07/30/2012

Schuler introduces new possibilities for multi-step process of wire forming and cold heading

The FormMaster FM500-6 SDT, built by Schuler, is the first press of its kind in the world with Servo drive in the world to offer a horizontal, multi-step process for wire forming and cold heading.

Key features of this new press, which features ServoDirect Technology (SDT), include:

• Higher output
• Improved reliable part transport
• More product diversity.

The FM500-6 SDT is able to increase output, while keeping quality intact. As a result of optimized motion of the stroke during forming and transfer, the production cycle is reduced.

In addition, the FormMaster FM500-6 SDT, with its extremely strong frame to ensure long service life for tools and the guarantee of high quality parts, has the distinction of being the first-ever, horizontal wire forming press with slide movement that is programmable in a targeted manner. In fact, the length of parts can be increased by up to 20 percent without having to use a bigger press with a longer stroke. Because of the freely programmable kinematics, the application spectrum widens significantly.

Lower stroke speeds made possible

In the past, available work energy used to depend on the size of the flywheel and its speed. Schuler’s Servo motors, however, are able to use their nominal torque, even at low rpms. One illustration of this technology is an analogy between electric cars and motorcycles. Anyone who has ever driven an electric vehicle knows that when the stoplight turns green, you leave every sports car and motorcycle in the dust because your full torque is available immediately.

The setup and tryout functionality of the FormMaster also benefits. The speed of the slide movement is adjustable without losing any press capacity, and the forward/reverse movements are carried out without any delay. The Quick Lift feature immediately clears the die space to ensure a quicker and safer access to tooling. Maintenance and service efforts are reduced, too, because the Servo press is composed of fewer mechanical components, such as flywheel brake, clutch/brake combination, drive belt or slide lock.

Improved Safety

The machines in the FormMaster series feature five to seven horizontal forming stations, a wire feeding system, and an NC transfer system that—with the help of grippers—moves each component after the cutting process. The reliability of part transport has increased even more with the FM500-6 SDT; parts can be manufactured at a rate of up to 90 per minute.

Also, vertical placement of the forming stations allows for extremely easy access to the tooling area, and the tooling can be changed with little effort. It can also be prepared outside of the press. This allows for a streamlined manufacturing process—even for smaller lots.

Customer onboard

A. + E. Keller will receive the first new version of the FormMaster (with press capacity of 500 tons) in December of this year. Located in Arnsberg, Germany, A. + E. Keller is an expert in the field of cold-forming technology.

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