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Efficient, economical and reliable automation.

The historically grown core processes of ball cage and steel wheel manufacturing machinery and services, as well as customers' needs with regard to applications such as production of heads or

forged parts have one thing in common: comparably large forces in unusual environments. Ball cages with a wall thickness up to 6 mm or wheel discs of truck wheel rims with a sheet thickness of 16 mm require solutions that are not always typical for the market. Therefore, Georg Maschinentechnik manufactures high-value and durable solutions.

Siemens has been the strategic partner of Georg Maschinentechnik for decades. Hardware and software that can be internationally serviced by our customers as well ensure best plant availability and customer satisfaction in an intercultural environment and global time zones.


SYSTEM PLATTFORM

Based on the Siemens-S7-1500-TF modules, we implement safe presses and cell solutions. High-performance servo drives with synchronous/asynchronous motors or a torque motor are part of our drive landscape via Profinet and IO-link. Our customers profit from our internal control cabinet manufacturing. This enables us to efficiently adjust to the individual electrical execution provisions of our customers. They include:

//   Component selection
//   Wiring provisions
//   Free spaces in the control cabinet
//   Execution of the minor devices

Project planning is implemented with certified safety components that correspond to safety class SIL3 according to EN 62061 or according to EPL e EN ISO 13849-1. PC controlled units are also possible on the customer’s requirement. Project planning guideline:

//   Creation of the control software in the Siemens TIA Portal, Step 7
//   Visualisation in the TIA Portal with WinCC taking efficient and well-structured operation into account
//   Programming languages according to IEC 1131-5, Structured Text (ST), function plan (FUP), command list (AWL)
//   Connection to master control systems


SAVING ENERGY

We look at the energy requirements of a press in project planning in an integrated fashion, i.e. including losses in the interim circuit of a servo press and losses in the secondary flow of a hydraulic press. The strict separation of power lines and signal lines leads to an elaborate but operationally safe cable routing at our machines.


PRODUCT RANGE

In essence, our automations are representative of the design principles underlying standard solutions of machines commonly found on the market of a more solid build. Our product range for special applications in forming technology include:

//   Coil lines
//   Stacking and destacking plants
//   Transfer Systems
//   Robot Solutions
//   Gantries for Pick and Place Automation
//   Loading devices
//   Unloading devices
//   Manipulators
//   Special-purpose machines
//   Die change devices
//   Sorting and feeding devices
//   Performance increases
//   Function extensions
//   Industry 4.0 / Internet of Things IoT


MANIPULATORS

Gripping and introduction of the parts to be formed is an important part of automation. Typically, suction devices are used in sheet metal forming in combination with robot automation or gantries. In progressive die presses, parts transport takes place via the roll feed in combination with search pins and holes at the continuous strip. Transfer presses transport the parts from station to station with tongs as well as an alternative to suction devices. There are common solutions on the market for sheet metal forming.

For the more solid applications, e.g. in the forge, in production of heads or in production of steel wheels, we develop our own precise manipulators and grippers.


PLANT ENGINEERING

Increasing demands on productivity in production plants is now a topic for global debate. Economic growth in emerging countries has brought with it a rise in their labour costs. Georg Maschinentechnik solves this task with control modules that are assembled into cell control units or overall plants and that can be supplemented by customer-specific solutions.

Linking in the ball cage industry is similar to the linking of machine tools. The resulting machine comprises linked belts, conveyors and different Poka-Yoke systems as well as other quality-assuring mechanisms.

In the hot area of the forging industry, manual intervention with tongs is often at the centre of the protection concept of the plants.


SPECIAL-PURPOSE MACHINES

We also produce special-purpose machines, such as pipe frame bending machines for producing frames to take up Industrial-Bulk-Containers (IBC) of plastic, in cooperation with our customers. We supply parts for blow-forming machines for this product as well.


DIE CHANGE DEVICES

Stationary die change devices for inserting and removing dies with weights of up to 15,000 kg are tasks that match our table sizes. These dies are usually removed with external lifting gear. Rail-bound die change carts for die weights up to 15,000 kg are also part of the Georg product range. It is important to note that typical two-point presses have no moving bolsters as they are known from car body presses.

The importance of both container management and die change when planning a plant often surprises laymen. The die change system comprises the following essential items

//   Centring
//   Identification
//   Plug-in screw Connection
//   Die clamping
//   Die insertion and removal
//   Die transport to and from site


SORTING AND FEEDING DEVICES

Supply and feeding devices for pipe sections upstream of an automated ball cage forming press are some often-used standard solutions. A supply of parts that is somewhat unfamiliar in classical forming technology can be found, for example, in ball cage production and when introducing connections in pipe frame bending machines.

Hoppers, separators and vertical conveyors, as well as synchronous conveyors, are some typical machines here.


PERFORMANCE INCREASE

The expansion of our customers' product range in forming technology is often driven by international competition and increasing market demands. This is usually about larger cross-sections and higher material strengths. Because of these, existing plants reach their limits and their products and services must be expanded.

One example here is the mandrel of a single-side uncoiler. Design changes and FEM calculation enabled the customer to considerably expand his product range.


FUNCTION EXTENSION

While the adjacent modification refers to expanded products and services, a function extension of the automation or machines may also be required in order to react to higher demands.

The illustration shows the die cushion and ejector device with the active pull function. Retrofitting, e.g. of a hydraulic 10,000 kN press, enables the customer to apply additional process steps.


INDUSTRY 4.0 / INTERNET OF THINKS IOT

Where there are existing structures and where an MES in the press shop may be missing, the start into digitisation via a usable function on site ("Edge") may be of benefit. Based on this insight, we have developed the Edge Data Analyzer EDA.

The concept of the solution for digitisation of press shops by Georg Maschinentechnik takes particular account of the durability of top class presses like those produced by Georg Maschinentechnik. Therefore, both analogue and digital signals with different protocols of several generations of control units are the basis for digitisation by Georg.

The largest part of the analysis (static or neuronal) takes place locally and in a fail-safe manner. Communication is the important module of the cyber-physical systems. It takes place, e.g., via XML interfaces that must be adjusted individually for further integration into superordinate systems. The data are displayed as a quick overview at the EDA and as fully functional display in HTML5 format either on the screen of the press (HMI) or on external equipment.

The EDA is not competing with superordinate systems such as SCADA, MES or ERP. The EDA rather prepares the data of any press of any brand or age with specific knowledge programmed by a press manufacturer, develops forecasts already at the machine and displays them. The EDA is particularly beneficial for medium-sized press shop operators who are looking for initial experience and use in the area of Industry 4.0 / Internet of Things IoT.

Please visit our separate website for the Edge Data Analyzer EDA:

www.eda.biz