AUTOMATION OF A PRODUCTION LINE
FOR FLASHLESS PRECISION FüRGING
J, Pilgrim
Weidmuller ConneXt GmbH, Detmold, Germany
B. Mussig and B.C. Schmidt
University of Hannover, Hannover, Germany
KEY WORDS: Automation, Precision forging, Decentralised control system, Finishing accuracy
ABSTRACT: Automation is an important approach to achieving more economical production
systems. But most automated production lines are inflexible. Flexibility is an essential topic for
manufacturing lines which have high machine costs and whose various products are made on
variably combined aggregatessuch as forging lines for example. For the innovative technology of
flashless precision forging an automated production line has been developed at the IPH - Institut
für Integrierte Produktion Hannover to demoostrate a new concept of flexible automation in
forging. With the flashless forging process gearwheels are produced in one forming step with such
precision that only final grinding after forging is necessary.
All aggregates needed for the complete process chain such as material handling, heating system,
forging piece handling, die cooling and lubrication system, forging press, heat treatment and
clipping press are inter-connected via a field bus and controlled by decentralised CAN-Bus-
components located directly at the machines.
One advantage of the decentralised CAN-Bus-technology compared to conventional central control
is the possibility of fast changes of manufacturing aggregates without new wiring of sensors and
actors. Another advantage is the possibility of integrating the existing machine controls. Both
factors contribute a deal to a flexible production line at a favourable price.
All process parameters are controlled in almost real-time by an on-line monitaring system since
they have to be maintained in a very small range of tolerances for the demanded precision. The
visualisation and data processing of the process parameters and process steps allow fast reaction to
problems and enable an effective quality assurance.
Publishcd in: E. Kuljanic (Ed.) Adi'Unced Manujäcwring Srstems and Teclzno/ogy,
CISM Coursesand Lectures No. 406, Springer Verlag, Wien Ncw York, 1999.
454 J. Pilgrim, 8. Mussig and B.C. Schmidt
1. INTRODUCTION
New and innovative methods for massive forming combined with considerab1e
improvement of finishing accuracy require high-technology manufacturing concepts.
Today, forging parts can be produced with such precision that fimctional surfaces areready
for installation. This requires a high constancy of the quality relevant process parameters
and extremely small tolerances of tools and handling systems. A solution for this problern
is a fully automated and reproducible production process which ensures an improvement of
the process stability and thus manufacturing with higher accuracy.
Furthermore, production lines should be flexible and easy to configure to be able to fulfil
the customers' wishes such as just-in-time-delivery and wide product variety, together with
1ow batch sizes. Because of the otherwise high investment costs it makes sense to use
existing equipment and its installed controlling systems as far as possible. The opportunity
to install and exchange parts of the production line must exist. A non-central concept for a
controlling system shall meet the demands mentioned above.
The first step for introducing automation is an analysis and an assessment of the existing
production line. According to that, the interfaces will be determined. The second step is the
compilation of a detailed Iist of requirements which contains the necessary steps based on
the analysis of the production process. Starting from there, the automation is designed in
order to achieve a flexible solution which is compatible with the existing Controlling
systems. The last step is the implementation, the commissioning and the testing of the
production system.
2. OBJECTIVES
The subject of this research is the automation of a flashless precision forging line for
gearwheels. The gearwheels are formed in one step. The demands on the automated forging
line are flexibility, easy adjustment of parameters via PC-based monitoring, reasonable
price by integrating of existing machinery and resistance against adverse workshop
conditions. Moreover, the automationshall assure the required reproducibility and accuracy
of the forging process. The prerequisite is an automated handling device for the exact
positioning of workpieces in the die and the monitaring of relevant parameters that
influence the process, for example forming temperature and force. The accuracy of the
forging parts, the defmed material characteristics as weil as high productivity can only be
gained by controlled heating combined with automatic selection of incorrectly warmed
workpieces. During the start-up of the line most workpieces do not reach the correct
temperature. They have to be separated. After the forming process the material gains its
desired characteristics by controlled heat treatment on a cooling conveyor. Pieces that are
submitted to an incorrect march of temperature while being cooled down, have defective
material characteristics and must also be separated.
Working cycles of about 15 to 20 seconds and process transparency for trouble shooting
are demanded for economic production. Because just-in-time-delivery will be required
more often in the future, it can be expected that the batch size of forging parts will