Machine and plant manufacture forstamping and forming technology

PAUSt

HIGH-PERFORMANCE TRANSFER FORMING AUTOMATIC PRESSES

160 – 8,000 kN

Tradition and innovation –High quality and economically

The high-performance transfer forming automatic presses assist in the cost-ef-fective large-series production of complex drawn, bent, stamped or cut parts with a wide range of forming stages. During production, the blanks and forming parts are transported from one forming stage

to the next by the transfer system. Part families can be modified and produced at reasonable cost with low tooling input. The machines can be used as stand-alone units or can be integrated in a press line.

Undercrank drive> Extremely low-vibration run due to

low center of gravity > Optimum working height without

foundation pit

Overcrank drive> For extreme stroke height> For more force and working capacity

> Conventional with intermediate transmission> Complete drive> Drag-link drive> SERVO drive with intermediate plan-

etary gear

PROCESS-ORIENTED SOLUTIONS TOINDIVIDUAL CUSTOMER REQUIREMENTS

DRIVE VERSIONS DRIVE CONCEPTS

Example of an 8-step drawing process

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> Press frames in heat-treated, multi-piece welded steel construction con-nected by hydraulically prestressed tensioning rods; very rigid

> Rigid frame and ram with proof of FEM calculation

> Optimum dynamic behavior under extreme load

> High working capacity> Highest parallelism of the two tool

clamping surfaces under load> Part production: drawing possible

with the opening up or down > Quick tool change and exact position-

ing of the tool clamping force under load by indexing pins and clamping eccentrics

> Automated tool changing> Mechanical or hydraulic tool clamp-

ing> Adjustable tool carriers (manual or

by motor) with electronic overload protection

> Hydraulic overload protection in the ram

> Up to 260 stokes per minute, depend-ing on machine version

> Light-weight construction of the ram at high stroke frequency

> 4-column roller guides, zero-backlash for precise ram angular run

> Low-maintenance 8-fold ram sliding guidance

> Zero-backlash 16-fold ram rolling guide > Ram angular run at high precision

(better than DIN requirements)> Pneumatic ram and overhead tool

weight counterbalance by bellows cylinder (maintenance-free)

> Pneumatic ejector in ram, setting manual or by motor

> Round blank cutting in separate side table/side ram

> Round blank lifter in vicinity of blank cut for low-noise cutting of blanks near the BDC

> External cutting step powered by side ram

> Ejection mechanisms> Drawing cushion mechanisms> Stripper and fold holder mechanism

(hold-down)> Part transfer mechanical, cam-con-

trolled and/or by SERVO motor> Stepless main drive control combined

with creep speed drive

> Scrap cutter> Special shafts in the working space,

synchronized with the crankshaft side machining operations

> Material feed to the first tool loca-tion using an electronic roller feed device with two-axis positioning in zigzag version

An IPC controller with TFT screen and user surface is used for optimum and user-oriented operation of the machine.> Tool data management > Operating data acquisition > Actual/target comparisons> Password levels> Fault diagnosis > Remote maintenance> Integration of strip equipment and

automation> Main bearing temperature monitor-

ing> Part flow control

CHARACTERISTICS AND OPTIONALLY SELECTABLE FEATURES

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PAUSt 36

4

PAUSt 30w

The outstanding characteristics of the transfer forming automatic presses stage forming units are extremely high accu-

racy combined with high stroke counts. The flexibility of these automatic units is guaranteed for any application thanks to

a wide range of accessories. This machine fulfils the highest in accuracy require-ments and product quality at low cost.

High-speed transfer forming automatic presses

1) Number of strokes variable steplessly 2) Main dimensions without strip line depends on the number of stages and the tool center spacingData is typical; other data on request

TECHNICAL PARAMETERS

Type Rated pressing

force (kN)

Number of tool stages

Ram stroke(mm)

Tool center spacing(mm)

Working strokes 1)

(strokes/min)

Max. strip width (mm)

Weight (kg)

Width 2)

(mm)Depth 2)

(mm)Height 2)

above floor level

(mm)

PAUSt 25 250 21/14 60/80/100/120 50/75 40 – 200 120 8,500 3,000 2,200 3,000

PAUSt 30 300 21/14 60/80/100/120 50/75 50 – 260 140 13,000 3,000 2,200 3,000

PAUSt 50 500 20/15 120/160 75/100 30 – 150 160 15,000 4,100 2,700 4,200

PAUSt 30

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The transfer forming automatic presses with bottom drive from Raster-Zeulen-roda have been proving themselves for decades when it comes to large series and volume production of deep-drawn,

bent, stamped or cut parts. These presses stand out due to their low construction height, low center of gravity and opti-mum working height for the operator.

The low center of gravity, which is the result of the bottom drive, ensures very silent running of the machine and there-fore high precision and continuity of part production.

Transfer forming automatic presses with bottom drive

PAUSt 125

1) Number of strokes variable steplessly 2) Main dimensions without strip line depends on the number of stages and the tool center spacingData is typical; other data on request

TECHNICAL PARAMETERS

Type Rated pressing

force (kN)

Number of tool stages

Ram stroke(mm)

Tool center spacing(mm)

Working strokes 1)

(strokes/min)

Max. strip width (mm)

Weight (kg)

Width 2)

(mm)Depth 2) Height 2)

above floor level

(mm)

PAUSt 16 160 12/10 80 75/90 63 – 240 125 5,000 2,500 1,800 3,600

PAUSt 25 250 12/10 80 75/90 63 – 180 125 8,500 2,500 1,800 3,600

PAUSt 32 320 12/10 80 75/90 63 – 180 125 13,000 2,500 1,800 3,600

PAUSt 63 630 12 200 170 28 – 125 280 20,000 5,600 2,900 3,600

PAUSt 80 800 14 230 120 28 – 112 320 25,000 5,600 2,900 3,600

PAUSt 100 1,000 13/10 260 160/220 18 – 100 360 35,000 6,500 3,200 4,200

PAUSt 125 1,250 10/13/20 260 220/160/100 18 – 90 360/200 45,000 6,500 3,200 4,200

PAUSt 160 1,600 14 260/330 220/170 18-80/15-70 370/300 68,000 8,000 3,800 5,400

PAUSt 125

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This compact range of machines with es-pecially generously dimensioned working capacity is designed for processing thick and high-strength strip.

Good access to the drive units in addition to the use of most modern components, such as CNC roller feeds with zigzag movement and CNC transfer devices,

add to the attraction of this range of machines. An optimum operating height is achieved by lowering the machine in the foundation.

1) Number of strokes variable steplessly 2) Main dimensions without strip line depends on the number of stages and the tool center spacingData is typical; other data on request

Transfer forming automatic presses with overhead drive

PAUSt 125

TECHNICAL PARAMETERS

Type Rated pressing

force (kN)

Number of tool stages

Ram stroke(mm)

Tool center spacing(mm)

Working strokes 1)

(strokes/min)

Max. strip width (mm)

Weight (kg)

Width 2)

(mm)Depth 2)

(mm)Height 2)

above floor level

(mm))

PAUSt 200 2,000 1+16 270 170 20 – 80 320 95,000 7,600 3,000 6,500

PAUSt 260 2,600 1+8 630 350 40 665 140,000 9,200 4,000 6,500

PAUSt 300 3,000 1+19 270 170 15 – 60 320 120,000 8,200 3,000 6,500

PAUSt 300 3,000 16/1+19 315 225 20 – 60 320 125,000 7,900 4,000 6,900

PAUSt 400 4,000 5 250/300 250/300 10 – 50 400 135,000 8,800 4,500 7,200

PAUSt 500 5,000 5 250/300 250/300 10 – 40 500 145,000 8,800 4,500 7,500

PAUSt 630 6,300 7 300 300 10 – 50 Round blank feed 170,000 9,000 4,000 8,200

PAUSt 800 8,000 7 300 300 55 Round blank feed 220,000 9,000 4,000 8,500

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Schleppkurbel

PAUSt 160

To increase part production even at low forming speed, transfer forming automatic presses with link drive are the ideal solu-tion. Whereas the forming speed of the machine remains the same for the part in production, the ram impact speed, including the overhead tool, is substan-tially slower than for conventional drive solutions. All auxiliary process times are reduced substantially by the special gear in the machine, which increases part output. The additional articulation in the

drive system has a positive effect on the ram movement. In addition, the tool life is increased considerably.This drive system ensures that forces generated by the forming process that act on the eccentric shaft are not trans-ferred into the drive system. Transfer forming automatic presses with link drive are adapted individually to versions with bottom or overhead drive as required for the customer’s needs.

Benefits:> Longer tool life> Fast upward travel > Increased part output> Slower impact speed of the ram, including the overhead tool > Increased part output also at slow

forming speed

Transfer forming automatic presses with link drive

Link drive

Type Rated pressing

force (kN)

Number of tool stages

Ram stroke(mm)

Tool center spacing(mm)

Working strokes 1)

(strokes/min)

Max. strip width (mm)

Weight (kg)

Width 2)

(mm)Depth 2)

(mm)Height 2)

above floor level

(mm))

PAUSt 200 2,000 1+16 270 170 20 – 80 320 95,000 7,600 3,000 6,500

PAUSt 260 2,600 1+8 630 350 40 665 140,000 9,200 4,000 6,500

PAUSt 300 3,000 1+19 270 170 15 – 60 320 120,000 8,200 3,000 6,500

PAUSt 300 3,000 16/1+19 315 225 20 – 60 320 125,000 7,900 4,000 6,900

PAUSt 400 4,000 5 250/300 250/300 10 – 50 400 135,000 8,800 4,500 7,200

PAUSt 500 5,000 5 250/300 250/300 10 – 40 500 145,000 8,800 4,500 7,500

PAUSt 630 6,300 7 300 300 10 – 50 Round blank feed 170,000 9,000 4,000 8,200

PAUSt 800 8,000 7 300 300 55 Round blank feed 220,000 9,000 4,000 8,500

Innovative drive technology for flexible production:The transfer forming automatic presses with SERVO drive use a modern and in-novative drive concept which provides constant torque and working capacity across the entire speed range. Flexible speed modification during the stroke movement is another important feature of these machines. The result of this development is higher product output. Quick tool change is a great advantage for the production of parts of different design and runs.

SERVO drive (as direct drive or with intermediate planetary gear)The drive power is provided by a high-torque motor which – depending on the application – is connected directly to the eccentric shaft or by a low-backlash planetary gear. This SERVO motor is the power source of the machine. The intel-ligent control supports programming different speed profiles, which makes the machine highly flexible and suitable for different applications. The machine output can also be increased due to this configuration. The speed of the stepless- control torque motor is adjustable at the operator panel.

Features of the SERVO drive:> High torque with compact design and

small construction volume > Optimized mechatronic solution> Highest rigidity> High speeds possible> Improves productivity and product

quality > High dynamic action (fast acceleration)> Excellent true running > The suitable motor for low-energy

solutions

Energy management:> Based on capacitor modules; or> Electromechanical storage > The generator energy is stored in the

intermediate circuit in such a way that the total connected load of the trans-fer forming automatic press is similar to or lower than that of mechanical machines

> Provides constant torque and work-ing capacity across the entire speed range

The advantages are:> Gentle cutting> Difficult contours are produced very

exactly > Long tool life> Low noise emission> Fast upward travel > High output of parts > Reduced auxiliary process times> Supports spotting

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PAUSt 25 SERVO

Transfer forming automatic presses with SERVO drive

DESCH-SERVOX®-planetary gear

Die Drehzahl des Torque-Motors ist über das Bedienpult stufenlos regelbar.

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PAUSt 100 SERVO

PAUSt 800 SERVO in 3-D view

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Visualization system

Comprehensive comfortable

Raster-Zeulenroda visualization based on

Windows XP Pro

Simple visualization based on Siemens

WinCC flexible

Visualization based on SiemensWinCC

Cont

rol,

field

bus

BeckhoffTwinCAT,EtherCAT

SIMATIC S7,Profibus

SIMOTIONProfinet

OVERVIEW OF CONTROL VERSIONS

Photo credits: Beckhoff Automation GmbH

Optimum support for the press operator:> Complete information on the press

and the job at any time> Automatic operator prompts

Optimum support for the tool setter:> Simple, function-oriented program-

ming of tool data, notepad and photo album for every tool

> Reference function to prior tool set-tings or other tools

Optimum support for maintenance:> Extensive press diagnostic function

with link to on-line help (Beckhoff)> On-line help with photos of all sen-

sors for quick localization to speed up problem resolution (Beckhoff)

> Maintenance interval with reminder function (for machine, peripherals and tool)

Support of production planning:> Automatic recording of job-specific

data> Automatic update of the job history Optional:> Web server for remote monitoring of

the machine via the intranet

Comprehensive remote service:> User support> Program updates

Control from Beckhoff orSiemens:> TFT color screen control on basis of

Beckhoff PC control with soft PLC> PC-integrated operating hours coun-

ter; Raster-Zeulenroda visualization under Windows

> PLC with Simatic S7-300 and 15’’ touch panel with color display; programming with structured text

(SCL + SCL-Petri nets); visualization based on WinCC flexible

> Simotion control for presses with SERVO direct drive;

Raster-Zeulenroda- visualization un-der Windows

The press control – comfortable and reliable

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PAUSt 32 with external cutting stage

PAUSt 25

Ram PAUSt 125with motorized adjustment tool carrier

Köln 530 kmLeipzig 110 km

Hamburg 600 km

Hannover 460 km Berlin 300 km

Dresden 180 km

ZeulenrodaFrankfurt 380 km

Stuttgart 400 km

Nürnberg 180 km

München 340 km

Prag 300 km

Wien 650 km

Raster-ZeulenrodaWerkzeugmaschinen GmbH

Triebeser Straße 5D - 07937 Zeulenroda-TriebesTel.: + 49 (0) 3 66 28 / 42 - 0Fax: + 49 (0) 3 66 28 / 42 - 239Email: info@raster-zeulenroda.dewww.raster-zeulenroda.de

Machine and plant manufacture forstamping and forming technology

> TRANSFER FORMING AUTOMATIC PRESSES> STAMPING AND FORMING AUTOMATIC PRESSES > TOOL TESTING AND PRODUCTION PRESSES > HYDRAULIC OPEN-FRONT AND DOUBLE-SIDED PRESSES > SPECIAL-PURPOSE PRESSES AND SPECIAL CONSTRUCTIONS > SERVICE AND GENERAL MAINTENANCE> JOB ORDER PRODUCTION

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