DIE-FREE BLANKING IN TODAYS PRESS SHOP

How die-free laser cutting, using DynamicFlow-Technology from Schuler can make your press shop more efficient.

The Laser Blanking line saves space and increases the OEE
The Laser Blanking line saves space and increases the OEE

CUTTING WITHOUT DIES

Laser blanking lines with DynamicFlow Technology (DFT) are a highly flexible, productive manufacturing systems. We use extremely powerful fiber lasers for the continuous cutting of coiled material. The result is a high production rate, a superior cutting quality and an excellent contour precision, even for sensitive outer-body-blanks.

Stacked blanks ready for the forming process
Stacked blanks ready for the forming process

QUALITY AND FLEXIBILITY IN ONE SYSTEM

DynamicFlow Technology makes it possible to cut various materials, such as steel, aluminum and high-strength steels, on the same production line. Even the use of material combinations as AlSi-coated steel coils (hot-forming parts) for car-body-frames, poses no problems for our system.

DynamicFlow Technology for flexible production
DynamicFlow Technology for flexible production

LASER BLANKING WITH DYNAMICFLOW TECHNOLOGY

Thanks to DynamicFlow Technology, cost intensive dies, time-consuming die repairs and die storage are overcome. Backed by Schuler’s years of experience with the specific requirements of the automotive industry, laser blanking lines with DynamicFlow Technology delivers an impressive package of incredibly flexible production conditions at comparatively low investment costs. This makes them a legitimate alternative to conventional, die-based blanking systems in the press shop.

Laser Blanking Lines for producing blanks in the industrial production of tomorrow
Laser Blanking Lines for producing blanks in the industrial production of tomorrow

MODULAR DESIGN OF THE SYSTEM

Schuler blanking lines offer the complete process chain – from coil to blank stack – from a single source. They work with state-of-the-art safety and control concepts. Their modular design makes customized solutions for the individual user possible. All system components have been proven in practice, are precisely aligned with each other and stand for top availability and reliability. Expansions for processing aluminum and high-strength steel can be integrated easily. No matter where the Schuler system will be used – our services are available worldwide.

Schuler Feeding line for smooth material transportation and high flatness
Schuler Feeding line for smooth material transportation and high flatness

MATERIAL FEED FROM THE COIL

Optimized for efficient setup times, our over-floor feed line for coils weighing up to 30 tons and measuring up to 2 150 mm wide ensures smooth material transport, a high level of flatness, and optimal delivery of the material to the laser cell. 

High dynamic cutting heads working on-the-fly
High dynamic cutting heads working on-the-fly

BLANKING WITH SEVERAL CUTTING HEADS ON-THE-FLY

In the laser cell highly dynamic, simultaneously moving laser cutting heads cut the programmed blank contour on-the-fly out of the continuously moving material. These heads realizes cutting speeds over 100 m/min. During the cutting process the material is protected from process contamination by the special transport system and the dynamic cutting gap.

The product specific programs for the blank contours are created offline by an user-friendly software. All material-specific parameters can be easily loaded and contour or nesting can be modified in no time at all.

Excellent blank quality assured by innovative blank cleaning system
Excellent blank quality assured by innovative blank cleaning system

SEPARATING BLANK AND SCRAP

After the cutting process the blanks must be separated from the rest of material (scrap). This is realized by automated systems according to the range of products.  Once separated the blanks runs through a blank cleaning device into the automatic stacking system. Excellent outer-body-quality blanks can be assured.

Stacked blanks ready for the forming process
Stacked blanks ready for the forming process

STACKING THE BLANKS

Stop-2-Drop Stackers and also alternative stacking systems are available to assure excellent pile quality.

TECHNICAL DATA IN COMPARISON

Variants

LBL-2.18

LBL-2.21

 

Coil width

max. 1880

max. 2150

mm

Coil weight

max. 30

 to

Coil material

Steel, Aluminum, High Strength Steel

Coil thickness

0.6 - 3.0

 mm

Coil speed

max. 60

m/min

Cutting head positioning speed

180

m/min

Cutting speed

max. over 100

m/min

Number of lasers

2

Rated power per laser

4

kW

Blank length

max. 4500

mm

Stack height

max. 750

mm

Stack weight

max. 12

to

YOUR ADVANTAGES WITH DYNAMIC FLOW TECHNOLOGY

Where lasers are used to cut blanks, the blank contours are programmed to a programming station that is integrated into the system. These contours can then be loaded, as well as modified and saved at any time. The resulting flexibility significantly accelerates the blank development process while also enabling fast, demand-based manufacturing. This simplifies production planning, reduces the amount of storage space needed, and helps cut logistics expenses. The ability to make simple contour adjustments also provides the necessary degree of optimization within the forming process and opens up new possibilities for cutting a vast array of different contours from the material—all while utilizing as much of the coil width as possible.

Bildbeschreibung am Bild ändern

Cutting blanks directly from the aluminum coil, for example, in a continuous process allows manufacturers to use up to 10% less material compared to the conventional laser blanking method, which uses rectangular panels. In today's industry, both the shape of the blank and the degree of material it uses are also constrained by the inherent limits of die design. Many parts are simply fabricated from rectangles or trapezoidal shapes since these are easy to produce. 

The contour design flexibility provided by CNC programming unlocks new potential for easily achieving optimal degrees of material utilization thanks to the following features:

· Optimized blank nesting on the material line
· Combination of multiple parts on a single material line
· Arrangement of blanks at different angles
· Elimination of separating bars between parts
· Reduced variety of coils since blanks can be freely arranged

Up to 90%, and in some cases even more, of the blank cost is determined by the price of the material used, which can be aluminum, sheet metal, stainless steel or other types of metal, for example. One of the most effective ways to lower this cost is by reducing the amount of scrap produced in the process. Reducing the amount of material that ends up as scrap by just 1% can produce annual savings of up to 1 million euros on a blanking line.

With its laser cutting heads, Schuler’s laser blanking line doesn’t require a below-ground pit, and can be installed without costly foundation work. The costs associated with the transport, storage and maintenance of the blanking dies, which can weight up to 40 tons, are completely eliminated. Thanks to the system’s simple modular installation, blank production can also be implemented in smaller halls and press shops—making in-house or next door production an attractive option, since the costly shipping of blank stacks is no longer an issue.

Profitability is paramount to each and every manufacturing process. Blank costs are not only determined by the cost of cutting the parts themselves, but also specifically by the material, quality, die maintenance, production time, personnel, logistics and buildings involved. Considering the overall impact a die-free production system has on the manufacturing process, it is easy to see the significant savings a laser blanking line provides over conventional die-based manufacturing techniques.

Daimler orders Laser Blanking Lines from Schuler

Laser beams instead of heavy dies: Daimler has commissioned two laser blanking lines at its Kuppenheim plant. Both the lines, which are meant for the serial production of compact vehicles, can be changed instantly to another cutting style at the touch of a button. The programming of the contours is done offline and can be simulated for production optimization.

WE ARE HERE FOR YOU!

Find out more about the full range of advantages offered by Schuler’s laser blanking lines. We’re happy to help you with service for your existing equipment, and can assist you with the planning of new systems. Turn around!

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