Press technology Availability as the highest good

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Only when it runs does it make money. A press has to work and produce output. You don't want damage to it or the tool. Therefore, BSH has again invested in servo press technology with adjusted peripherals.

If the cake tastes good, you bake the recipe again. If you are satisfied, you repeat. Investments for example. This is also how BSH Hausgeräte GmbH does it in its press shop. After the first servo press of the DSF-TE4 type from Aida in the 800-ton class moved to the Traunreut site in 2018, the second one followed at the beginning of this year. The largest appliance manufacturer in Europe uses the presses for the production of, for example, components for oven and stove housings. Approximately 5.5 million parts per year are produced on each press.

The new press, called "Aida 2", is the replacement for two old stocks from the 60s. Of course, current servo technology means increased efficiency, a better energy balance and higher output at this point. And the problem of spare part availability is also solved for years. Aida 1 and 2 are considered standard platform presses: The tools of the 800-ton class are interchangeable, which is a huge advantage for BSH. This also makes the provision of spare parts for the tools much easier. Since the controls are almost identical, the new system was also a walk in the park for the machine operators to learn.

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Technical availability at 98 percent

Like the first one, the second press is also pimped with some intelligent solutions, which serve solely to increase the availability of the plant to the maximum. For example with the sensor solutions from Consenses: Among other things, linear sensors, acceleration sensors and force measuring screws are installed. With their help, Christian Mayer and Sascha Radloff (both Factory Cooking Traunreut) gain data from which, in short, measures can be derived that improve the longevity of the press and the tools. The system is complemented by a press force monitoring from Unidor.

For band lubrication via a spray system, BSH relies on Raziol, the transfer solutions come from Hagel Automation and the band layout was supplied by Schuler. Band widths from 160 to 1400 millimeters are processed. A new generation of motors from Aida makes the 2 even more dynamic than the 1. "Just because of the new drive, we have a 15 to 20 percent increase here," Mayer is pleased. "With the Aida 2, up to 40 strokes per minute are possible." Since all involved faculties have worked hand in hand in the interests of the customer, Radloff and Mayer can already look at a technical availability of the plant of 98 percent directly after commissioning.

Maintenance of press and tool

In addition, both Aida 1 (retrofitted here) and Aida 2 (from the start here) are equipped with Visual Die Protection from Schuler. The camera-based monitoring system serves to protect against tool damage and machine downtime. The system compares real-time images of the tools. If it detects an anomaly (such as a fallen out stamp), the press stops immediately - even before closing the tool. "This way we avoid costly tool crashes," explains Radloff.

The 4.0 solutions that BSH has installed all interlock and primarily serve to maintain the health of the press and tool. If there is no anomaly that Visual Die Protection detects, something can still happen in the press. Mayer explains: "Consenses helps us see what happens to the tool during a stroke. Here we detect the forces of the individual strokes in the millisecond range." This way conclusions can be drawn - for example, how a tool is best balanced. "Especially when a new tool is introduced, we can thus, for example, track tilting."

A comparison of Aida 1 and 2 is also possible thanks to the data. "In the best case, it should always be shown that the tools behave the same on both presses," says Mayer.

Save time when setting up

Only in one point does the new press have the edge over its older sister: When setting up, the BSH team is faster on the Aida 2. It is tooled approximately every 3 to 4 hours, the process is semi-automated. Here, the machine operators do not need 15 minutes. That's 5 minutes faster than with the Aida 1. "One reason for this, for example, is that the ram on the Aida 2 can be adjusted faster for setup. In addition, thanks to a second tool change car, we can set up in parallel here. We designed it this way in the construction phase," reports Mayer.

Mayer and Radloff are very satisfied with this project. 4.0 solutions coupled with servo press technology mean productivity, efficiency, and cost reductions for BSH.