Product News: Machinery & Machining Tools

High-Speed Press facilitates electric motor production.

Press Release Summary:

Dec 13, 2012 - Featuring temperature-controlled, cast iron body, Smartline SA-S can blank out electric motor laminations that are .007 in. thin. During same process step, individual laminations are interlocked into stacks, which form core of electric motor. Depth-penetration control software assesses distance between slide and lamination on every stroke, adjusting accordingly for precision manufacturing. Centrally controlled and operated via Smartline's control monitor, FeedMax servo feeder operates at 328 fpm.

Schuler Group - Canton, MI

Original Press Release

Schuler Highlights New High-Speed Press for Electric Motor Production at FABTECH 2012

Press release date: Nov 12, 2012

Smartline SA-S increases output up to 30 percent and stamps out laminations which are .007 inches (or 0.2 millimeters) thin

Canton, Mich., - As the automotive industry continues to develop more advanced technologies, eventually, electric motors could replace traditional combustion engines as a means of powering the world's vehicles. As a result, the need for manufacturing machines to produce these motors is expected to boom in the coming years. To meet this demand, Schuler has unveiled its new high-speed press, the Smartline SA-S, which minimizes process steps, improves precision and increases production of highly efficient electric motor laminations.

The Smartline SA-S can blank out electric motor laminations that are .007 inches (or 0.2 millimeters) thin. During the same process step, the individual laminations are interlocked into stacks, which form the core of the electric motor. Due to the machine's ability to produce thinner laminations, the eddy current losses are reduced, improving vehicle and fuel efficiency.

"As the global leader in metal forming technologies, we continue to provide manufacturing systems, tooling, services and process expertise that help to revolutionize the industry as it continues to advance the capabilities of today's engines and vehicles," said Tim McCaughey, president and CEO of Schuler Inc. "Through our expertise, we've developed a forming process that eliminates crucial time barriers in order to better streamline production and maximize efficiency."

Fine tuning within fractions of a second
Although it weighs several tons, the machine's slide must work precisely within tolerances of hundred thousandths of an inch (or hundredths of a millimeter) – a tall order considering speeds of several hundred strokes per minute and a press bed on which the die is clamped up to 10.8 feet (or 3.30 meters) (SA-315S-3.3 and SA-500S-3.3). Such precision cannot be guaranteed by the rigidity of the press alone, which consists of a temperature-controlled, cast-iron body, nor by the play-free slide guiding system. Instead, the depth-penetration control software assesses the distance between the slide and lamination on every stroke, adjusting accordingly for precision manufacturing. Therefore, the slide's bottom, dead-center position remains constant, helping to control interlocking. The electronic system is located in the press body, as compared to traditional placement in the slide, protecting it from potentially problematic vibrations.

Conventional presses often work until the slide is abruptly stopped and the machine is overloaded, causing harsh effects on the machine and die. Until recently, the alternative was to decrease possible overloads by manually measuring and adjusting. Now, with Schuler's Smartline press system, the entire process from measurement to adjustment takes just a few hundredths of a second, eliminating process steps and simplifying set-up after die changes, which results in greater efficiency while ultimately reducing potential damages to both components.

Torsional drive optimized
The electronic system also improves production output by up to 30 percent, maximizing performance and streamlining efficiency. With traditional systems, there was a bottleneck in the turning chamber making the stacks, which rotated individual laminations by up to 180 degrees in order to balance out any surface irregularities. Now, the optimized software in conjunction with the servo motor ensures forming remains in sync with the rest of the machine by guaranteeing smooth acceleration.

With a performance of 328 feet (or 100 meters) per minute, the servo feeder "FeedMax" also can handle high speeds. Together with the coil line, press and interlocking die, it is centrally controlled and operated via the Smartline's control monitor, ruling out any potential interface problems.

With its innovative systems, Schuler is delivering the most cutting-edge manufacturing techniques to benefit automakers around the globe.

Kellie Treppa
Schuler Incorporated, Manager, Marketing Communications
Phone: 734-207-7230

About the Schuler Group
Schuler is the global leader of innovative metal forming systems and technologies, which enables the company to deliver highly-productive solutions that positively impact profitability, flexibility and efficiency for its customers. The company supplies equipment, turn-key production lines, dies, process consulting and services for the entire metal forming industry, including car manufacturers and their suppliers, as well as companies in the packaging, household equipment, forging, aerospace and defense.

Schuler is also the market leader in coin minting technology. The company employs 5,500 people and operates facilities and sales offices in 40 countries around the world. The Schuler Group includes Muller Weingarten, which it acquired in April 2007.

Schuler Incorporated, headquartered in Canton, Michigan, represents the Schuler Group in North America. The company offers sales management and project coordination for state-of-the-art metal forming system solutions. Its after-sales service, spare parts, PM programs, and retrofit and rebuild programs are able to support new and existing metal forming systems. Schuler Inc. also offers a full spectrum of hydroforming services, including part design, FEA analysis, consultation, prototyping and commercial production for both large and small quantities.

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