ДизайнThese systems are encountered in all types of press machines and production processes used by the automotive industry and its suppliers to form large car body parts such as doors, spoilers, floor plates and the complete side frames of cars.
The large variety of machines and equipment to be controlled by the automation system is immediately apparent from the production flow: The starting material is sheet steel or aluminium which is delivered wrapped in coils weighing several tons. The metal sheet is cut into even pieces called blanks. The blanks are stacked on pallets for further transport. Blanks are increasingly being prepared from separate pieces of different quality - a process which requires laser welding equipment. The result is a "tailored blank". The next stage of the production flow is the head of the forming press. Here, the blank loader separates the blanks from the stack, cleans them, and lubricates them for the forming process. The forming processes from blank to finished part take place in several stages. The part is transported through several forming tools, starting with the drawing stage and proceeding through four or more further stages.
Superimposed on these task-related topologies are the additional structures resulting from the physical arrangement of the machine units:
- The conveyor system consists of a series of units including the coil loading station, the coiler, the flattener, roll feed, the cutting apparatus with cross-cutting shears or cutting press, and a stacker for the tailored blanks.
- A press line consists of a collection of individual presses arranged along the flow of production, completed by a blank loader at the top of the line and an outgoing stacker for the finished parts.
- A large-part transfer press (implemented as an extended compact press line), again consisting of several press stages with a blank loader and outgoing stacker.
Primary importance is attached to the synchronized transport of the parts between the individual forming stages. These transport tasks are performed by:
- Feeders with multi-axis floor units
- Electronic transfer with orientation stations
- Swivel-arm robots with up to 6 axes
It is the task of the automation system to map out these features in an intelligent configuration. The system is therefore:
- Distributed with powerful communication connections
- Capable of modular expansion
- Structured in a uniform hierarchy with each machine component conforming to the same set of rules
- Mainly designed with distributed I/Os to reduce wiring and start-up costs
- Equipped for the increased use of control subsystems for complex open and closed-loop control tasks (main drive control, motion control for electronic transfer, feeder control, die cushion control)
- Based on transparent bus architectures for easy operation and maintenance (PROFIBUS DP system bus)
Solution details
This page provides information on products generally used for press applications. The details can vary according to the project. We would be happy to suggest a suitable system for your own specific application.
Machine control system
The machine control system is based on the SIMATIC S7-400 and its wide range of high-performance CPUs with integrated PROFIBUS DP interfaces. The FM 452 cam controller is used to track the movement of the punch and coordinate operations on the press. CP 443-5 communication processors are used to exchange data between the other machine controllers on the plant network.
Distributed I/Os
The ET 200 distributed I/O system is used in conjunction with PROFIBUS DP. 6SE70 SIMOVERT MASTERDRIVES are used for positioning, together with Mini-Master units and complete valve islands. The setpoints are transmitted to these devices via PROFIBUS DP.
Centralized control console
- SIMATIC HMI OP47 (vibration-resistant to 1.5 g)
- SIMATIC PC FI25
- With optional printer
- TCP/IP interface for host connection
- PROFIBUS DP interface to machine controllers
- WinCC visualization system and database
Local operator panels
- SIMATIC HMI OP25, OP37 with ProTool
- Connection to the machine control level via MPI or PROFIBUS DP
Main press drive
- Increasing application of large-scale drives using low-maintenance AC technology: 6SE70 SIMOVERT MASTERDRIVES with 1LA motors
- Optional 1G.6 DC drives with SIMOREG 6RA24 converter
- Power range from 100 kW to 1 MW
- Drive cabinets with degree of protection IP54 because of critical ambient conditions
- The drives are equipped for continuous operation in the torque control range.
Highly dynamic movement axes
The dynamic response and intelligence of the movement axes is of major importance to the implementation of a sheet processing or large press system, since the positioning movements take place during the main production period: one stroke more per minute means over one thousand parts produced more per day. We have based all our solutions on brushless AC technology for these types of axis:
- SIMODRIVE 611 and SIMOVERT MASTERDRIVES 6SE70 with 1FT5, 1FT6, 1FK6 and 1PH7 motors
- Linear direct drives with SIMODRIVE 611 digital
The following components are used as motion controls:
- WF 723C in SIMATIC S7-400 for roll feed, feeder automation and floor units/orientation stations
- SINUMERIK 840D in SIMODRIVE 611 digital for synchronizing the actuation of the transfer (command value encoder on the press punch) and for absolute displacement measurement of the transfer axes.
Press safety control system
Even when operated in automatic mode, presses are required to use operator safety equipment complying with Category 4 of EN 954-1. The S5 95 F/P PLC is an electronic safety control certified by the German trade association "Iron and Metal III". It includes:
- Safety doors and safety guard protection during automatic operation
- Comprehensive EMERGENCY OFF equipment
- Load voltage feedforwarding
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