25,000-Kilonewton Press Successfully Commissioned Efficient Tryout Solutions for the Automotive Industry

Related Vendors

Maschinenfabrik Lauffer GmbH & Co. KG

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

SIMTOS (Seoul International Machine Tool Show)

Tryout presses play a crucial role in sheet metal forming and toolmaking. They allow for the setup, testing, and optimization of forming tools before they transition to mass production.

For companies in the automotive industry, this means reduced downtime, increased process reliability, and improved product quality.

Against this background, Wagon Automotive Nagold GmbH, a leading system supplier for sheet metal forming, body construction, and surface coating, decided to invest in a high-performance hydraulic tryout press. The goal was to relieve the existing production facilities and make the tool testing process more efficient.

Gallery

Tailored to Customer Requirements

For the implementation of this project, Wagon Automotive selected Maschinenfabrik Lauffer GmbH & Co. KG as a partner. The machine manufacturer from Horb, with over 150 years of experience, is among the leading providers of hydraulic presses for metal forming. In the joint project, a custom-made tryout press with 25,000 kilonewtons of press force was developed and installed, precisely tailored to the specific requirements of the customer. The challenge was to realize a technically high-quality solution that is also economically viable—particularly since tryout presses are not directly involved in value creation and play a subordinate role in the daily production process.

The delivered system impresses with numerous technical features that ensure flexibility, user comfort, and process reliability. These include a moving table with a table surface of 5,000 x 3,000 millimeters (approx. 200 x 118 inches), an installation space of 2,400 millimeters (approx. 95 iches), and a stroke of 1,600 millimeters (approx. 60 inches). A regulated 6,000-kilonewton 4-point draw cushion in the table with a 400-millimeter (approx. 16 inch) stroke and 4 individually controlled cylinders provides sufficient capacity for drawing operations, as the multi-point cushion allows for individual adjustment of the draw cushion forces on the blank holder at 4 points.

Reduction of Mechanical Stresses

The press also features a 3,000-kilonewton ram cushion, which further increases flexibility in complex forming processes. A 4-point impact damping system significantly reduces mechanical stresses on the tools, thereby contributing to the longevity of the components used. A spotting function via joystick enables precise setup through intuitive operation, while comprehensive analysis tools such as envelope monitoring and process diagnostics support quality assurance. At the heart of the system is Lauffer's proven La-HMI control system, which impresses with its powerful visualization, ease of operation, and high diagnostic depth.

As a flexible supplier, Wagon is thus able to produce with several hundred forming tools from various customers in the car and truck segments in such a way that the specific requirements and respective load distributions for a highly accurate drawing process can be precisely replicated.

Additional Production Capacity Gained

A key factor for the successful implementation of the project was the international collaboration with an established Chinese press manufacturer. The cooperation has existed for over 35 years and has been significantly expanded in recent years.

Thus, the mechanical part of the press was realized cost-efficiently, while Lauffer fully implemented the design of the hydraulics, the safety-relevant components, and the control system. The assembly and commissioning of the system were carried out by experienced Lauffer technicians directly on-site at the customer's location. Project management and quality assurance were also handled by Lauffer. This model combines the advantages of global manufacturing with German engineering and project management. For service, the customer benefits from the high expertise and local proximity of the Swabian press manufacturer.

The investment also resulted in numerous additional advantages. By outsourcing tool tests, repairs, and maintenance to a separate tryout press, additional production capacity is freed up on the serial production systems, positively impacting overall equipment effectiveness. Furthermore, the new press allows for testing tools from external customers—an additional financial benefit. Lastly, the project's cost-effectiveness was also convincing, delivering a high-performance large press with German control and high availability at an attractive price-performance ratio.

Close Support During the Project Phase

"With Lauffer, we not only found an economical solution but also a partner who understood and professionally implemented our requirements. In particular, the reliable and close support during the project phase convinced us of Lauffer," summarize the project managers Volker Koch and Sebastian Merkle from Wagon.

The project is also regarded as a success on the part of Lauffer. Jürgen Deutschle, Head of Project Management at Lauffer, explains: "The close coordination with the customer and the combination of our experience with an efficient manufacturing approach have demonstrated how high-performance press solutions can also be implemented from an economic perspective."

The project illustrates how strategic partnerships and clear responsibilities can lead to customized press solutions that are both functional and economically compelling. For Lauffer, the successful implementation serves as further evidence of its expertise in hydraulic forming presses, ranging from compact workshop solutions to complex turnkey systems. In the future, topics such as automation, press lines, and system solutions will be the focus to provide even more comprehensive support to customers in the automotive and supplier industries.

*Hannes Gutekunst, Sales Manager Forming Technology, Maschinenfabrik Lauffer

Secure and Compliant Authentication in Laboratories

Secure & Contactless User Authentication at GMP/GLP