Transfer Presses Precise Oiling for Maximum Process Safety

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BSH Hausgeräte GmbH

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BSH Hausgeräte GmbH in Traunreut, Germany, produces around 140 million sheet metal parts per year for all its plants in Europe on 13 presses weighing between 80 and 1,000 tons. The contactless lubrication systems are all supplied by Raziol.

The vertical range of manufacture in Traunreut is enormous and the machinery is impressive. The press shop includes machines from Andritz, Erfurt and Aida. Parts for stoves, hobs and ovens, for example, are manufactured here. The majority of the tools used come from the company's own tool shop in Traunreut, Germany.

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BSH has been working with Raziol for lubrication solutions for 25 years and now works with Raziol in many pressing plants worldwide, relying on both the systems and the lubricants from a single source. Markus Berngruber, a manager in prefabrication, recalls: "The collaboration here in Traunreut started with a bang in a positive sense - Raziol saved us back then. We had a welding task to complete on the baking ovens, which presented us with challenges, as we were getting oil inclusions in the sheet metal during oven welding, which caused defects after enameling. Thanks to a specially designed forming lubricant from Raziol, we were able to prevent the inclusions. This is where the first spray lubrication system from Raziol came into play."

Belt Lubrication Systems Work Sectorially or Partially

Raziol spray lubrication systems can work sectorially or partially. This means that either a full-surface or strip-shaped lubrication pattern (tailored to the component) can be applied to the sheet metal, both in terms of the local alignment and the amount of oil. Targeted lubrication increases process reliability and reduces lubricant consumption. As BSH has very high requirements for the workplace design of its employees, various Raziol extraction solutions with H13 filters on the press lines help to improve air pollution control in the production hall.

The partnership between BSH and Raziol has now been renewed for the servo transfer presses from Aida. Both sealed and oiled sheets are processed on the systems. Previously, post-processing steps such as extensive cleaning were required for the sealed sheets. "We therefore wanted the conveyor systems to be able to run 100% dry, i.e. reliably oil-free," explains Berngruber. The Raziol team rose to the challenge and worked in partnership with BSH to develop a system that enables the spray chambers to be lowered fully automatically below the pass line of the coil, which achieves the desired effect of 100% drip-free operation. Christian Mayer, production planner at BSH, is very satisfied: "We have already stored the lubrication in the data records of the tools. This means that the spray chambers of the two-chamber system automatically move up and down in the system during set-up. This enables us to achieve maximum set-up times of 20 minutes." This agility is a benchmark in the household appliance sector, which is otherwise only known from the automotive industry. "You could say that thanks to these various Raziol solutions, we have achieved an improvement in OEE of around 3 to 5% per press," says Mayer.

Creation of Alternative Spray Patterns

It is also possible, for example, to measure and record the oil quantities for each feed stroke for the top and bottom sides of the sheets and the nozzle calibration tool enables the actual flow rates of each nozzle to be checked against the target flow rate in ml/min. The option of creating alternative spray patterns is also very popular in Traunreut. A modified spray pattern can be generated in an adjustable cycle. "For example, every 20 parts we additionally spray onto an otherwise unoiled area of the part, as otherwise there would be abrasion in the tool, which would cause surface defects. This feature was a special request from BSH Traunreut and was implemented excellently by Raziol in a very short time," explains Thomas Schillinger, production planner and responsible for all spray lubrication systems at BSH in Traunreut.

The sales managers at  Raziol, Mathias Schmeier and Torsten Simski,  are just as satisfied with the collaboration as BSH. "It is good to understand the systems used with a customer who has such a high level of technical understanding and self-interest. We have a very open exchange of experience with BSH Traunreut - it is impressive to see the technical possibilities that have arisen from this over 25 years of partnership and which are consistently used at BSH."
 This long-standing partnership was also significantly shaped by Raziol colleague Markus Habiger, who, together with the management at the time, was able to win BSH as a customer and provided on-site support for the entire duration of the collaboration. Continuous commitment and a close relationship with the customer are an essential part of the successful collaboration.