The Smart Press Shop [credit: Schuler]
The first major members of Smart Press Shop GmbH have arrived at the Star Park industrial area in Halle (Saxony-Anhalt). These are the components for a ServoLine 20, induction press and laser-blanking line, which is to be put into operation in 2021 in the state-of-the-art press shop of the joint venture between Porsche and Schuler. In this newly emerging press shop, the body parts of the Porsche Macan II are pressed, followed by assembly at the body shop in the Porsche plant in Leipzig.
The press line with an output of up to 20 strokes-per-minute (for example 40 doors, 80 fenders) has numerous intelligent functions from the Industry 4.0 kit by Schuler.
For example, cameras monitor the drawn edge of the shaped components. Under consistent conditions in the forming process, the shape and size of this drawn edge remain largely the same. If there is a change here, it indicates a deviation in material properties, lubrication or pulling forces. Process-monitoring is used to inform the plant operator, so corrections can be made at an early stage to avoid expensive scrap/rework parts to a large extent.
The camera-based tool monitoring "Visual Die Protection" controls the correct attachment of connections, detects foreign objects such as wrenches or punch residues in the tool and checks whether the parts have been inserted, reshaped and removed correctly. In the event of a registered deviation from the target state, the press stops immediately to avoid costly consequential damage in the tool.
The oil circulating in the system is continuously monitored to determine the aging of the lubricant. The aim is to change the oil only when its condition requires it, which significantly increases the useful life. In addition, lubricating-oil monitoring allows detection of short-term changes in oil properties, for example, indicating contamination with water or foreign particles.
The documentation of the entire system is also available in digital form; this saves employees from spending time searching. The files are available from each control station with HMI and screen as well as from mobile devices that all employees of the Smart Press Shop carry. For faster identification, electrical and fluid components of the system are equipped with a DMC code.
