Editorial New start at Lahr plant Strip levelling machines for South Korea Interview with Volker Ihling Cut-to-length line for sheet metal cuts

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1 NEWS issue 1/2014 Editorial New start at Lahr plant Strip levelling machines for South Korea Interview with Volker Ihling Cut-to-length line for sheet metal cuts

2 Editorial KOHLER is equipped for growth! Dear Readers, If you take biology as an example, you realize that growth is a highly complex process. If you examine the process even more closely, it becomes clear that all growth is rooted in individual intelligent cells. If the basic conditions are right and the stimulation required from outside is provided, cells can grow and multiply. So the DNA allows new life to be created. If the biological definition of growth is used in the context of a company, it quickly becomes clear that similar principles apply there too. The intelligent cells are our employees. Engineering, innovation and creativity lead to new ideas and solutions and therefore new jobs. Our parent company, Wintersteiger AG, has also created the best possible basic conditions for us. We are constantly receiving stimulation for further growth from our customers, and our DNA therefore allows state-of-the-art levelling technology to be created on a daily basis. Speaking of basic conditions, we are about to move into our new plant at the airport in Lahr (you ll find more information about this on page 3). In addition, a separate subsidiary complete with a showroom and highly trained service personnel opened in Shanghai a few months ago. It is hoped that this will accelerate our growth in China. Reiner Blohorn, Managing Director Among other things, the following pages describe several current reference projects in which our DNA has resulted in excellent customer-specific solutions. This is further proof that KOHLER is a partner that is in demand all over the world. We would be delighted to tell you more about all that s mentioned here in person at EuroBLECH 2014 in Hanover, which is a very important exhibition for KOHLER. You are warmly invited to visit us at stand D16 in hall 27. Our EuroBLECH team is already looking forward to lots of good conversation with you! Yours faithfully, Reiner Blohorn Managing Director

We can only confirm that this is true because our new Competence Center Levelling on the west side of the airport site in Lahr has been completed.

3 New start at lahr plant 2 3 The assembly halls And every new beginning has its own magic. Hermann Hesse It's complete! It is for a happy reason that we would like to begin this short article with a quote from Hermann Hesse: And every new beginning has its own magic. We can only confirm that this is true because our new Competence Center Levelling on the west side of the airport site in Lahr has been completed. We included the exact details of the new building in the last issue of KOHLER News after all. A new modern building with approximately 10,000 m² of usable space awaits us. It is divided into assembly and production areas, and an administration wing with an exhibition and demonstration room. After having been at our current premises for over 50 years, we will be moving into our new premises in the next few weeks and will be shifting our company s headquarters to the nearby city of Lahr. These photos give you an impression of the Com petence Center Levelling now, however. We are all looking forward to working at the new plant and the great opportunities it will offer us. Reiner Blohorn Managing Director, KOHLER Maschinenbau GmbH One of two assembly halls with crane systems

Strip levelling machines for South Korea KOHLER: Two more strip levelling machines for international automotive supplier KOHLER Maschinenbau GmbH is supplying to an international automotive supplier

It wasn t just the customer-specific design and layout, the on-site advice and the solid quality of already delivered lines that were crucial to the placement of this order, but also the outstanding

4 Strip levelling machines for South Korea KOHLER: Two more strip levelling machines for international automotive supplier KOHLER Maschinenbau GmbH is supplying to an international automotive supplier in South Korea two new levelling machines, which are being installed on Minster presses. They will be used at a new production plant where parts for gearboxes are made. It wasn t just the customer-specific design and layout, the on-site advice and the solid quality of already delivered lines that were crucial to the placement of this order, but also the outstanding precision levels that KOHLER is known for. Excellent levelling results with a high degree of plastification The materials to be processed will range from 0.8 to 3.5 mm in thickness and will be processed on two separate production lines depending on the customer s requirements. KOHLER has used high-precision /21 and /21 levelling machines, so that excellent levelling results can be achieved along with the highest possible degree of plastification. Efficiency starts with the coil handling A coil loading car with a carrying capacity of up to 4,000 kg is used to move the original coil to the right position for processing thicker materials. Once the indoor crane has loaded the coil, it loads the decoiler, with the coil loading car automatically moving towards the decoiler on bottom rails and stopping about 50 mm before the decoiler shaft. Through the alignment of hydraulically driven rotating rollers, the coil can be turned and moved into the best position. The lifting device is designed as a hydraulic scissor lifting table, and the height is adjusted using scanning. Once the decoiler s loading position has been reached, the anti-tilting devices at the front FACT BOX Customer-specific design and layout Outstanding levelling quality Fully automated production process High level of customer satisfaction with machines supplied years ago The levelling machine being set

4 5 The line being inspected by the customer swivel away hydraulically, and the coil is pushed onto the decoiler shaft just in front of the rear coil retainer.

5 4 5 The line being inspected by the customer swivel away hydraulically, and the coil is pushed onto the decoiler shaft just in front of the rear coil retainer. Next, the coil loading car moves down into its lower end position, and the front coil retainer swivels in hydraulically. In addition, the decoiler expansion is extended and the pressure arm is put on the outer layer of the coil. The operator moves the coil loading car into the park position and can then remove the strapping bands safely. Safe sheet transfer thanks to a leading-in device With the help of a leading-in device, the line operator can safely feed the strip to be processed into a roller driver from the coiler. Depending on the properties of the material, it can be unwound from either the top or the bottom. If it is being unwound from the bottom, the coil loading car acts as a pressure arm at the same time, and the hydraulically driven rollers keep the layers of the coil taut throughout the process. The driver pulls the strip from the decoiler and moves it to the first inspection table and then on to a hydraulic cropping shear. Cropping shear for outer layers The hydraulic cropping shear cuts the damaged outer layers of the coil into predefined lengths for scrap, and these are deposited straight into a manual scrap con - tainer. The scrap chute needed to open the required temporary depository is pneumatic. Once the scrap chute has closed, it serves as a second inspection table, where the material undergoes a visual check. The roller driver continues to push the strip into the levelling machine until the strip take-off device is reached. Once the strip take-off device has closed, the roller driver opens and the strip take-off device starts removing the strip from the decoiler and pushing the material through

Strip levelling machines for South Korea the levelling machine, which will have been set with the best possible roller frame adjustment values.

The strip loop has also been designed as a strip transfer device, i.e. a transfer table is formed when the beginning of the strip is fed in and only starts to move downwards once the strip has been fed in, so that the strip loop can be formed.

6 Strip levelling machines for South Korea the levelling machine, which will have been set with the best possible roller frame adjustment values. Levelling followed by the press To ensure the press operates in the start-stop manner required while the levelling machine operates continuously, a strip loop has been integrated between the levelling machine and the press infeed. To store a longer length of strip material, this has been designed with a deep pit in the foundation, which ensures there is enough material available if the press is started up quickly. The strip loop has also been designed as a strip transfer device, i.e. a transfer table is formed when the beginning of the strip is fed in and only starts to move downwards once the strip has been fed in, so that the strip loop can be formed. Customer-specific solutions on principle The second machine, which can accommodate thicknesses of up to 1.6 mm, emphasizes the fact that KOHLER is extremely flexible and able to meet other customer-specific requirements too. Here, it was the express wish of the customer to have an existing decoiler integrated into the line. The expectation of the customer to work with an existing double decoiler without coil loading car was a big challenge already in the design phase. After passing through the decoiler, a leading-in device transfers the material to the levelling machine without the operator having to touch the material manually. The strip take-off device on the levelling machine closes and uses the levelling process and hydraulically lifted transfer table to move the material to the roller feed of the press. The roller frame is moved exactly in accordance with the settings calculated by KOHLER, which results in excellent plastification of the material and guarantees the highest possible level of customer satisfaction in the production process. Smooth production processes Once the press has indicated that the feed is closed via an interface signal, the transfer table moves down hydraulically, the levelling machine pushes the material through and the strip loop is formed. The strip loop is then adjusted using an ultrasonic sensor, which enables processes to run smoothly at the customer s production plant. Patrick Kientz Project Manager, KOHLER Maschinenbau GmbH A strip going through one of the leading-in devices Cropping shear These strip levelling machines are further proof of KOHLER s international reputation.. Reiner Blohorn, Managing Director, KOHLER Maschinenbau GmbH Side view of the strip levelling machines

Interview 6 7 The big interview! At EuroBLECH 2012, KOHLER presented the Peak Performer GC, a part levelling machine that was expected to revolutionize the market in technology terms.

7 Interview 6 7 The big interview! At EuroBLECH 2012, KOHLER presented the Peak Performer GC, a part levelling machine that was expected to revolutionize the market in technology terms. Two years after the machine s market launch seems a good time to ask whether it really has been a success story. And who would know better than KOHLER Sales Manager Volker Ihling? We decided to interview him. When the Peak Performer GC was launched onto the market, many believed it would lead to a revolution. Is that not what often happens at the start of big changes? That is a good question. I would say we re currently in the middle of a revolution, because more and more companies and decision-makers around the world are becoming aware of the Peak Performer GC. We have received lots of requests from both within Germany and other countries, and sales figures are significantly higher than expected. We received the first orders straight after EuroBLECH 2012, and the good sales figures mean we re even able to seriesproduce the machine in particular sizes. What is revolutionary about this part levelling machine? Before, there were only part levelling machines with hydraulic levelling gap control. KOHLER replaced this technology, which had become a bit long in the tooth, with electromechanical levelling gap control. Thanks to the electro-mechanical technology, the Peak Performer GC is able to work without any hydraulic elements at all and therefore doesn t have any exposed oils or grease either. Our machine also offers high saving potential, whether it s operating, service or maintenance costs. For the energy alone, we re talking about cost reductions of 20 to 40%, depending on the size of the machine. What reduces the service or maintenance costs? The standard version of the Peak Performer GC is already equipped with the proven cleaning and quick-change system, and once the front bearing bars have been demounted, the levelling rollers and support rollers can be removed from the machine from the side. These can also be mounted on a slide plate and therefore taken out of the machine completely. This allows the levelling cassettes to be checked, cleaned or serviced safely and very quickly outside the machine. Technical superiority, efficiency and ensuring that machines are easy to service are extremely important to us. In the advert, you describe the Peak Performer GC as an efficiency wonder. What is this efficiency down to? I ve already explained some of the reasons, but there are of course other factors that make this machine a small wonder. For example, it has a real reversing function, which allows levelling in both directions where double levelling is necessary. This halves the time required for the process. The servomotor-driven levelling gap control means that the levelling machine s infeed and outfeed settings can be changed within fractions of a second, which allows material to be fed into the machine from both sides. You have said everything you have to say about efficiency now though, right? No, not quite! What else is there? The machine has intelligent overload protection, which prevents mechanical damage and so reduces waste to a large extent. And finally, an expert calculation system makes it easier to set the machine for specific materials and shortens the time required to do this. A userfriendly, intuitive control unit allows settings to be saved. Can you sum up all the advantages of the machine in one sentence? The Peak Performer GC is probably the cleanest, most economical and most efficient machine on the market. We ve managed to produce a paradigm shift in part levelling with the Peak Performer GC. Volker Ihling, Sales Manager at KOHLER Maschinenbau GmbH You mentioned series production at the beginning. What effect does this have on the price of the machine? When a customer buys a Peak Performer GC, they get a machine that has cutting-edge technology and that is extremely economical for a very reasonable price. This explains the huge market acceptance on one hand and why many customers are replacing their hydraulic levelling machines with a Peak Performer GC on the other hand. So it really is a nice success story. Thanks very much for talking to us!

Cut-to-length line for sheet metal cuts Machine for scratch-free transport and maximum levelling quality Over the last few months, KOHLER has designed and built a modern cut-to-length line for a

8 Cut-to-length line for sheet metal cuts Machine for scratch-free transport and maximum levelling quality Over the last few months, KOHLER has designed and built a modern cut-to-length line for a leading manufacturer and supplier of sheet metal cuts. The company supplies all sorts of industries with customer-specific cuts, which meant a high degree of individualization had be incorporated into the line. Powerful and efficient, the line has been designed to allow smaller parts with a maximum length of 2,500 mm to be manufactured at a very high throughput. The high demands regarding surface quality, evenness and output also had to be fulfilled. KOHLER has met all the requirements perfectly. The following article tells you how.

8 9 Side view of the blast air brush blank stacking line Photo on left: view of the roller frame Coiler design and loading technology To keep the loading time as low as possible, KOHLER opted for a

9 8 9 Side view of the blast air brush blank stacking line Photo on left: view of the roller frame Coiler design and loading technology To keep the loading time as low as possible, KOHLER opted for a decoiler with a feeder turnstile. The loading procedure is automated and means the coil can be centered automatically with regard to both its height and its width. This is a significant help to the operator when it comes to loading the coil. Incidentally, several coils can be tightened on the coiler at the same time and then be processed one after the other. The expansion elements of the coiler are interlocked, which prevents the end of the strip from getting caught in the expansion system. The coiler drive is equipped with a powerful motor. It means the ideal winding tension can be selected for every strip cross section. The pressure roller, which has built-in anti-tilting support for the loading car, and the hydraulic coil retainers make the coiler area a firstclass assembly in terms of safety. Strip centering control for rectangular cuts The decoiler is equipped with strip centering control, which guarantees that the strip is always centered when it runs through the line. This in turn ensures that the parts manufactured are reproducible and perfectly rectangular. Excellent levelling and perfect cutting Once the strip has come through the leading-in device, a bending roller pair ensures that the end of the strip is fed into the levelling machine automatically. The levelling machine is followed immediately by a flying shear with an integrated driving roller pair and a measuring wheel. As much emphasis as possible was placed on making sure this special area was easy to service. The ergonomic design ensures that the knife exchange area is just as easy to access as it is to clean the roller surfaces. Patented cassette changing system in use The levelling machine is equipped with the cassette change system patented by KOHLER. This allows different roller diameters to be used, and the roller cassettes can be taken out to be examined individually. If any dirt particles get into the machine, they are removed using a felt cleaning device. The cleaning device can be put inside the machine when the coil is being changed. The felt oscillates between the levelling rollers and dislodges the dirt trapped there. Discharge stations for unhindered sampling The conveyor belt following the cut-to-length shear has points where test panels, scrap pieces and 2A blanks can be discharged. FACTBOX The line is highly individualized It meets very high surface quality demands Several coils can be tightened on the coiler at the same time and then processed one after the other Patented cassette changing system in use

Cut-to-length line for sheet metal cut Side view of the cut-to-length line Every one of these discharge stations can be accessed in automatic mode, meaning any sampling can be carried out without

Blast air brush stacker for careful stacking The blast air brush stacker that follows next places the blanks on pallets, ensuring that they are not damaged and are stacked extremely precisely in line

The empty pallets are automatically transported to the stacking point by an introduction table, and finished stacks of blanks are automatically weighed and strapped up with packing bands.

10 Cut-to-length line for sheet metal cut Side view of the cut-to-length line Every one of these discharge stations can be accessed in automatic mode, meaning any sampling can be carried out without stopping the line. Blast air brush stacker for careful stacking The blast air brush stacker that follows next places the blanks on pallets, ensuring that they are not damaged and are stacked extremely precisely in line with each other. The airflow, the use or not use of brush rollers, and the position of the brush rollers can all be programmed with any available setting. The empty pallets are automatically transported to the stacking point by an introduction table, and finished stacks of blanks are automatically weighed and strapped up with packing bands. Small pallets are grouped on transport pallets by a packet manipulator, tied up and then transported to where they are to be dispatched from. be stopped quickly and safely regardless of its current speed. Any braking energy accumulated by the coiler is fed back into the intermediate circuit and can be used by the drives of the levelling machine straight away. Along with the controlled hydraulics, this makes the line an impressive efficiency package. The entire line meets the relevant standards and regulations, of course, and can easily be controlled by one operator. Franz Müllerleile Technical Manager, KOHLER Maschinenbau GmbH Roller frame Integrated data management and visualization An integrated data management system, which stores details of the different materials used (including their dimensions), is also state of the art, as is its visualization, which provides relevant support for the operator. Efficiency through the use of braking energy All the main drives are connected via the intermediate circuit, which means the line can View of the stacker from the rear

KOHLER s reputation as a producer of excellent tailor-made levelling technology solutions for industrial production processes extends well beyond the borders of Germany.

11 Superior cutting, time after time! Cutting lines by KOHLER. Our solutions help you reach your targets. We prepare the way to your targets and requirements with individually designed cutting lines and leadingedge technology. KOHLER s reputation as a producer of excellent tailor-made levelling technology solutions for industrial production processes extends well beyond the borders of Germany. One of the reasons for this international reputation is our cutting lines. They are adapted to meet individual material, quality, precision and budget requirements exactly, and the end result is exactly what you have every right to expect: cutting lines that fit into the levelling process perfectly! Visit us at EuroBLECH in Hanover! October 21st 25th, 2014, stand D16, hall 27 Peak Performance Levelling Machines

12 Kohler Maschinenbau GmbH Einsteinallee Lahr, Germany Phone: +49 / (0)7821 / Fax: +49 / (0)7821 / info@kohler-germany.com

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

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 EDITORIAL KOHLER writes company history!