09/13/2007

Increased slide stroke, increased possibilities: world premiere for Schuler’s knuckle-joint presses with optional “Quick Lift System”

When it comes to the manufacturing of ready-to-install parts – and especially flat components – knuckle-joint presses are always first choice. They enable fast and flexible production of a wide range of parts for the most diverse of needs. Due to the general trend toward lightweight construction methods, high-strength steels are being increasingly used and formed into complex geometries. And the more complex the part, the more space is generally needed in the press. This is where conventional automatic blanking and forming presses with knuckle-joint drives soon reach their limits. With the aid of a modified drive – the Quick Lift System – Schuler has succeeded in creating more space in the die mounting area of the press and has thus expanded the scope of this tried and tested technology. The new drive technology was premiered at an in-house fair of Gräbener Pressensysteme in Netphen-Werthenbach, Germany, on September 13 and 14.

The available space in the die mounting area of the press can be a limiting factor for the use of knuckle-joint presses. The rule of thumb was: stroke height of the die mounting area divided by three equals maximum part height. With a modified knuckle-joint drive, Schuler subsidiary Gräbener Pressensysteme has now developed a unique solution which combines the benefits of the knuckle-joint press with the higher slide stroke of eccentric presses.

“Quick-Lift” creates more space in the mounting area

Schuler’s “Quick-Lift” system provides up to 500 millimeters of additional slide stroke. The press performance is not affected, as it is purely a lifting stroke in the TDC area of the slide. With the aid of servo motors, a lever is swiveled to raise the slide in the load-free area. Thanks to the space gained, higher parts can now also be moved by the press transfer system through the die mounting area. For the forming operation itself, the slide movement corresponds to the tried and trusted technology.

Ideal for forming high-strength steels

The benefits of the new drive technology are particularly relevant for the forming of high-strength steels, as used in particular by car part suppliers. The increasing variety of standard equipment coupled with rising ecological awareness is leading car manufacturers to demand further weight savings from their suppliers. This trend toward lightweight construction can also be seen in other industries. The challenge in producing such parts are the various forces needed to form the material. This is where knuckle-joint technology boasts clear advantages. Due to the high rigidity of the overall system, off-center loads pose no problems. The precision of the slide movement guarantees utmost part quality and the optimized adjustment of the slide speed in the bottom dead center minimizes material strain – thus reducing the danger of stress cracks after the forming operation. For the user, this means greater process reliability and excellent part quality and maximum line availability.

Wide application spectrum and reliable technology provide investment security

The high level of process reliability is guaranteed above all by the tried and trusted technology of knuckle-joint presses. Over 90 percent of parts used in the new press generation are largely unchanged. The real innovation is in the drive technology. The new automatic blanking and forming presses with Quick Lift functionality represent an ideal addition to the existing machine base, while at the same time offering more investment security: the machine concept has been proving its worth for some 20 years now on a daily basis; operators and developers are well acquainted with the basic technology; and the new drive concept also expands machine use considerably for future applications. Whether for the automotive and electrical industries or other sectors: wherever ready-to-assemble parts with greater heights are required, these can now be manufactured far more economically. Moreover, it is also possible to carry out several steps on one press – such as drawing, bending, embossing, blanking and calibrating – and to combine them with each other.

Extensive information program and live demonstrations

Customers and other visitors will be able to witness the benefits of the new drive concept on September 13 and 14. On these two days, Gräbener Pressensysteme will be hosting an in-house fair at its facility in Netphen-Werthenbach with the official world premiere of the new knuckle-joint presses. In addition to extensive information on the new technology, there will also be live demonstrations of a line already being used for serial production.