Pressmac specializes in the design, production, and development of machines in the field of stamping and welding. The company relies on control and drive technology from Siemens for a new model of an extremely fast and flexible NC (numerical control) slide machine for stamping and welding tasks. Cycle times can now be improved by up to 50 percent, resulting in faster production rates. In addition, the solution speeds up retooling by 75 percent, thereby doubling the setting range of the previous model, and ensures a high standard of quality thanks to extremely precise processing at every step.
Pressmac developed a completely new concept for the CMP 400 NC slide machine that replaces mechanical cams with numerically controlled axes. This allows strip material to be processed while applying tremendous bending force. Pressmac uses a seamless solution from the Siemens motion control portfolio to control and drive up to 16 of these axes, thereby achieving setting ranges and infeed speeds that were impossible in the past.
Seamless and clever overall concept
The motion control of the CMP 400 is performed by a Simotion D455-2 motion controller. The motion controller specifies electronic cam disks for all the individual axes and subsequently synchronizes all process steps. This ensures highly precise production. The axes are each driven by a high-torque water-cooled Simotics S-1FT7 motor and Sinamics S120 converters. "For the linear slides, we have a setting range of 120 mm – before, it was 60 mm. That gives us more options during processing. We also reach a high speed of 300 strokes per minute when feeding in strip material, and tremendous forces of 40 metric tons on the press module," says Marcel Becker, Managing Director at Pressmac. The entire unit is controlled by a failsafe Simatic S7-1512F, including the LDrySafe library, which facilitates the implementation of all safety-related applications. Simatic ET 200AL and ET 200SP distributed I/O modules, which read in and output standard and safety signals, complete the system.
Precision and speed optimize production rates
Thanks to the new seamless solution, Pressmac can achieve 50 percent faster cycle times of 150 to 180 cycles per minute and 75 percent faster retooling times with the new CMP 400. This speeds up production rates significantly. The 100 percent longer setting range improves design flexibility and, thanks to the synchronization of all process steps in the Simotion motion control system, highly precise production and fast retooling are possible. "Switching to a completely different system was not easy, especially in the narrow timeframe for implementation. It was important to us to launch not only a unique machine but a machine using standard elements without any "teething problems." The Siemens teams provided us with excellent support to help us achieve our goal," concludes Becker.