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MAGAZINE FOR HIGH PERFORMANCE STAMPING TECHNIQUE
NEW AND INTERESTING TRENDSFROM THE WORLD OF STAMPINGNews about the latest newcomers, successfuljubilees, new application fields and the top-eventsin the second part of this year
STEPPER AND BRUDERER –COMPOUNDED PERFECTIONWhen BRUDERER sold a high performance stampingpress in Korea and STEPPER developed the matchingdie, people in Asia were surprised
INNOVATIONS AROUND THEMANUFACTURING PROCESSReports from innovative partner companies –from standard parts over surface technologiesto system suppliers
NEWS FROM THE WORLDOF B-CONTROLThree reports about new software functions of theBRUDERER B-Control, which can have a deep impacton the process with little efforts
In June 2005 Kleiner GmbH was able to look back over 20successful years in business as a respected authority inprecision pressings and high-performance tools for theautomotive, plastics, electrical engineering and electronicsindustries.
The company was founded by the brothers Thomas andJoachim Kleiner. The focus back then was the making ofhigh-performance punching tools. Today, 20 years on andwith a workforce of 120, Kleiner GmbH is one of the leadingspecialists in the production of precision parts.
Under the direction of the two managing directors Thomasund Joachim Kleiner and with a team of highly-qualified staffand know-how that always reflects the state of the art, KleinerGmbH could not be better equipped for the constantly in-creasing demands of the market.
"We have a passion forinnovation, and complex taskssimply increase our motivation,"says Thomas Kleiner,summarising the reasons for thecompany’s success. He adds:"The motivation of ouremployees is just as importantfor us as a modern machineinventory, because at Kleinerman and machine always workhand-in-hand to constantlyachieve maximum quality and
KLEINER’S 20TH ANNIVERSARY – A PASSION FOR PRECISION
EDITORIAL
Dear customers and business partners,
I would like to start by thanking you for theoverwhelmingly positive feedback that we have receivedfrom many countries following the publication of the firstedition of our new customer magazine "STAMPER". Thisgreat response encourages us to continue to develop thisnew channel of communication.
In this context I would particularly like to draw yourattention to an article based on research that we carriedout with our customer STEPPER. This report examines avariety of representative aspects of this company,including a successful application in South Korea. Thisapplication, which combines Swiss engineering andGerman toolmaking know-how, enormous increases inproductivity have been realised, leaving a Japanesecompetitor standing.
Furthermore, the reports from partner companies onpages 6 and 7 or the report about new software modulesfor our B-Control on page 8 supply important startingpoints in optimising production – because only processesthat are consistently perfected offer us the basis for facingthe future confidently.
We, too, as makers of high performance punchingpresses can ultimately only be as good as the challengesthat you present us with. Of course, I cannot exclude thepossibility in specific cases that some goals cannot beattained without an unreasonable expenditure of time orresources. But I can make this promise with self-confidentoptimism: If it can be done, it can be done with BRUDERER!
It only remains for me to wish you much enjoyment inreading this issue and to once more invite you tocommunicate with us directly. No matter whether it’s bymeans of a phone call or face-to-face at the"StampingDays" in Pforzheim/Germany from 21 to 23September, to which I warmly invite you. We'd also like totake this opportunity, to encourage you to sendyour ideas, questions or criticism directly to us [email protected]. Whatever form ittakes, we look forward to getting more of your feedback.
Yours Markus E. Bruderer
Markus E. Bruderer, CEO Bruderer AG Stanzautomaten
COMPLETE RANGE
Process safety, and this applies no less to automaticpunching presses, is constantly increasing in importance.With the conclusion of the BSTA 1250 and BSTA 1600developments, all BRUDERER machines are now equippedwith the new ram height adjustment mechanism whichenables an adjustment during the stamping process. It isindisputable that this represents a major advance in theprovision of a more accurate and safer punching process forlarger applications.
The two series of the redesigned BSTA 1250 and BSTA 1600round up the top end of the BRUDERER range that will infuture be even more impressively precise and safe.
Other key components in the drive of the above models withrated forces of 1250 and 1600 kN respectively besides theram height adjustment were completely redesigned. Moreovera lot of importance was attached to the ease of service andlong service life of both the machine and the control system.
However, the outstanding feature of the new series iscertainly that the ram height can now be adjusted during thestamping operation. This enables the operator to maintain theBDC position of the ram within the narrowest toleranceswithout interrupting the punching process.
Another contribution is made by analogue measuringsystems that can be installed in the tool and can compensatefor the even the slightest deviations in the ram height via themachine control system. Both the BSTA 1250 and the BSTA1600 series will be available for delivery from March on 2006.
Even if you choose used high performance stampingmachines, you can rely on BRUDERER competence. Ageneral overhaul restores the precision and productivity ofused BRUDERER machines to good-as-new standards.
And that’s not all: After a complete mechanical and electricaloverhaul, customers receive a full guarantee for allreconditioned parts. And of course each machine iscustomised to the respective customer requirements.
This offer also applies if there is a change in a user’s productstructure. It should also be emphasised at this juncture thatBRUDERER customers who buy a used machine of courseenjoy unrestricted access to the BURDERER Group’s uniqueworldwide maintenance service.
So, with used machines from this manufacturer you can besure of unproblematic, high-precision and high-performanceproduction.
Impressum
Publisher: BRUDERER AG – High Performance Stamping MachinesCH-9320 FrasnachtPhone +41 71 447 75 00, Fax +41 71 447 77 [email protected], Layout and Editing:TECHCARE MEDIEN – AUSTRIA, Egatha 2, A-6842 KoblachPhone +43 5523 6 93 93, Fax +43 5523 6 93 93-4
© 2005 BRUDERER AG Stanzautomaten All Rights reserved
customer satisfaction."So that this objective can continue to be met in the
long-term, training of technical staff enjoys a high priority inthe company culture. This is underlined by the 20 youngpeople – an impressively large number for a company of thissize – that are at present laying the foundations forsuccessful careers at Kleiner in traineeships of various kinds.
Furthermore, Kleiner GmbH has decided to enter a specialrelationship on the occasion of its 20th anniversary and is tobecome a sponsor of the "Jugend forscht*" Foundation. Thisstep will allow the specific promotion of useful projects, withschool pupils from the immediate vicinity being supported inthe practical realisation of their ideas.
www.kleiner-gmbh.de
* A national foundation in Germany for investment in the development of young people.
RECONDITIONING
TECHNICAL DATA BSTA 1250 BSTA 1600
Tool loading area L – R mm 1170 / 1510 / 1810 1170 / 1510 / 1810
Standard stroke range mm 16 – 75 (in 10 steps) 16 – 75 (in 10 steps)
Special stroke range mm 19 – 100 (in 9 steps) 19 – 100 (in 9 steps)
Speed range spm 100 – 850 100 – 800
Ram adjustment range mm 89 89
After just one event, the"Stamping Days" in Pforzheim
have become established asan excellent platform forthe presentation of newtechnologies in sheet metal
processing and especiallyfor the whole process chain in
high performance punchingtechnology. Accordingly, this event
has become one of the top three exhibitions of the year forBRUDERER, along with BlechExpo and Productronica. Thistime the focus is on an intensive dialogue on the subject ofinnovative processes in punching technology. "We want toacquaint customers, whether actual or potential, withpunched parts that to date have not, perhaps unjustly, beenregarded as core competencies of BRUDERER," is the wordfrom company headquarters in Frasnacht.
As no machines can be presented at the event, BRUDERERwill concentrate on applications, particularly for the industrialfield, i.e. applications in which the key criteria are precisionand flexible machine use and not high stroke rates. Contraryto popular opinion, the BSTA series is also highly suitable forsuch applications. It has long been accepted that the BSTAseries is synonymous with precision – although mostly inconjunction with electronic and other small components. Atthe same time, it is a fact that high-precision equipment isalso absolutely essential in industrial applications in order toachieve greater process security and hence reduceproduction costs.
Did you know, for example, that a BSTA can be operated at arate of about 60 strokes per minute? Or that even at lowerspeeds, the available torque can be conveniently increasedwith a simple mechanism? BRUDERER looks forward to theopportunity of discussing these and other subjectspersonally with customers at stand 3-21.
www.stampingdays.de
MICROSTATEC GmbH is a young innovative company in themicro-punching segment. High-precision punching toolsused by the company for the manufacture of high-precisionmicro-parts of the most compact dimensions are designedand produced on its 450 m2 production site.
"Our attitude is that precision is the essential prerequisitefor quality and functionality – and hence the starting point forfunctional, reliable technology and ultimately for the successof products on the market," says Wolfgang G. Christoph,highlighting the philosophy of his company that was onlyestablished last year. "Our know-how was acquired inprecision engineering – specifically, the watch industry. Hereit was always our job to work to the nearest µm," says thecommitted company boss, who says that his success isbased on four strategic pillars:
– exceeding quality requirements – permanent gains in the miniaturisation of components– assurance of reliable and timely delivery– competitive pricing through the application of know-how
and technology
The basis for the above is the continuous improvement ofthe know-how and high-tech processes within the companythat are in any case already of an impressively high standard.The development of new technologies, materials and surfacesconstantly places new and ever greater demands onemployees and machines, the realisation of which ultimatelyresults in the advanced production of quality-assured andcompetitive products.
And on the subject of quality, Christoph says: "Qualityorientation is achieved in our company, on one hand, throughquality targets that are reset annually and that are monitoredby regular reviews. On the other, highly qualified workers andstate-of-the-art machines like BRUDERER stampingmachines, provide assurance of the sustainable provision ofhigh quality in services, performance and products."
www.microstatec.de
A BREATH OF FRESH AIR IN MICRO TECHNOLOGY
STAMPING DAYS 2005
BRUDERER's new BBV 260 feed unit is the successor tothe highly successful BBV 202. The roll feed updates thefamily of mechanical driven feeders and features severalimpressive innovations. The automated thickness settingand the quick-action roller change are only two examples.
The mechanical design of the BRUDERER BBV 260 strip feedunit is very similar to the BBV 450 which has been introducedto the market two years ago. In comparison with thepredecessor model – the BBV 202 – the new feed has beenconsistently developed to increase the advantages forcustomers yet further. One improvement is the automaticmaterial thickness adjustment that dispenses with manualadjustments or the use of adjustment motors. This uniquefeature has been realised through the rearrangement ofrocker arms and rollers and through the selected length ratiosof the components.
As it is now unnecessary to adjust the material thicknessaxis during the retooling process, the set-up sequence issignificantly faster and easier. Moreover the rollers can berapidly and simply clipped in and out for cleaning,replacement or profiling. This also extends the range of appli-cations of the new BBV 260 to those sections in whichpre-punched and profiled strips are used. These and otherinnovative solutions combine guaranteed maximum precisionwith the highest reliability and availability. The first BBV 260will be used in conjunction with the equally new BSTA 1250and BSTA 1600 types and will be available from March 2006.The product range will then be extended to embrace machineswith press forces of 500 kN plus..
BRUDERER will be present at "Productronica" from15th-18th November in Munich, sharing a stand with SLEElectronics. The BSTA 250-75 will be demonstrated alongwith a KRAMSKI high-performance stamping die. Theinteresting feature is that the punched part now beingproduced on the systems was previously machined with farless discharge of parts...
The exhibition stand is designed so that visitors can watchthe complete production process of a wire harness for theautomotive industry. This is an absolute first in this form andwill certainly draw many visitors to the stand. The com-panies WIELAND, SLE and BRUDERER have also organised aseminar that offers solutions for increased competitivenessunder the slogan "Process chain in the field of high perfor-mance stamping".
All interested visitors to "Productronica" can obtain aninvitation from any of the above companies for seminarscheduled for Wednesday 16 November 2005. You can alsoget more information from BRUDERER by sending us an e-mailto the following address:
NEW FEED PRODUCTRONICA 2005
Most specialists are aware of the mechanical advantagesof a BRUDERER automatic stamping machine. However, notmany of them are aware that a standard BSTA can be easilyadapted to make it eminently suitable for deep drawing andbending jobs.
The first solution for this purpose is the additional drivepulley that not only raises the available torque capacity butalso reduces the minimum stroke rate depending onapplication to between 50 and 60 strokes per minute. Thus itis possible to perform trial and obviously also production runsat lower stroke rates, thereby increasing safety in set-upmode. At the same time, the same BSTA can also be operatedat high stroke rates and is therefore equally suitable forconventional applications.
Another optional feature is the stroke heights. Each 250 kNor higher BSTA can be equipped with longer strokes than listedas standards. This increases its range of possible applicationswithout reducing upward performance.
Finally, the BRUDERER servo feed unit type BSV allows youto adjust the feed angles. Here too, the feed does not restrictthe performance for conventional applications butnonetheless enormously extends the options for bending anddeep drawing jobs.
As you can see, a BRUDERER high-performance automaticpunch is not only suitable for flat punching applications butcan also offer, after minor adaptations, its well-knownattributes in successfully performing in other segments.
FIT FOR DEEP DRAWING
ECHNICAL SPECIFICATIONS BBV 260
Feed length mm 80 / 120 / 150
Strip width max. mm 300
Stroke rate max. spm 1500
Strip thickness mm 0 – 6
Feed angle degrees 180
Roller width mm 120
STEPPER – JOINING FORCES FOR PERFECTION
High-performance automated punches continue toenjoy a special position in the industry. However eventhe best equipment cannot attain top performanceunless the tool also meets the highest specifications. Bythe same token, even the best tool in the world cannotperform if the automatic punch does not offer (in thefullest meaning of the term) the required framework.
Anyone who as a producer of punched parts demandsuncompromising quality and maximum productivity is welladvised not to lose sight of optimising symbiosis instead ofconcentrating unduly on short-term cost savings whenmaking investment decisions. That said, most European,and above all German metal stamping operations alreadysubscribe to this credo. The best evidence for this isBruderer’s sales success and especially the expansion of
the highly expert toolmaking companies in and aroundPforzheim.
Internationally, too, quality is increasingly gaining insignificance, as the joint solution offered by BRUDERER andSTEPPER for a customer in Korea shows. A local customerordered a high-performance BSTA 500-110B automaticpunching press from BRUDERER AG for an existingsubcontracted component and then looked for aninnovative and thus productive tool technology. Instead ofstaying in the country or at least the region, the Koreansdecided to call in Pforzheim-based Fritz Stepper GmbH &Co. KG, a company that now clearly enjoys an excellentreputation in the Far East. In view of the rationalizationeffects promised during negotiations, the parties sooncame to terms.
About the project: Previously, the customer had producedthe range of parts in question on up to four stampingmachines seven days a week, around the clock to meet thedemand for around 350 million parts. It is hardly necessaryto emphasise that the machines still in use were notproduced by BRUDERER and the tools not by STEPPER –what is perhaps more interesting is that in both cases theywere provided by Japanese suppliers.
We do not know what will happen with theselocal stamping machines: Where the existingset-up struggled to achieve at production rate of 400strokes per minute, the BRUDERER/STEPPER combinationraises the pace to 800 strokes per minute and laidout as a double out die, that works out at no less that1600 parts per minute. And these are rationalisation
effects that are even making people in Asia sit up and takenotice.
However speed is by no means everything, as MichaelStepper, the managing director of the family business,makes clear, pointing to the high standards of availabilitydemanded of the machine/tool system. And that’s certainlythe case: For it is only when the complete picture of highstroke rates, tandem production and extreme reliabilityover a three-shift production cycle is taken intoconsideration does a good solution reveal itself assomething special, if not unique.
Much of the system’s high-performance can be explainedby a glance at the highly robust design of the BRUDERERpresses that make no compromises in respect ofextremely high precision. The basis for this is high degreeof vertical integration of the Swiss specialists – although itis easy to say the same of STEPPER. There too, eachqualitatively critical component of the tools is designed andbuilt in-house.
The range of STEPPER products is divided into the threeareas: starting with tools from the PROTO range (fordrawing-based, production-proximate prototypes and shortdelivery times) through tools of the MODULAR 1 generation(for the cost-effective production of small andmedium-sized series and for complete product families) tothe likewise modular F1 SUPERTEC technology (for bigproduction runs with optimum efficiency).
Michael Stepper is especially proud, on one hand, of themodular concept with which his father revolutionisedMichael Stepper, Managing Director, Fritz Stepper GmbH & Co. KG //
This small selection of stamping parts illustrates the impressive precision, which has to be provided even in a STEPPER-die, to make such fascinating parts out of simple strip material //
traditional toolmaking in the mid-1970s and on the other, ofthe F1 SUPERTEC development, which has been causingexcitement all over the world since the start of the newmillennium. The main features of SUPERTEC tools, saysMichael Stepper are "super material, super technology andsuper coatings".
Besides the use of special ceramics, in this case "supermaterial" means the application of a hardened metal thatwas especially developed for STEPPER with an extremelyfine-grained structure with a grain size of only 0.3 µm (forcomparison: normal hardened metals have a grain size ofat best 0.7 to 1 µm). And precisely because STEPPERhardened metal is so fine-grained, it provides the basis forextreme edge stability and therefore a very long usefulproduction life, whereby other factors also come to bearhere of course.
These factors include the super surface-technologydeveloped in-house with makes it possible to reliablyproduce extreme surface qualities up to Ra 0.01 µm andcontour precision with tolerances of 1 µm. Another exampleis provided by STEPPER’s own coating facility forhardnesses up to 5000 HV.
To summarise its impressive properties, F1 SUPERTECrepresents the perfect symbiosis of highest precision andmaximum productivity. And for Michael Stepper thisdevelopment is the best evidence for the contention that itis still possible to make money with tools "Made inGermany" – all over the world!
In fact, Michael Stepper, supported by his team which
currently comprises 110 highly-qualified members, stillregards himself primarily as a toolmaker, as he says: "Ourgoal is not to be the largest toolmaker on the planet, but tomake the best high-performance punching tools in theworld." In accordance with this credo, there is no possibilityof extending the business in other direction.
The fact that his workshop accommodates numerousautomatic punching machines (it goes without saying allfrom BRUDERER) is not for him a contradiction: "On onehand, a punching shop is essential for us so that we cantest and run-in our tools or so that we can developinnovative processes.
On the other, we of course have customers without their
own expertise in punching metal for which we provideproduction capacity and other customers who need help tocope with capacity bottlenecks."
If you want to find out more about STEPPER, the"StampingDays" in Pforzheim provide an excellentopportunity to make contact. As well as being present therewith its own stand, the company is organising ashuttle-service to the company premises, where you willbe able to see the latest development of the BSV 75T servofeed unit in innovative combination with a two-trackpunching tool.
www.stepper.de
Above: Progressive die in perfection „made by STEPPER“ // From the left:The “open” B-Control guarantees also at STEPPER best operating comfort // The latest proof for the “compounded perfection” is thenew servo feed unit in double design from BRUDERER in ideal interplay with the innovative Two-Track die from STEPPER // “Only BRUDERER” – that’s what the STEPPER company chooses when it comesto perfect stamping parts //
The result of a complex Two-Track production: highly precise contacts at the outlet of a STEPPER-die //
precious metals (in some cases considerably) and makingpossible new technical solutions.
The range of services offered by OTB has been continuouslyextended over the years and now embraces the highlyselective coating of 2 and 3 dimensional punched strips, thespecial galvanisation of single components, the gentleremoval of grease and particles from punched strips and theproduction of strip galvanisation, deflashing and cleaningsystems for the electronics industry as well as the delivery ofturnkey galvanisation systems with all the associatedinfrastructure.
OTB OBERFLÄCHENTECHNIK– SURFACE TREATMENT SURFACES
Since it was established in 1987, OTB OberflächentechnikGmbH & Co. has developed into an effective, reliable, highlyflexible and innovative partner for its customers inpunching applications and electronic componentproduction.
OTB regards itself as a technical service provider that incooperation with its costumers provides surface technologysolutions for the economic and technical challenges thrownup by the market. To this end, the company has developednew selective plating systems such as special brushtechnologies, SPINJET, DMS and MMS, as a result significantlycutting production costs, reducing the consumption of
LFT MACHINE TECHNOLOGY – AMBITIOUS ONE-STOP-SHOP SUPPLIER
OTB has also developed an environment-friendly goldrecycling and refining technology for the recovery of wastecontaining precious metals produced during the punching ofhard-faced strips and markets this from its headquarters inBerlin. Especially today where the prices for gold and silverare very high, the small but very effective machinesguarantee therefore a very fast return on investment.
Increasing quality expectations and the constant reductionin the size of components have turned cleaning into one of theprincipal preoccupations of the electronics industry. OTB hasdeveloped small and compact high-pressure water jets andatmospheric plasma systems specifically for machiningfiligree. These systems that can be integrated in productionprocesses (e.g. they can be post-connected to the automaticpunching machine) are used for cleaning and deburringpunched parts, for deflashing plastic spray-coated chips andto activate metal and plastic surfaces. OTB’s SPOX® cleaningsystems are proving their performance reliability in Europeand South-East Asia for companies in the electronics andautomotive industry.
Moving beyond its homebase in Germany, OTB will offer inthe course of 2005 galvanisation services and above allselective punching strip coating to its customers in China.
www.otb-group.com
security. The many different processes that LFT offers,increases design options and reduces development times.Moreover LFT offers the flexibility to react rapidly andeffectively to product changes – whether it’s a matter offurther developments in the product cycle or versions of anexisting product family.
Along with hoses, cables are a special challenge inassembly work. These non-rigid components must be handledwith special care. LFT has many years of experience in dealingwith them.
Finally, LFT has several patents in the area of punched andbent products. By using them, the customer obtains a uniqueadvantage and also objectively quantifiable competitiveadvantages.
www.lft-lange.de
on, all have the following in common: demanding technicalrequirements and an optimum price/performance ratio.
Easily scratched coatings or brittle galvanised surfacesmust be punched and formed appropriately. Critical materialssuch as wolfram or niobium demand specialist machining.Processes such as clinching, welding or soldering are onlysuccessful if all parameters are precisely adjusted. Criticalproducts, such as those that are typically used in the safetyengineering of modern cars, must be 100 % tested. Basic partscan also become a challenge simply because of theextremely large volumes required for production.
Special-purpose machines
At LFT, the in-house scope for developing machines extendsto all key areas: starting from design through the productionof components and the assembly of production facilities totoolmaking. Curve controllers are the centrepiece of themachines. Coupled with the latest control electronics,machines are produced that can work very quickly, yet withhigh precision.
The linear arrangement of processing stations results incompact designs. They are easily serviced and require littlespace, yet operate with maximum reliability. In conjunctionwith standard cells, astonishingly modestly priced systemscan be created, whereby each machine is completed withcomprehensive measuring and testing technology.
OEM products
In addition to investments in its own systems, LFT can alsosupply its customers with OEM products. The advantages arereadily apparent: the high availability of the machines resultsin a favourable price/performance ratio and increases supply
What comes after the stamping? This question is one ofthe central issues in high-performance punchingtechnology. Often stamped parts undergo finishingprocesses such as assembly and over-moulding, forexample, to create the final product. The prerequisite forsuccessful products is the precise integration of severalsub-processes into a carefully coordinated main process.LFT Lange Feinwerktechnik GmbH (LFT MachineTechnology) based in Ölbronn-Dürrn has mastered thisrequirement for more than 20 years and has establisheditself as a leading supplier of special machines as well asprecision parts and modules.
LFT develops special machines and produces customisedparts and modules ranging from a few cubic millimetres to thesize of a shoebox. These stamped parts, assemblies inautomotive production, medical diagnostics products and so
With its complete range of products and services, SLEGmbH offers its customers in the world of high-performancepunching technology a continuous system for surface tre-atment which can optimise the entire process chain.Depending on the punching operation in question, variousprocess parameters are selected and combined to create anoptimum surface structure.
The prerequisite for theindustrial processing ofpunched components, suchas coating, soldering orbonding, is a grease-freesurface. Optimum productquality can only be
guaranteed with flash-free and oil-free surfaces.
Depending on cleanliness requirements, appropriatemodules are combined from the SPR Cleaning System.Spraying, flushing and steaming modules in all imaginablecombinations are selected to remove oils and coolants.Flashes and burrs are removed by a combined high-pressureand deburring module.
A punch stripwith a width of 20to 110 mm and athroughput speedof for example upto 8 m/min can bedeburred, with thewhole operationfully integrated inthe productionprocess.
AGATHON AG NORMALIEN – PRECISION PAYS
SLE – INTEGRATED SOLUTIONS FOR CLEANING PUNCHINGS
wear measurement system checks brush quality and adjuststhem with a tolerance of ± 0.15 mm.
Finally, high-pressure cleaning is performed at a pressureof about 180 bar. The cleaning liquid (water) jets that hit thepunched strips have a very strong mechanical cleaning effectthat reliably removes flash, grinding dust and in many casesany burrs.
www.sle-electronic.com
Before the actual brushingprocess, the punchings arepre-rinsed to remove anygrease. Any punchedstrips that have beencontaminated with oil aredegreased with pure waterin order to prevent thebrushes sticking orbecoming contaminated.
The strip is then returnedto the deburring module inwhich the brushes arearrayed for cross-grindingwith a quick-change unitand can be simplyswapped out and inaccording to strip width.
For optimised processing, the brush speed can becontinuously set up to 20 m/sec, while an integrated brush
In view of the extent of the range of standardised punchingcomponents and bearing elements, anyone who wants tosimply get an overview and save themselves a lot of effortcan do this with AGATHON’s electronic product catalogue.
Instead of producing drawings themselves, users can thedownload the required components as a 2D/3D file via theISO/DIN/AFNOR program and insert them directly into theirdrawings. The CADENAS software used is compatible withmost CAD programs.
Agathon AG NormalienPostfach, 4503 Solothurn/SchweizTelefon: +41(0)32 617 4502Telefax: +41(0)32 617 4701E-Mail: [email protected]
www.agathon.com
that extend service intervals and also increase the service lifeof the tools. The complete product range is as follows:
- Range of bearing components as per ISO/DIN standardsCylindrical, quick-change die sets and for installation on the bearing plate
° Sliding bearings
° Ball bearings for high precision radial and axial movements (patented)
° Roller bearings (patented)
° Cage retaining system (patented)- Miniature linear guides, Ø 3 to 12 mm- Guide elements dimensioned in inches in accordance
with the AFNOR standard and for mould making- Die sets in cast iron, steel and aluminium- Special parts according to customer specifications/
drawings (e.g. in non-corrosive materials)
Another example from thewide range is the rollerbearings. The roller cageshave been equipped withnewly developed retainingpockets for holding therollers with correspondingcaulking, produced in aprocess (patented) in whichburrs were eliminated. Thisensures high dimensionalrigidity even under highradial loading and increaseduptime.
Tradition is written just as large at AGATHON asinnovation. Established back in 1918, the company hasearned its reputation as a leading manufacturer ofstandardised punching tool components as well asbearings for machines, forms and tool sets.
The products of the Swiss company AGATHON AG Normalienare above all distinguished by the highest material quality,the highest quality of finish and the narrowest tolerances.Other impressive features include:
- Special leading edge geometries on die sets and collets for a longer service life
- The patented hot caulking of rollers guarantees optimum play and hold in the cage
- Delivery of standardised parts from stock- An impressive price/performance ratio
An example of the high-performance of AGATHON AGstandardised components is provided by the roller bearings
PREVIEW OF STAMPER ISSUE 1/06After the first two editions of STAMPER appeared in short
succession due to the close juxtaposition of BlechExpo andStampingDays, there will now be a somewhat longerinterval to the next issue. The next edition of STAMPER willnot appear until March 2006 and again it will be full of newdevelopments to do with punching. Among the plannedarticles are reports on the following subjects:
> A report about an application from a customer in the
industrial applications segment
> Innovations in the punching processes
> The latest news about control systems
production facility through the central display of errormessages and an immediate response in the rectification toan increase in productivity and cost-effectiveness.
The "Customised Error Messages" module is immediatelyavailable for automatic punching machines with B-Control andcan be retrofitted to existing machines with the same controlsystem. Moreover the values recorded by the control systemsupport a functional extension to establish Machine DataCapture (MDC).
If you are interested in this option, the specialists atBRUDERER are of course available at any time for a personaldiscussion.
Complex production systems are composed of anassociation of various devices from different suppliers.Immediate diagnosis of why a punching process is notrunning is the basis for its optimisation and at the sametime is a decisive factor in the productivity and thecost-effectiveness of the entire production line.
The "Customised Error Messages" module createstransparency and enables the operating statuses of alldevices that are integrated in a B-Control system to bedisplayed. Inbound error messages – generated by externalperipheral devices – are displayed centrally on the B-Controldisplay panel and permit the operator to deal with theproblem immediately.
The new "Customised Error Messages" module in theBRUDERER B-Control features:
- free parameterisation of message texts by the customer - saving of a message text for each error signal (multilingual
format also supported)- establishment of dependency of enablement of operating
mode and tool dataparameterisation of inbound error messages to initiate a TDC stop/immediate stop or parameterisation without stop
- definition of time delay in response to each signal- definition of an automatic reset so that once an error has
been rectified the display is automatically reset- definition of whether in set-up mode, the error message can
be cancelled without the error being rectified
Two examples of "Customised Error Messages" frompractice are the delayed stop in automatic mode because of"open sound protection doors in the cabin" or a TDC stopbecause "suction device full".
The advantages of the new control options are manifest:starting with the transparency of the operating status of the
EVERYTHING UNDER CONTROL
The monitoring of tool functions is essential for a secureprocess and constant workpiece quality. Moreover itprotects the tool and machine from expensive damage.
With position monitoring, "analogue" sensors can be usedfor tool monitoring. One or more sensors are used to measurethe closing position of the spring plate. If the spring plate doesnot reach the set tolerance range in the BDC area, this isrecognised as an error and the machine is stopped. The causemay be a doubling up of the material or slugs, etc.
The use of high-resolution, inductive distance sensors(eddy current sensors) means that narrow monitoringtolerances can be employed so that positional aberrations ofless than 1/100 can be reliably detected.
The teaching-in of required positions simplifies the use andoperation of the position monitoring system. The display ofthe current and previous positional values keeps the operatorconstantly informed about the tool status. The highlights ofthe analogue sensors can be summarised as follows:
- narrow monitoring tolerances- simple application through "teaching-in" of parameters- high-resolution sensors for measuring distances
Ram position control with sensor in the tool
The adjustability of the ram during the process is a vital andunique design feature of BRUDERER machines to keep thebottom dead centre position of the tool constant. Due toprocess effects (heating of the machine, tool and punch), theoptimum tool closing position may change during therun-time.
For setting purposes, as depicted in the example, thedistance R between a reference punch and the analoguesensor in the die is measured (see Fig. below). After theparameters have been taught in and the setting is activated,
the distance is kept constant by automatic adjustment of theram height. The setting leads to an optimum result if a changein the closing dimension can be detected and compensatedfor, through adjustment of the ram position, thus keep thequality of components constant.
Accordingly the most important features of ram positionadjustment by sensor in the tool are:
- measuring and controlling of the BDC within the die and hence near the process
- ram BDC position adjustment during the stamping process- retrofittable with BRUDERER B-Control*
The ram position monitoring system is an add-on module forthe B-Control and the ram position adjustment can beimplemented as an additional function for the positionmonitoring system.
The * in the above list signifies that retrofitting of theposition monitoring system and ram BDC positionadjustment of an existing machine with a B-Control isin principle possible but must first be discussed withBRUDERER.
SAVE AT NIGHT
In Europe in particular, the issue of how to increaseproductivity while at the same time reducing operatingcosts is a hot topic. This is precisely where BRUDERER’s"Energy control/night switch" can help by supporting lesslabour-intensive production, reduced energy consumptionand increasing the profitability of the entire production line.
This feature supports agradual reduction of themachine drive status in apredefined scenario. Fourenergy saving functionsare available which areactivated with a timedelay on receipt of aninternal or external stopsignal:
- Reduction to set-up speed- Switch off main drive- Switch off oil pump- Main switch off/isolate machine from main power supply
Peripheral devices that are supplied with power from thesockets in the automatic punching machine can also be shutdown via this module. In order to avoid data loss, in this eventa warning signal is sent to the devices instructing them tosave their data.
The "Energy control/night switch" module is immediatelyavailable for automatic punching machines with B-Control andcan be retrofitted to existing machines with the same controlsystem under certain conditions.
INDIVIDUAL ERROR MESSAGES
