operates fully automatically and is thus a real demonstration of efficiency. All the way down to the end of the strip, the material is processed into good parts in zig-zag operation. The results thus achieved again confirm KOHLER's excellent reputation as a manufacturer of special-purpose machinery.

12 KOHLER Maschinenbau GmbH Einsteinallee Lahr, Germany Tel.: +49 (0) Fax: +49 (0) info@kohler-germany.com