Big bolts for wind power plants “FlexiMat“ for material efficiency

Transcription

up
grade
Newsletter for customers, employees and partners
volume 18, issue no. 34, August 2015
Trends + Markets
“FlexiMat“ for
material efficiency
The new pre-forming unit “FlexiMat“
allows material savings of 20% and is
the out-come of a collaborative research
project subsidized by the Federal
Government.
Know-how
Servo drive for
forging hammers
LASCO is now trying out servo drive
technology with die forging hammers, too.
LASCO servo drives have been proving
themselves for years. The functioning of
hammers has issued other challenges to
the engineers, though.
In practice
Big bolts for wind
power plants
At Sternberg GmbH (Germany) LASCO
technology is the preferred production
equipment for making fasteners that
must withstand extreme stress. And it
has also to do with matters like climate,
environmental protection and safeguarding
our future energy supply.
LASCO UMFORMTECHNIK
WERKZEUGMASCHINENFABRIK
Editorial
Trends + Markets
Forge Fair 2015 in Cleveland/Ohio (USA)
Demand in the USA clearly on
the increase
Friedrich Herdan
Gesellschafter
Vorsitzender der Geschäftsführung
Langenstein & Schemann GmbH
Giving a signal just now
The economic crisis in Russia and the
controversies with the EU are leaving
deep marks in German mechanical
engineering. According to the VDMA
(German Engineering Association)
machine exports to this very important
country for our line of industry
dropped by around another 28
percent in the first quarter of this year
compared to last year. Unfortunately
LASCO, too, is affected by this
development. Nevertheless it is just
now that we have founded a service
company in Russia, the OOO “LASCO
Umformtechnik Service” (cf. article on
page 6).
In our opinion it is important and
the right step to give our customers
a signal of our reliability. In addition,
we are confident that political
controversies can be surmounted,
and we believe in the fair balancing
of justified interests as well as in
the future of our good business
relationship built up over many
decades. Therefore, in the current
phase we are moving even closer to
our Russian business partners.
Almost the same goes for business
relations as for qualified personnel
in a company: Stability is a key
success factor, whereas fluctuation
is counterproductive. LASCO can
be proud of a company history of
150 years not least because trusting
partnership and task sharing both
with customers and suppliers have
always been and will continue to be
the guiding principles of our company
culture. This is exactly what we also
want to demonstrate by investing
in Russia in times of political
controversies. We are confidently
looking ahead! Let’s do it jointly!
Yours
Friedrich Herdan
2
up grade LASCO 34/15
The clear upswing of the US
economy also gave fresh
impetus to the Forge Fair, the
leading trade fair of the US
American forging industry.
According to the host Forging Industry
Association the trade fair in Cleveland/Ohio
(April 14 – 16, 2015) has been the biggest
and most successful exhibition of the forging
industry in America ever. 160 exhibitors from
24 countries presented their products to
1770 visitors.
Centrally located LASCO’s booth was much
frequented by trade visitors. Their interest especially in further developments and
automation solutions was reflected in very
concrete questions and projects the LASCO
experts were confronted with. The first HO
with hydraulic servo direct drive shown at
the booth stimulated numerous discussions.
A number of technical presentations about
specific topics of the forging industry in the
supporting programme added to the quality of
the discussions.
According to findings of the “Germany Trade
& Invest” the US economy is defying the
world-wide economic downward trend. The
stimulation of growth that could already
be seen to emerge at the end of 2014 has
considerably strengthened and the tendency
to invest has noticeably improved in the
last few months. With an overall increase
in imports those from Germany continue
to develop better than average. This is also
due to the weaker Euro, which is lowering
the cost of German goods in the USA.
German industrial equipment is especially
in demand in the automotive industry which
is currently regaining strength. Suppliers
of industrial equipment are benefiting from
the robust economy of OEMs and subsuppliers. The surge in demand for forming
units is focussing on hammers and presses.
Great interest can be seen both in the
modernisation and automation of existing
production equipment.
Turkey: LASCO symposium in Istanbul
The lasting economic growth in Turkey is also
stimulating the tendency to invest within the
local forging industry. This became obvious
during the LASCO symposium which took
place in Istanbul in May. More than 20
participants from enterprises of the Turkish
forging industry informed themselves in the
one-day event, in which presentations on
the current situation and future perspectives
in this industry in Turkey and on envisaged
innovations in forging technology and processes
were given by Jochen Günnel and Emile
Fortanier from LASCO as well as by guest
speakers. Orhan Metin from the Turkish forging
association DÖVSADER presented “The forging
industry in Turkey” and Prof. Dr. Mustafa Gökler
from the Middle East Technical University
Ankara reported on “Heating systems for
forging tools”.
News
New unit “FlexiMat” optimizes pre-forming
Focus on material savings
The new “FlexiMat” distinctly increases material efficiency in the
forming process being a special unit for pre-forming operations.
Through the cooperation of science and practice an average of 20 %
material can be saved.
This is the outcome of a research project
in which the flexible pre-forming unit was
developed. The project funded by the Federal
Ministry of Education and Research under the
Funding Number 17PNT023 was carried out
jointly by the Labor für Massivumformung/
LFM (Laboratory of Massive Forming Iserlohn/Germany), headed by Prof. Dr. Rainer
Herbertz, and LASCO and was supported
by CDP Bharat Forge GmbH (Ennepetal),
Hirschvogel Umformtechnik GmbH
(Denklingen), Mahle Brockhaus GmbH and
Rasche Umformtechnik GmbH & Co. KG (both
in Plettenberg).
A pre-forming unit for massive forming was
designed, developed in its basic functions
and its efficiency was evaluated. Starting with
heated round billets nearly any pre-forming
geometries can be produced in one or several
steps without flash and in cycle times specific
to the line. Exemplary examinations for a
representative range of parts have shown that
20 % material on average can be saved.
axis each as well as several upsetting axes.
Seven basic shapes can be produced with
them. Combining them far more complex
geometries can be produced in several preforming steps.
The concept of the “FlexiMat” is based on
the main concept of a hydraulic press with
additional horizontal upsetting cylinders.
Three impressions are envisaged, and
the parts will be moved on via a
specially adapted conveying system
that both allows forming step by step
or forming in up to three impressions
simultaneously. The forming unit,
which has been developed further
by LASCO and reached the maturity
phase meanwhile, has attracted wide
interest right from the start. A first
order for a FlexiMat 40/60 with a
horizontal upsetting force of 4,000 kN
and a closing force of 6,000 kN was recently
placed.
The development of the “FlexiMat” has been
completed and the unit is now available to the
market.
The basic idea was to develop a pre-forming
machine with one vertical closing and forming
Working Committee Automation met in Coburg
Possibilities of the forging industry expanded
Like in many other industries
automation in the forging
industry has not been stretched
to its limits yet.
This was the outcome of the latest meeting
of the Working Committee Automation of
the Confederation of the Massive Forming
Industry that was held in Coburg on 9
December 2014 at LASCO’s invitation.
The meeting, in which 38 experts from
all over Germany participated, focused
on developments and experience in the
automation of forming units. Proven
experts from the application industry,
the mechanical engineering sector and
from science contributed to it by giving
technical reports: Dr. Martin Dietze talked
about the experience of Buderus Edelstahl
Schmiedetechnik GmbH (Wetzlar) in the
automation of forging lines, Julia Fischer
from Automatic-Systeme Dreher GmbH
(Sulz am Neckar) reported about the “Latest
developments in the automation of die forging
presses through transfer systems considering
the retrofit of conventional forging lines”,
Manuel Mönnig from the Fraunhofer Institute
of Production Technology and Automation IPA
(Stuttgart) presented a “Two-armed robotic
system for quick bin picking” and the leader
of the workshop, Prof. Dr. Rainer Herbetz
from the Labor für Massivumformung/LFM
(Iserlohn) presented the new development
“FlexiMat” (see article above) together
with Sebastian Frank, Manager Project &
Technical Engineering at LASCO. Frank also
gave an overview of “Latest developments in
the automation of forging lines”.
Since 2006 manufacturers of automation
technology for the metal forming industry
have met with representatives of companies
of the massive forming sector in the Working
Committee Automation of the Confederation
of the Massive Forming Industry to discuss
new developments in all fields of the
process chain.
3
Know-how
Highest efficiency and accuracy
Servo drive technolo
LASCO has always rated the die forging hammer as
optimum forging unit for massive forming and has
optimised it continually. Our article reports about
the current development projects for the use of
servo drives in die forging hammers.
Hydraulic servo direct drive
The servomotor and the hydraulic pump form
the drive unit of the new LASCO hydraulics,
which serves to position the ram, to adjust
the speed and thus to set the blow energy.
Highly dynamic servo motors drive
constant axial piston pumps reliably in
the new drive concept. But still the new
technology cannot do completely without
hydraulic valves. Legally required safety
functions or the filling of large cylinder
cavities during quick movements require
switchable and partly also controllable valves.
However, the clear and neat structure of the
hydraulic components increases the ease of
service and maintenance many times over
compared with conventional drives, and
troubleshooting can be carried out much
more easily and quickly.
Hydraulic servo direct drive of a
LASCO die forging hammer
The converters of the “servo hammer” with
intermediate circuit and energy storage
replace the accumulators – an essential
progress compared with the conventional
hydraulic double-acting drive.
At first glance the new drive differs only little
from conventional solutions. A servo motor
equipped with constant pump generates
pressure and oil volume. Following the cycle
of the hammer ram, four cartridge valves
control the oil flow from the upper side of
the piston during the blow onto the ring
side of the piston during the up-movement.
Another servo motor, coupled with a hydro
motor, takes the function of the generator.
The displaced oil during the up-movement
on the upper side of the piston or during the
blow below the ring side of the piston drives
the hydro motor, which in turn drives the
servo motor as generator. Using this principle,
electric energy is constantly fed into the
intermediate circuit of the converter and is
available to the following movement.
The new drive concept was presented at the
Forge Fair 2015 in the USA for the first time.
The prototype is currently being tested.
Hydraulic servo direct drive - the advantages at a glance
4

Excellent controllability of the servo motor with regard to speed, torque and position

Very easy service and maintenance

Much better energy balance due to a degree of efficiency of the servo motor of >90% (cos phi = 1)

Standstill of the servo motors and pumps during standstill of the die forging hammer

Simplified diagnosis due to clear drive design

All setting data allow digitized storage and documentation
Know-how
ogy for die forging hammers
Electric linear drive hammer
Intensive discussions have been going on
for some time now regarding the linear drive
hammer as a variant type of the “servo drive
hammer”.
The drive variant “LASCO linear drive” is
another research project besides the “hydraulic servo direct drive” in the field of
alternative drive technology for die forging
hammers. The drive has been developed,
however practical tests still remain to be
carried out.
Basically there are two types of linear
drives: the “synchronous linear drive” and
the “asynchronous linear drive”. The primary
and the secondary part of the linear motor
correspond with the stator and the rotor of
the rotary motor. Distinctive feature is the
type of the secondary part. Whereas the
secondary part of the synchronous linear
drive is equipped with a permanent magnet,
the secondary part of the asynchronous drive
is designed as squirrel cage rotor. Both follow
the same principle: A magnetic travelling field
running along the inside of the primary part
sets the secondary part in motion.
The modern hydraulic LASCO HO-U drive
uses a flexible connection of the piston rod
with the ram. This basic idea of a flexible
connection has been developed to the
point of perfection over the years and will
be adopted for our new development of the
linear motor. Our solution includes a similarly
flexible connection of the secondary part with
the ram, as it is realised with the piston rod.
The transverse and impact forces inherent in
the system are thus considerably reduced.
The permanent magnets of a synchronous
linear drive are the weak spots of this
concept, as they must be connected with the
ram durably. In case of standard synchronous
motors the magnets are glued on. High shock
values and insufficient cooling can dissolve
this connection, which can lead to major
motor damages. The permanent magnets
develop high attractive force and must be
protected against pollution, especially by
metallic contaminants. Due to the working
conditions of the die forging hammer this
point has to be given special attention. Repair
work also requires special caution, and the
service personnel must be specially trained.
Linear drive of a
LASCO die forging hammer
5
Internal
25 years with LASCO
Thomas Koppitz Michael Rauscher Detlef Schmidt
Walter Reißenweber Roland Martin 01.01.2015
01.01.2015
17.01.2015
19.03.2015
01.04.2015
40 years with LASCO
Karl-Heinz Fuchs
01.04.2015
Recently retired
Bernhard Präcklein
31.05.2015
Sadly mourned
Emil Müller
Jürgen Heß 23.05.2015
10.06.2015
More welcoming bistro for our staff
An employee survey on the future catering concept was carried out last year by LASCO’s works council
on behalf of the managing board to consider staff requirements as much as possible. The evaluation
of the survey by the architect’s office Eichhorn, Coburg, clearly suggested the concept of a bistro.
This was realized with a bistro kitchen following the latest technical and hygienic standards with an
integrated counter for light meals, salads and various hot dishes. The LASCO bistro is conceived to
be a place where both employees and visitors can communicate with each other at ease. The tasteful
exterior completes the overall picture of the “LASCO meeting place”.
LASCO enhances commitment in Russia
Service support centre opened
LASCO is getting nearer to its
customers in Russia.
Fairs + dates
The newly founded OOO “LASCO
Umformtechnik Service” (ul.
Elektrozawodskaja 5, dom 8 – 600009
Wladimir) in Wladimir – conveniently located
as regards transport facilities between
Moscow and Nishni Novgorod - opened up
in July. Rainer Scheler (picture), graduate
mechanical engineer with many years’
experience in Russia, was appointed General
Director. He will be working on site. By
establishing this company we want to express
our intention to expand
LASCO’s service activities
in Russia. It will be located
in a part of a building with a
factory area of approx.
450 m2 at first. The
conversion work for the
access road and the communications ports
have largely been completed. Service staff
will be hired and a stock of spare parts will be
built up. Furthermore it is envisaged for later
on to carry out repair work in Wladimir and to
complete assemblies and machines as well.
ChinaForge Fair
Shanghai, China
16. – 19.09.2015
EMO
Mailand, Italien
05. – 10.10.2015
Senafor
Porto Alegre, Brasilien
07. – 09.10.2015
Respectable performance of LASCO apprentices
up grade
Volume 18, issue no. 34 – August 2015
Publisher: LASCO Umformtechnik GmbH
Hahnweg 139 - 96450 Coburg
Senior Editor: Dr.-Ing. Stefan Erxleben
Photos: LASCO Umformtechnik, Sternberg
GmbH, Georg Weber.
6
LASCO apprentices have again attracted attention with their respectable performance. The ten
participants in the final exams at the Chamber of Commerce and Industry in winter 2014/2015 reached
an average mark of 2.0. The best mark was attained by Lukas Hannemann, who is taking part in an
integrated degree programme at LASCO. Like his nine colleagues he now received a skilled worker’s
certificate (as electronics technician). At the end of his studies at the University of Applied Sciences in
Coburg he will graduate as Bachelor of Engineering. In the picture (from left): Björn Bühling (training
supervisor), Frederik Wegener and René Reißenweber (industrial mechanics), Simon Göckel (cutting
machine operator), Lukas Hannemann, Fabian Fischer and Nikolai Engelhardt (electronics technicians),
Marius Kinhirt and Moritz Rudolf (industrial mechanics), Maximilian Vogler (cutting machine operator),
Felix Heimrich (design draughtsman) as well as Julian Spindler and Georg Pfeuffer (training supervisors).
Internal
Four former LASCO apprentices are now graduates in business management (VWA)
Diploma acquired
Four former apprentices have
successfully completed their
advanced further training
qualification as graduates in
business management (VWA) –
in extra-occupational studies!
The “Dual Vocational Training System”
in theory (vocational school) and practice
(training company) Germany is envied for
by numerous countries has recently been
expanded: Young qualified personnel have
now the opportunity to combine their jobs
and the attendance of special lectures at a
University of Applied Sciences and to qualify
for responsible tasks after having acquired a
degree.
Four young industrial clerks of LASCO did this
successfully: Luisa Wachsmann (23), Steffen
Müller (26), Mario Giuffrè (28) and Faruk
Ciritoglu (24). They attended lectures in
Business Administration and Economics, Law
(Private and Public Law) and Quantitative
Methods of Management for 3.5 years (7
semesters). For this reason their path did
not lead them home but to the University of
Applied Sciences in Coburg after office hours
at LASCO on two to four evenings per week.
There they gained extended knowledge in
units of three hours each. They also had to
take several course-related exams at the end
of each semester in which their academic
achievement was assessed. After having
passed the final exam and written a thesis
Mario Giuffrè, Steffen Müller, Luisa Wachsmann and Faruk Ciritoglu (from right) seized the op-portunity
for their advanced further training qualification at LASCO with discipline and perfor-mance. After 3.5
years of extra-occupational studies and passing their final exams they received their diplomas as
graduates in business management (VWA). Gernot Losert, Managing Director Administration/Production
(left) and Lothar Bauersachs, Managing Director Engineering/Sales (right) were one of the first to
congratulate them.
the four graduates received their diplomas in
economy and are allowed to hold the title of
“graduate in business management” (VWA)
now.
One of the first congratulators was LASCO’s
Managing Director Administration/Production
Gernot Losert. He congratulated the
graduates also on behalf of the company
management and their colleagues and was
pleased that their high share of hard work,
discipline and free time they invested has
been worthwhile for any of them and that it
has opened up the way for their future career
in the company.
Physics lesson at the mechanical engineering company
Once again LASCO’s assembly halls became the “physics classroom” for grammar school students.
The project “School physics meets mechanical engineering” initiated by the Chamber of Commerce
in Coburg made it possible for 15 young people from the “Albertinum” grammar school to visit the
company LASCO in order to take part in a workshop on the technology of screw presses. They practiced
the sizing of a screw press for the production of flanged shafts in formula calculation without IT-support
and verified the results both in a computer simulation and in a practical demonstration. Jochen Günnel,
Deputy Sales Director (left), saw to the guests who were accompanied by their headmaster OStD Stefan
Adler and physics teacher OStR Thorsten Geißler. The picture shows the visitors during a tour of the
plant in one of the assembly halls together with Lothar Bauersachs, Managing Director Engineering/
Sales and Gernot Losert, Managing Director Administration/Production (right).
According to Gernot Losert the “Dual
Vocational Training System” realised in
extra-occupational studies is an important
instrument for securing LASCO’s demand
for skilled and executive personnel in the
medium and long term. For this reason
the company is promoting such a kind of
advanced further training qualification as
well as the “Integrated Degree Programme”
(combining vocational training and university
studies) offered by universities. He pointed
out that degrees which can be acquired this
way are superior to conventional university
degrees. Thus the “Dual Vocational Training
System” is not least for this reason a most
interesting alternative to the purely academic
education for young people, as the extraoccupational way ensures both regular income
and subsequent employment. In addition
employers also appreciate the practical
experience of the graduates.
All four graduates in business administration
(VWA) already completed their commercial
vocational training at LASCO after having
finished school. Luisa Wachsmann has taken
responsibility as training supervisor of the
commercial apprentices and performs her
tasks in commercial administration. Mario
Giuffrè was appointed department manager
of the shipping/incoming goods department.
Steffen Müller is engaged in highly
responsible tasks in financial accounting.
Faruk Ciritoglu is entrusted with demanding
tasks as the deputy head of the costing/cost
accounting department.
7
In practice
Sternberg forges big bolts
Wolfgang Naumann
Executive Partner
Sternberg GmbH
Hohenstein-Ernstthal
Benchmark for
the industry
up grade: Mr. Naumann, what parameters of
the LASCO forging line are especially important
to Sternberg?
Wolfgang Naumann: We hope you’ll
understand that we do not want to disclose
them for competitive reasons. I can tell
you, though, that we stated our aims
regarding quality and productivity together
with a number of requests regarding control
technology, ease of operation as well as
special requirements in our specifications.
This was the basis for searching and selecting
suitable machine manufacturers. Very quickly
we then exclusively talked with LASCO
engineers about details, modified the project
also with regard to feasibility and finally
realised it.
up grade: What do you especially appreciate
about the technology delivered by LASCO?
Naumann: The innovative forming unit has
satisfied all expectations for more than two
and a half years in continuous operation
now. This is appreciated by our staff as
much as the high ease of operation as well
as the perfect integration into our production
environment and the relevant processes.
Fast right from
the start
Sternberg GmbH in Hohenstein-Ernstthal (Saxony/Germany) produces
big bolts very successfully with innovative LASCO technology such
as the first horizontal double-pressing unit HDPV 100.
Sternberg produces fasteners for wind
generators. Extremely robust and reliable
bolts up to size M72 are required for these
modern systems which are used for the
production of renewable energy.
LASCO screw presses are ideally suited for
forging on bolt heads. Sternberg’s visions
of production went far beyond this process
step, though. They were aiming at a fully
automatic solution optimally connecting the
following production steps in a fully automatic
line: heating up the billets made from round
steel (length up to 620 mm, diameter up to
72 mm), forging the bolt heads, chamfering
the bolt ends and finally cold drawing for
the subsequent thread-rolling process. The
essential parts of the forging line are a
LASCO screw press SPR 800, an inductive
heating system with 8 heating stations,
a double-milling machine, the doublepressing unit as well as numerous other line
components for automation. The horizontal
double-pressing unit HDPV 100 was
developed by LASCO with the involvement
of Sternberg and the Fraunhofer Institute of
Forming Technology in Chemnitz (drawing
dies) for the special requirement of cold
drawing (diameter reduction). The special
press can be used both for drawing and for
trimming.
The line, put into operation at the end of
2012, reaches an output of up to 180 M72
bolts per hour. The time needed for the
partial heating of the steel billets is acting
like a “brake”. Thus using a second induction
system the cycle time can be doubled of
course.
up grade: Where do you see Sternberg’s
strength and competitiveness?
Naumann: With the new forging line we set
the state-of-the-art regarding the parameters
“production”, “flexibility” and “energy
consumption”. At the same time it is opening
up the opportunity of producing forming
parts other than bolts, too. We are pleased to
answer any questions from prospects and are
looking forward to receiving enquiries from
potential customers.
Five specially adapted industrial robots enable a fully automatic production process at Sternberg.