Whenever body panels are produced for cars, the first stage of the forming process is always the production of sheet metal blanks. Various blank sizes are first cut out of a coil of sheet metal and then formed into doors or engine hoods in a second production stage. It soon becomes apparent, therefore, why blanking lines play such an important role for the overall process: poor surface quality of the blanks can hardly be corrected at a later stage. Moreover, this first production step has an impact on the economic efficiency of the entire process.

Securing the quality of panel parts

In this connection, it is particularly interesting that the experts of Schuler will be installing the latest generation of blanking lines at Baosteel??s facility in Changchun. ??We??ve installed similar lines at German facilities, but this is the first of its kind in China,?? explains Robin Reid, responsible for the overall concept of the new blanking lines at Schuler. Why has one of China??s largest part suppliers chosen this concept? ??Baosteel??s customers in China also produce models known from Europe. Obviously, these car manufacturers also want their suppliers to use identical processes for the production of blanks. This helps guarantee the required premium quality of the finished body panels,?? states Reid. At the same time, the new machine generation stands for a veritable leap in blank production output: increases of up to 50 percent are possible compared to older lines. This leap has been made possible by the perfect synchronization of all components in the line. The coil feed line and roll feed unit at the beginning of the line and Stop2Drop stackers at the end are all perfectly adapted to the movement curve of the programmable servo presses.

Always tailored to the material??s requirements

Schuler??s servo technology has also proved to be the ideal drive for a line which, if required, can also process aluminum ?C a highly sensitive material. The cutting speed can be adjusted to the material strength or to the quality of the dies used. Output remains high, however, as the monoblock servo press with a press force of 800 metric tons can draw on its key strength ?C the ability to program the slide??s movement curve ?C during the actual cutting process. The cut itself happens extremely quickly, while the movement of the slide during material transport is slowed down. The system thus ensures high output levels.

The line is expected to go into operation at Baosteel??s Changchun facility in spring 2012. ??Baosteel will then be able to meet the highest blank standards of the major premium car manufacturers. And with regard to the dynamic development of the Chinese car market, we are convinced that this technology will also be interesting for other Chinese part suppliers,?? says Reid.