Uebersicht Broschuere Produkte Blechumformung e PDF

The entire world of
metal forming
Components for sheet metal forming.
Table of contents / The entire world of metal forming
CONTENT.
The entire world of metal forming.
Welcome to the stamping plant. 04 07 | Tryout systems 78

Welcome to Schuler. Cost-effective die startup with hydraulic and
mechanical tryout presses, tryout centers, die
01 | Blanking lines 06 turnover devices and simulators.
Individual solutions for your production.
08 | Lightweight technologies 86
02 | Hydraulic presses 14 Lines for press hardening (hot stamping), for cold and
Flexible presses for suppliers to the automobile aluminum forming. For forming fiber-reinforced
industry, the household appliance industry and for plastics and for hydroforming.
multiple metalforming applications.
09 | Die and forming technologies 96
03 | Mechanical presses 22 From simulation to series production.
Fast, flexible and cost-effective. C-frame presses,
blanking presses, knuckle-joint presses, transfer 10 | Systems large pipe manufacturing 100
and prog-die presses and servo presses. Spiral pipe welding lines and system solutions for
longitudinally welded pipes.
04 | Automation of presses 50
Coil lines, roll feed units, tri-axis transfer systems 11 | Schuler Service 106
and destackers. Technical customer service, components and
accessories, project business, special services and
05 | Press lines 60 used machines on your doorstep, worldwide.
Hydraulic, hybrid, mechanical or servo press lines
are fully automated system solutions. 12 | TechCenter 110
Experience Schuler products live and on the spot
06 | Automation of press lines 70 contact us.
Schuler press lines are equipped with the appropriate
mechanization concept for the range of parts, 13 | Sites 114
productivity and space requirements. Production facilities, service sites, TechCenter and
agencies there for you in 40 countries.
Subject to technical modifications and amendments to content | 2014/15

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TABLE OF CONTENTS
Welcome to the stamping plant.

Welcome to Schuler.
Transfer press with ServoDirect technology.

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TABLE OF CONTENTS Welcome to Schuler / The entire world of metal forming
As a world market leader in the technology of metal forming, Schuler offers presses,
automation solutions, dies, process technology and service for the entire metal working
industry and lightweight automotive construction. Its customers include automobile
manufacturers and components suppliers as well as companies in the forging,
domestic appliances, packaging, energy and electrical industries. Schuler is a leader in
coin minting technology and produces system solutions for the aerospace, railway and
large pipe industries. 5,500 people work for the company worldwide. The Schuler Group
is present in 40 countries and is majority-owned by the Austrian Andritz-Group.
We support you in all phases of a project, in planning new stamping plants through
to integrating forming lines into existing structures. In close cooperation with your
planning departments, technical purchasing, stamping plant and maintenance, we
handle the installation, commissioning and production startup of lines and automation
components. In this process, you also benefit from the extensive know-how of our
project teams installations all over the world. We are also in daily contact with users
of mechanical and hydraulic press technology regarding modernization, rebuilding,
relocation and performance enhancements available for existing forming lines.
Together we can find solutions that improve the cost-effectiveness of the
stamping plant.
This book provides you with an overview of our range of products and services. We are
just right for the job wherever the highest parts quality, maximum plant availability and
reliable press engineering is required day-in, day-out. From blanking and the forming
process through stacking the finished components our lines offer the right answer to
future requirements including increased use of high and extra high-strength steels
or integration of additional process steps in the forming process.
Put us to the test.
SCHULER online
Would you like to find out more about our selections? Further information is available on the Internet at
www.schulergroup.com. You can also follow us on Facebook at www.facebook.com/schulergroup or on
Youtube at http://bit.ly/1gQpND8. There you will find interesting news and worthwhile information.
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01
TABLE OF CONTENTS
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TABLE OF CONTENTS Blanking lines / The entire world of metal forming
AT A GLANCE
Blanking lines
Blanking lines from Schuler offer the complete process BLANKING LINE WITH PRESS 10
sequence from the coil through the blank stack from
a single source. You work with the latest safety and control BLANKING LINE WITH CROSS-CUT SHEAR 11
concepts. Their modular structure permits solutions that
are individually tailored to the user. All the components BLANKING LINE WITH LASER CELL 12
of the line have been tested in practical operations, are
precisely adapted to one another and guarantee the
highest levels of availability and reliability. Expansions for
processing aluminum and high-strength steels can be easily
retrofitted. And it does not matter where the Schuler line
will be used our services are available worldwide.
SCHULER online
Would you like to find out more about our blanking lines? You can find our complete product range
at www.schulergroup.com/automotive. There, you will find extensive information about our system
solutions for large-scale mass production.
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TABLE OF CONTENTS
Blanking lines
Individual solutions, flexible applications
Maximum productivity with ServoDirect presses

In addition to the use of conventional presses (mechanical
or hydraulic), lines for manufacturing shaped blanks
are preferably equipped with servo presses nowadays.
ServoDirect technology from Schuler enables movement
sequences of the press to be adapted individually to the
different blanking dies. This increases productivity and the
service lives of dies significantly. Also, lines with this
technology are configured for processing an extremely
wide range of materials such as aluminum or high-strength
steels. Material with a sensitive surface can also be
processed carefully, using a press blanking line with the
highest productivity.
All upstream and downstream automation components,

such as the roll feed unit driven directly by servomotors
or the flexible Stop2Drop stacker, support the impressive
Blanking line with servo press. press performance and ensure powerful dynamic
properties in blanking. A high level of automation ensures
quick production changes and a smooth production
process.
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Blanking line with cross-cut shear. Blanking line with laser cell.
Blanking with cross-cut shear the solution This means there is no need, whatsoever, to invest in dies,
for straightforward blank shapes die maintenance and die warehousing. The compact design
Schuler offers blanking lines equipped with cross-cut of the line means it can be used even when space is
shears for manufacturing blanks with a rectangular, limited and overhead heights are low. With their innovative
parallelogram or curved shape. If the manufacturing DynamicFlow technology, they offer the most flexible
process is restricted to straightforward blank shapes, then possible production conditions with comparatively low
cross-cut shears represent the ideal solution both with investment costs. The laser cutting line processes an
regard to purchase costs and their productivity. Optionally, extremely wide range of materials such as aluminum or
the shears can be equipped with an automatic die change. high-strength steels, and guarantees high productivity
even with skin panels that have sensitive surfaces.
Laser cutting: Flexible production,
compact line design
Blanking lines with lasers are particularly suitable for
production sequences with frequent product changes
as well, because no tooling is used for laser cutting.
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TABLE OF CONTENTS
Blanking lines
Blanking line with press
Blank shapes when using a press with die (max. stroke rate 105 spm).
Output rate of blanking line with servo press

Feed length [mm] 300 500 750 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500
Servo press basic version [strokes/min] 75 73 66 61 51 43 38 31 28 27 24
Servo press with more powerful motor [strokes/min] 93 82 73 67 51 43 38 31 28 27 24
Advantages
Ideal for producing shaped blanks Reducing die wear with ServoDirect technology
High output performance Proven technology
High level of automation
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Blanking lines
Blanking line with cross-cut shear
Blank shapes when using a cross-cut shear (max. stroke rate 120 spm).
Output rate of blanking line with four-column cross-cut shear

Feed length [mm] 300 500 750 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500
Cross-cut shear [strokes/min] 108 90 77 68 51 43 38 31 28 27 24
Advantages
Ideal for producing blanks with a rectangular, High output performance

parallelogram or curved shape High level of automation
Attractive price/performance ratio Proven technology
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TABLE OF CONTENTS
Blanking lines
Blanking line with laser cell
Blank shapes when using laser cutting heads.
Output rate of a blanking line with laser

The productivity of a laser line must always be seen in the
context of sheet metal thickness, blank contour and laser
power. We would be happy to calculate the possible
productivity for you on the basis of your product data.
The advantages
Suitable for all blank shapes Reduced material costs

No costs for dies and die warehousing High energy efficiency
Fast product change, delivering a high level of availability Reduced investment volume
Adaptation of blank contours after production startup Space-saving line design
Simultaneous production of different blank shapes
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Blanking line with ServoDirect technology
In practice
Customer: Automotive supplier, People's Republic of China
1 3 4 5 7 8 9 11 12 13
2 14
6 15 10
1.Decoiler 7. Roll feed unit 11. Telescopic conveyor

2. Coil infeed 8. Telescopic roller train with 12. Vacuum blower for stacking
3. Crop shear left-over coil feed aluminum blanks
4. Coil washing machine 9. Blanking press with 13. Blank stacker
5. Leveling machine ServoDirect technology 14. Stack cart
6. Loop pit 10. Cutting die 15. Hydraulic unit
The requirements: The solution: Leveling machine with crowning

Delivery of a blanking line for Fully automated blanking line with function with 2 cassettes (17 rolls)
producing shaped blanks with blanking press in ServoDirect Loop equipment
the shortest downtimes during a technology. Roll feed unit with weld detection
coil change. Coil loading cart for two coils Blanking press with 8,000
Cutting steel, aluminum and Moving decoiler for 35 tons kilonewtons in ServoDirect
high-strength steels up to Threading unit with dirt and technology
1,200newtons/square millimeter clean rolls Stacker in Fly2Drop and Stop2Drop
Coil width: 2,150 millimeters Cropping station stacker technology (energy-efficient
Coil thickness: 0.5 to 2.5 millimeters Coil washing machine vacuum generation by blower)
Coil weight: 35 tonnes
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TABLE OF CONTENTS Hydraulic presses / The entire world of metal forming
AT A GLANCE
Hydraulic presses
You've got to be flexible. We've got the machines for this. Hydraulic presses 16
Hydraulic press systems from Schuler are extraordinarily
versatile and make it possible for you to achieve efficient Presses for the non-automotive 19
series production of a wide range of components from industry
the blank through to the finished part. At the same time,
innovative hydraulic solutions ensure high output levels, Hydraulic transfer presses 21
production reliability and the best quality. Whether in
classic metalforming, die tryout, die hardening, internal
high-pressure forming, precision blanking or processing
fiber-reinforced plastics: hydraulic presses from Schuler
can cope with any challenge round the clock, seven
days a week.
SCHULER online
Would you like to find out more about our hydraulic presses? You can find our complete selection at
www.schulergroup.com/hydraulic_press. In addition, you can download the Hydraulic press systems.
For the best component quality in the stamping plant brochure as a PDF file.
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TABLE OF CONTENTS
Hydraulic presses
Flexible application with high

production reliability
Economical, flexible and for

reliable production
Because of their versatility, hydraulic presses offer a wide
range of applications in the stamping plant. They can be
used as a single press, automated press line, transfer press
or tryout press. In combination with a coil line, destacker or
tri-axis transfer, this creates turnkey system solutions for
economical parts production. These have a modular
structure and offer users a wide range of expansion options.
Equipped with a hydraulic bed cushion, impact shock

dampening, slide parallelism control and cylinder mode
switching, hydraulic presses provide all the prerequisites
for efficient production in the component supplier's
stamping plant. A data analysis system assists the press
operator in straightforward fault diagnosis of the entire
system, at the same time as increasing productivity
Hydraulic presses offer flexible applications. by optimizing the process.
advantages
They can be used as a single press, in press lines or High flexibility through four-point impact shock
as a transfer press dampening and a hydraulic bed cushion
Production alternative for a wide range of parts Parallelism control increases parts quality and
Increase in output by dynamic cylinder mode switching reduces die wear
Simple operation by sequence chart user interface Precise eight-way slide guidance
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Hydraulic press with a press force of 4,000 kilonewtons
1. Press cylinder
2. Adjustable eight-way precision slide guidance
5
with maintenance-free guide jaws
6
3. Hydraulic drawing cushion
1 4. Hydraulically operated slide locking in upper end position as per
4 8 UVV (safety codes and regulations)
5. AC drive motors designed to suit application
6. High-performance axial piston pumps with electronic pump control
7. Torsion-resistant press frame
8. Slide/piston connection
10 2 9. Impact shock dampening cylinder

10. Slide limitation/impact shock dampening
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Model overview HYDRAULIC PRESSES 1,600 to 16,000 kilonewtons

Press force [kN] 2,500 3,150 4,000 5,000 6,300 8,000 10,000 12,500 16,000 Daylight [mm]
Bed length [mm] Standard Option
1,000 1,300 1,300 1,300

1,600 1,600 1,600 700 1,000
1,300 1,600 1,600 1,600 1,600 1,600 1,600

2,000 2,000 2,000 2,000 2,000 2,000 2,000 850 1,300
2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,500
1,600 2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,500

3,000 3,000 3,000 3,000 3,000 3,000 3,000 1,100 1,600
On request, hydraulic presses are available with alternative bed sizes and press forces up to 300,000 kN.
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TABLE OF CONTENTS
Hydraulic drawing press for manufacturing side sill plates
In practice
Customer: Automotive components supplier, Czech Republic
Hydraulic press for producing side sill Maximum output rate of the line: Semi-automatic die change in 15 minutes.
plates and roof bows. 12strokes/minute.
The requirements:
Delivery of a production line for finish-processing of preformed side sill plates
and roof bows.
Perform pick-up
Component transfer through the press
Hole punching and forming of specified contours
The solution:
Hydraulic blanking and coining press with tri-axis gripper transfer, blanking
and forming dies.
Press force: 2,500 kilonewtons

Bed size: 2,500 1,300 millimeters
Slide parallelism control with screw adjustment
Roll-formed component pick-up by robot
Part transfer into the press and through the die stations
Semi-automatic die change in 15 minutes
Maximum output rate: 12 strokes/minute
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Hydraulic presses
Presses for the non-automotive industry
Hydraulic presses for the

non-automotive industry
Hydraulic presses also represent an efficient solution for a
wide range of production tasks in the domestic appliance
industry and for manufacturers of components made from
stainless steel. Both single presses and automated produc-
tion systems increase users' competitiveness. The lines are
characterized by optimum reliability, high availability, fast
die changes as well as straightforward adaptation to
modified production conditions.
Pre-engineered press configurations in conjunction with a

wide variety of modular automation options and die change
techniques permit customer-specific manufacturing
solutions. The lines are also noted for their high degree
of user-friendliness.
Hydraulic presses for producing stainless steel sinks.
advantages
Reliable equipment with high levels of uptime Maintenance-friendly because of easy accessibility
Maximum flexibility of all components
Optimum line configuration using proven components High part quality due to sturdy design
Process analyses with integrated data analysis system
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TABLE OF CONTENTS
Hydraulic press for manufacturing heat exchanger plates
In practice
Customer: Manufacturer of heat exchanger plates, USA
Hydraulic coining press. Press force: Fully automatic production system for Heat exchanger plates of various sizes.
250,000 kN. manufacturing heat exchanger plates.
The requirements: The solution: THE PRODUCTION SYSTEM:

High requirements apply to fully The fully automated production system Blanking system with coil line
automated forming of heat exchanger has at its heart the hydraulic coining Lifting bar transfer system for
plates: high stamping forces, many press with multi-cylinder system in transporting parts in the press
different plate geometries, close short-stroke technology. The system Loading and unloading feeder
tolerances in stamping depth, permits flexible adaptation of Foil winding units
production process reliability and press force ranges to the different Fully automated die change system
high equipment availability. geometries and as well as a uniform Master controller
stamping depth by evenly distributed Press for edge trimming and
force application without shimming. hole-punching for fluid outlets
advantages
Flexible automatic adjustment of the pressure circuits Bowing or shimming of the dies no longer required
according to various plate geometries Deflection deviation between bed and slide reduced
Optimal press force distribution by force application over a to a minimum
large area and adjustment of individual cylinder pressures
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Hydraulic presses
Hydraulic transfer presses
Hydraulic transfer press. Press force: 25,000 kN. Feeder loading station with blank singling.
Efficiency, step by step

Hydraulic transfer presses permit part production on the capacity range for these presses is 5,000 to
multi-station transfer dies. High throughput rates can 30,000kilonewtons. The active electrohydraulic slide
be achieved due to hydraulic solutions such as the parallelism control and hydraulic impact shock
Schuler ring valve technology and dynamic cylinder mode dampening ensure superior part quality and reliability
switching. In single-slide or multi-slide design (with in the forming process. Other auxiliary functions
options for one or more bed and/or slide cushions), can be directly integrated into the die.
The advantages
Easy to adapt to different dies Production of deep components by counter drawing

Freely programmable slide motion curves Nominal capacity available over the entire stroke
Programmable pressure dwell in BDC Simple die startup
High level of availability
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TABLE OF CONTENTS
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TABLE OF CONTENTS mechanical presses / The entire world of metal forming
AT A GLANCE
Mechanical presses
Blanking and forming systems from Schuler are used ServoDirect technology for 24
successfully in a very wide range of industries. They permit blanking and forming systems
sheet metal parts to be produced flexibly and economically
with the best quality, and overcome challenges such as C-frame presses 26
large part quantities, complicated part geometries and
processing high-strength materials. The breadth of our Automatic blanking presses 28
product range for economical series production of high-
quality components is matched only by the requirements Blanking and forming systems 32
that exist in the various industries. Whether C-frame Servo presses 32
presses, automatic blanking presses, knuckle-joint Presses with TwinServo technology 38
presses, servo presses or conventional mechanical Transfer presses 40
transfer/ProgDie presses together, we can find the Multiple-slide transfer presses 41
right solution for your success. Knuckle-joint presses 42
Efficient process management 48
SCHULER live
Your direct contact to the Servo TechCenter:

Gppingen | Tel.: +49 7161 66-214 | E-mail: stc-goeppingen@schulergroup.com
Erfurt | Tel.: +49 751 401-2606 | E-mail: stc-erfurt@schulergroup.com
Tianjin, China | Tel.: +49 7161 66-9011 | E-mail: stc-tianjin@schulergroup.com
SCHULER online
Would you like to find out more about mechanical single presses? You can find our complete selection at
www.schulergroup.com/stamping_cutting. In addition, you can download the At Home in Every Industry.
Blanking and Forming Systems from Schuler. brochure as a PDF file.
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TABLE OF CONTENTS
Mechanical presses
ServoDirect technology for blanking

and forming systems
Operating panel of a servo press. Production with optimally matched system components.
Success can be programmed

Presses with ServoDirect technology open completely new systems are created for a broad range of parts. The presses
perspectives: maximum flexibility in production, economical are driven directly by torque motors which permit highly
production of complex parts geometries and a high level of dynamic forming processes thanks to their high torque.
productivity with optimum parts quality. In combination with The lack of a flywheel and clutch/brake combination makes
highly dynamic Schuler roll feed units, coil lines, destackers the presses flexible, energy efficient and cuts down the
or tri-axis transfer systems, fully automatic forming maintenance required.
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FLEXIBILITY AND EFFICIENCY
Stroke [mm] Stroke [mm]

max.
max.
0 Reduction in cycle time Time [s] 0 Time [s]
Motion profile of conventionally driven eccentric press Oscillating mode, small stroke
Motion profile of the servo press with optimized performance Oscillating mode with rest position
Operation in oscillating stroke Pass-through mode
Individual programming of the slide motion reduces the cycle time ServoDirect technology allows the slide motion to be programmed
whilst keeping the forming speed constant. individually.
Programmable slide motion curves Oscillating stroke mode

The use of highly dynamic torque motors permits straight- Oscillating stroke mode permits user-programmable slide
forward and rapid programming of different movement stroke heights. The reversing movement of the torque motor
profiles in one press cycle. This means the slide kinematics means that the eccentric drive of the slide has an oscillating
can be quickly and easily adapted to the process parameters motion and alternates between forwards in one stroke and
of the die and the automation system, and optimized for a backwards in the next stroke. This means the cycle count
high stroke rate. and energy efficiency are improved significantly.
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TABLE OF CONTENTS
Mechanical presses
C-frame presses
For universal application

C-frame presses provide small and medium-size companies
high product quality at low per unit cost. Innovative solutions
for equipment and controls ensure an integrated manufac-
turing process. The machines are configured for manual
loading (CB series) and either manual loading or automatic
mode (C series).
MODULAR FLEXIBLE ERGONOMIC

The C-FLEXline (CFL) series is based on a combination of
experience gained from users and more than 70 years
of experience in building C-frame presses. The modular
structure makes it possible to adapt to changing production
conditions at any time from straightforward manual
loading through to fully automatic production. The presses
are converted quickly and ergonomically. Two different
control concepts allow the presses to be adapted to
C-FLEXline 630 kN comfort with foot pedal. individual customer requirements.
Model overview of C-frame presses
Model CB-250 CB-400 CFL-630 CFL-1000 CFL-1600 CFL-2500 CS-1000

C-400
Press force [kN] 250 400 630 1,000 1,600 2,500 1,000
Bed dimensions [mm] 465 360 650 480 820 590 950 660 1,250 750 1,400 860 950 660
Slide dimensions [mm] 220 160 370 300 470 410 540 510 850 630 1,000 700 550 460
Shut height [mm] 270 240 320 370 440 470 371
Slide stroke [mm] 5 75 5 100 8 120 10 130 12 180 19 250 160
Slide adjustment [mm] 50 70 100 100 110 130 80
Stroke rate [rpm] 150 60 140 30 120 30 90 20 70 20 60 150
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The torque motor of the CS-1000 is located directly on a

simple knuckle joint drive, the design of which means that
slow slide speeds are achieved during the forming phase.
The additional individual adaptation of the slide kinematics
to the particular process requirements in conjunction with
a zero-play driveline guarantees high precision of the
components.
The space-saving and ergonomically built press additionally

impresses with its lower energy consumption, reduced
noise development and touchscreen operation that is both
straightforward and intuitive.
A die change can be carried out quickly and easily because

of the slide adjustment by an electric motor with quick-lift
function. Following that, die spotting ensures that produc-
tion starts up smoothly and quickly.
C-frame press with ServoDirect drive CS-1000 with
1,000 kN press force. The entire press drive does not need lubricating oil, some-
thing which is advantageous both for the production process
EFFICIENT PRECISE INNOVATIVE and in terms of maintenance. The status-oriented mainte-
The newly developed CS-1000 C-frame press with nance concept with integrated maintenance plan and
ServoDirect technology offers a boost in terms of produc- innovative status monitoring via smart device increases
tivity and efficiency. Individual adaptation of the stroke process security for the entire line.
height in conjunction with a reversing movement of the
torque motor (oscillating stroke) leads to a significant
increase in output. At the same time, optimum adaptation
of the slide kinematics to the process parameters
achieves greater product quality and a longer die life.
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TABLE OF CONTENTS
Mechanical presses
Automatic blanking presses
Wide range of parts high output

Blanking presses (MC series) are standard machines with
extensive basic equipment for blanking classic sheet metal
components from the coil. In the range from 1,250 to 5,000
kilonewtons, they represent an optimally priced solution for
manufacturing components with high output rate.
The advantages:
Little bowing due to rigid welded construction
Long slideways ideally absorb off-center forces
Two transverse shafts compensate for rotational
forces without additional masses
Low-noise drive with helical gearing
Quick conversion to new die
Hydraulic overload protection protects the
machine and the die
Automatic blanking presses: the economical solution for

a wide range of parts.
Model overview AUTOMATIC BLANKING PRESSES (MC)

Model MC-1250 MC-2000 MC-3000 MC-4000 MC-5000
Press force [kN] 1,250 2,000 3,000 4,000 5,000
Bed length [mm] Bed width
1,400 1,000
1,800 1,100
2,200 1,300
3,000 1,300 1,400
Shut height [mm] 450 550 650 750 800
Slide adjustment [mm] 150 150 150 200 250
Slide stroke [mm] 20 180 20 220 40 315 40 315 40 315
Stroke rate [rpm] 30 150 30 130 25 100 20 80 20 70
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For small components with tight die clearances

The high-speed blanking press (MCF series) is designed for
producing components with output rates of up to 300
strokes/minute. The slide guidance system with preloaded,
play-free roller bearing units also guarantees the necessary
precision in the process: the best prerequisite for series
production of small components with tight die clearances.
The advantages:
Fast and reliable press type
Output rate up to 300 strokes/minute
Stress-relief annealed frame
Long die service lives
Longitudinal shaft machines with rotary mechanical
counterbalance
Linear roller bearings
Planetary gear unit ensures high available power,
Automatic blanking press with up to 300 strokes per minute. even at low speeds
Fully automatic stroke and slide adjustment
reduces die change times
Infinitely variable overload protection for
die and machine
Model overview of high-speed BLANKING PRESSES (MCF)

Model MCF-630 MCF-800 MCF-1000 MCF-1250 MCF-1600 MCF-2000
Press force [kN] 630 800 1,000 1,250 1,600 2,000
1,000 700 700
1,300 800 800
1,600 1,000 1,000
Shut height [mm] 350 350 400 400 500 500
Slide adjustment [mm] 70 70 100 100 100 100
Adjustable slide stroke [mm] 9 80 9 100 11 100 11 120 10 120 10 130
Stroke rate [spm] 30 300 30 300 30 280 30 280 30 260 30 260
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TABLE OF CONTENTS
Mechanical presses
Automatic blanking presses

With ServoDirect technology
Automatic blanking press MSC-2000 with 2,000 kN press force. 12-way preloaded slide guide with zero play.
For maximum flexibility and economy ServoDirect technology makes it possible both to adapt the
in production slide movement to the workpiece and to increase the stroke
The new generation of ServoDirect technology makes it rate with oscillating mode.
possible for a significant economy boost to be achieved with
MSC automatic banking presses. The new drive concept is The drive concept without lubricating oil impresses across
based on an innovative drive module comprising highly the board: it significantly improves process reliability
dynamic built-in torque motor, brake module, eccentric because there is no longer any possibility of mixing process
shaft with connecting rod, two knuckle joints and slide. The and press lubricants. As a result, this press generation is
two knuckle joints are synchronized by the drive control, also ideal for use in the packaging and foodstuffs industry.
there is no mechanical connection.
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Stroke [mm]
max.
0 Time [s]
Drawing Embossing Crank
Pre-programmed slide movement profiles. Control panel with touchscreen.
Precision and low-maintenance in harmony Operation of the press by the touchscreen is intuitive and
The zero-play driveline increases precision and means the simple. The menu can be individually configured and offers
possible die clearances can be even tighter, thereby also both basket and a favorite functions.
reducing die wear.
The status-oriented maintenance concept with integrated
The pre-programmed slide motion curves are designed for maintenance plan and innovative status monitoring via
various processes: Whether for punching, forming, blanking, smart device increases process security for the entire line.
embossing, bending or drawing the press can be quickly
and flexibly adapted to meet any requirement.
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TABLE OF CONTENTS
Mechanical presses
Blanking and forming systems

SERVO PRESSES IN MONOBLOCK AND TIE ROD DESIGN
Servo press MSD 250 in the Servo TechCenter at Gppingen Servo press MSD 630 with innovative Intra Trans transfer in the
specifically for the requirements of the stamping operation. ProTec Process and Technology Center, Lennestadt.
SCHULER SERVO DIRECT TECHNOLOGY SERVO PRESSES IN MONOBLOCK DESIGN

The servo presses are driven directly and via torque motors, The monoblock press body of the MSD series is implement-
which are the ideal drive for dynamic punching and forming ed as a stress-free annealed welded structure. The eccen-
processes because of their high torque. The slide kinematics tric gears have a double herringbone profile to provide axial
can be quickly and easily adapted to the process parameters guidance and to reduce noise, and the slide roller guide is
of the die and automation functions, something which not preloaded to eliminate play. All components are designed
only increases the die life but also improves component to ensure a high level of machine availability.
quality. A freely programmable stroke height and dynamic
reversing movements of the motor (oscillating stroke) ENERGY MANAGEMENT
significantly increases output and energy efficiency. Energy accumulators can be used as an option in order
to reduce the connected load. These collect the energy
released during the braking phase in generator mode,
and make it available again during the subsequent
acceleration phase.
32
Model overview of servo presses in monoblock design

Model MSD250 MSD 400 MSD 630 MSD800
Press force [kN] 2,500 4,000 6,300 8,000
2,000 1,100
2,500 1,100
3,050 1,400
4,000 1,800 1,800
Shut height [mm] 550 600 700 1,000 1,000
Slide stroke [mm] 32 160 40 200 60 300 80 400 80 400
Slide adjustment [mm] 150 200 250 300 300
Stroke rate [rpm]* 3 160 3 140 3 90 3 60 3 60
All information for systems with two-conrod design.

* Stroke rate depending on programmed stroke height and kinematics.
advantages
Significant increase in productivity compared to Short delivery times and optimized spare part management
conventionally driven mechanical presses due to standardized modules
Maximum production flexibility due to user-programmable Shorter die tryout times because of setup and tryout
stroke heights and motion sequences functions with hand wheel
Increased parts quality and longer die lives due to motion Lower energy costs due to efficient drive solution
sequences optimally adapted to the particular forming Easier maintenance compared to conventionally driven
requirements mechanical presses, because there are fewer mechanical
Greatest availability for production mode components
Best suited for processing high-strength steels
33
TABLE OF CONTENTS
SERVO PRESSES IN TIE ROD DESIGN

The TSD/TSC series has a large number of tryout functions,
amongst other features, which use a hand wheel to reduce
setup times: the Quick-Lift function allows quick opening of
the die; the die is closed with a variable set-up speed while
in the die spotting function, the drive force can be prese-
lected and the rest-in-rest movement can be reversed if
required. Short changeover times are achieved in combina-
tion with mature die change systems such as tandem
change cart or extendable bolster plates.
TSD 1100 servo press at the Servo TechCenter Erfurt.
Model overview of servo presses in tie rod design
Model TSD 630 TSD 800 TSD 1000 TSD 1100 TSD 1250 TSD 1600 TSD 2000 TSD 2500 TSD 3200
TSC 630 TSC 800 TSC 1000 TSC 1100 TSC 1250 TSC 1600 TSC 2000 TSC 2500 TSC 3200
Press force [kN] 6,300 8,000 10,000 11,000 12,500 16,000 20,000 25,000 32,000
4,000 1,600 1,800

4,600 1,800 2,200* 1,800
5,000 2,200*
5,100 2,200* 1,800 2,200* 1,800
6,000 2,500*
6,100 1,800 2,200* 1,800 2,500* 2,500* 2,500* 2,500*
7,000 2,500* 2,500* 2,500*
Shut height [mm] 900 1,100 1,100 1,100 1,200 1,100 1,200 1,100 1,300 1,400 1,400 1,400
Slide stroke [mm] 100350 120450 120500 120450 150600 120450 150600 150450 200600 200700 230700 230700
Slide adjustment
300 300 300 300 300 300 300 300 300 300 300 300
[mm]
Stroke rate** [rpm]

TSD 3 70 3 60 3 50 3 50 3 45 3 45 3 40 3 40 3 36 3 34 3 30 3 30
TSC 3 50 3 36 3 38 3 34 3 32
All information for systems with two-conrod design. * Four-conrod design.

34 ** Stroke rate depending on programmed stroke height and kinematics.
Servo press in tie rod design with automation
8 9 10
2 3 4 5 6 7 11
13 12
LEGEND
1. Material feed (operation either with coil feed 5. Roll feed unit 10. Combined sequential or transfer die
line or destacker) 6. Coil or blank lubricating unit 11. Exit conveyor
2. Decoiler 7. Transfer and centering station 12. Hydraulic, modular drawing cushion
3. Leveling machine 8. Servo press in tie rod design 13. Scrap disposal
4. Destacker, two destacker carts including 9. Electronic, modular tri-axis transfer
scissor-lift table and double-blank
depositing station
35
TABLE OF CONTENTS
Servo presses
In practice
Blanking trials and process integration
Seat shell. Component with welded nut. Cylinder head gasket.
Integration of follow-on make completely new working as well as by providing rest times.
processes methods possible here: Processes The result: economical production
Frequently, component production such as welding or lasering can be of complex parts geometries and
involves several production steps integrated reliably into the process maximum output levels with the
which performed one after another and with high productivity levels highest quality. For extra efficiency.
take up time and productivity. Highly thanks to the possibilities of user-
dynamic servomotors from Schuler programmable time/travel sequences
Formed part Operating mode Component-specific Depth of draw Max. stroke rate Max. stroke rate Increase
press force [kN] [mm] Conventional Servo
Flange Progressive 1,200 30 30 56 + 87 %

Gas generator holder Progressive 1,300 60 25 40 + 60 %
Holder Progressive 2,000 40 30 60 +100%
Cage Progressive 2,400 50 30 50 + 67 %
Cross plate Progressive 4,000 90 23 33 + 43 %
Cover Progressive 6,900 40 15 34 + 126%
Center console Transfer 6,000 190 12 17 + 42 %
Insert cup Transfer 6,600 130 8 15 + 88%
Support Transfer 7,190 67 14 30 +114%
Tank filler neck Transfer 9,650 145 14 18 + 29%
Side panel Transfer 14,750 80 19 29 + 53%
36
Servo presses
In practice
Customer: Automotive components supplier, Germany and Austria
Servo press in monoblock design. Press force: 4,000 kN. Servo press in tie rod design with 16,000 kN press force, coil feed
line and destacker combination.
The requirements: The requirements:

Delivery of a servo press for producing a wide range Delivery of a servo transfer press with complete automa-
of parts. tion for manufacturing structural components in progressive
or transfer mode.
The solution:
Servo press in monoblock design with a maximum press The solution:
force of 4,000 kilonewtons. Automated with coil line and Servo press in tie rod design with a press force of 16,000
feed unit. kilonewtons and Schuler automation components.
Monoblock design Coil feed line/destacker combination

Bed surface: 2,500 1,100 millimeters Roll feed unit
Slide stroke 300 millimeters Electronic, modular tri-axis transfer
Maximum stroke rate in continuous operation: Conveyor belt
80 strokes/minute Bed surface: 6,000 2,500 millimeters
Slide stroke: 600 millimeters
Tie rod design
37
TABLE OF CONTENTS
Mechanical presses

Presses with TwinServo technology
Advanced thinking in servo technology

Following the market launch of ServoDirect technology, the
next milestone in a success story was set with TwinServo
technology. The new press generation is driven by decen-
tralized TwinServo technology, which offers users additional
interesting possibilities in sheet metal forming. Schuler
impressively demonstrates the performance of the innova-
tive press technology in the Servo TechCenter Erfurt on a
new transfer press. The new press system produces at a
press force of 16,000 kilonewtons and is fully automated
with components from Schuler.
TwinServo transfer press at the Servo TechCenter Erfurt.
Model overview of TwinServo presses

Press force [kN] 10,000 16,000 20,000 25,000 30,000 35,000
Bed length [mm] Table width standard and option*
5,000 2,200 2,200* 2,500*/2,200* 3,000 / 2,500*
6,000 2,500 2,500*/2,200* 3,000/2,500* 3,000*/2,500* 3,000*
7,000 3,000 / 2,500* 3,000 / 2,500* 3,000*
8,000 3,000 / 2,500* 3,000
Slide stroke [mm] 600 600 600 750 750 750
Press force millimeters before BDT [mm] 6 6 6 6 6 6
Number of connection points 4 4 4 4 4 4
Stroke rate at max. stroke** and constant

40 / 400 35 / 500 40 / 900 30 / 1,200 25 / 1,500 25 / 1,500
speed [spm]/rated capacity [kJ]
Oscillating stroke rate 1/3 stroke**

50 / 250 50 / 250 60 / 400 40 / 650 35 / 700 30 / 900
[spm] /rated capacity [kJ]
* Option. ** Deviations possible depending on the motion curve and force profile.
38
Automated transfer press with TwinServo technology
In practice
Servo TechCenter Erfurt
Coil line with decoiler and leveling machine. Transfer press with TwinServo technology. Die change by moving bolster.
Press force: 16,000 kN.
The requirements: The solution:

In the ServoTech Center Erfurt, Press Destacker
the first transfer press with Decentralized TwinServo drive Destacker with removal feeder and
TwinServo technology has been Press force: 16,000 kilonewtons shuttle device in the press
installed. Main motors: 2 AC servo
torque motors 503 kilowatts Transfer
Four contact points Electronic tri-axis rhombus transfer
Bed dimensions (L W):
5,000 2,200 millimeters Additional equipment
Slide stroke: 600 millimeters Two moving bolsters and parts
Slide adjustment: outfeed belt
300 0.1 millimeter
Stroke rate: controllable Dimensions
3 30/minute, in oscillating Total length of the machine:
mode without transfer 25 meters
3 40/minute Press height over floor:
6.50 meters
Coil feed line Required foundation depth:
Coil line with decoiler, leveling 5.30 meters
machine, coil-end welding device,
PowerFeed roll feed unit and
spraying system, can be used with
aluminum
39
TABLE OF CONTENTS
Mechanical presses

Transfer presses
Individually adjustable forming stations

Multi-station presses differ from transfer presses mainly in
the ability to adjust individual forming stations. Another
difference in multi-station presses is the externally mounted
blanking slide for integrated blank production. Multi-station
presses are built both as single-slide and multi-slide
machines with a press force range from 2,500 kilonewtons
to 60,000 kilonewtons. Either mechanical or electronic rail
transfer systems are used for parts transport. The advan-
tages are high output and high availability, individual station
adjustment in each station and, if necessary, the externally
mounted blanking slide for integrated blank production.
Mechanical multi-station press.
Multi-station press with externally mounted blanking slide
1. Crown with press drive

1 2. Press upright
3. Drawing slide
2 4. Transfer system
5. Die change cart
3 6. Blanking slide
6
4 7. Drawing cushion
40
Mechanical presses

Multiple-slide transfer presses
Multifunctional mass production

Multi-slide transfer presses deliver impressive practical
performance as a functional unit comprising press, transfer
and material feed. The configuration is based on the parts
spectrum, die size and forming process. Single-slide,
double-slide or triple-slide machines are used, depending
on the parts spectrum, which also influences the size and
number of dies. Parts are transported by a rail transfer
system which can be equipped either with cam-controlled
or electronic drive.
Multi-slide transfer press.
Multi-slide transfer press
1 2 3 1. Destacker
2. Transfer press
4
3. Tie rod
4. Crown
5 5. Upright
6 6. Slide
7. Processed part unloading belt
8. Moving bolster
7 9. Damping element
10. Drawing cushion
10 9 8
41
TABLE OF CONTENTS
Mechanical presses

Knuckle-joint presses
Precise in operation
The very rigid press concept and the slide movement that
is characteristic of knuckle-joint presses guarantee
that ready-to-install precision parts can be manufactured
economically. Each machine permits efficient blanking,
drawing, embossing, punching and calibrating in one
operating sequence, while the various stations can also be
combined with one another. The optional use of ServoDirect
technology also ensures extra flexibility and productivity.
The new PSK and PSK PLUS series is the perfect solution
for components with increased requirements for precision
and smooth cutting proportion.
The versatile knuckle joint presses are simple to operate and

change over for high levels of availability and efficiency.
advantages
Optimized slide motion by modified knuckle-joint drive and High system rigidity for close component tolerances
maximum production flexibility with user-programmable and reduced cutting impact
stroke heights and motion sequences in knuckle-joint Excellently suited for processing high-strength steels
presses with servo drive Reliable repeat accuracies, even with fluctuating
Drawing, bending, cleaning, blanking and calibrating material thicknesses and strengths
operations in one press cycle Shorter die start-up times by precision setup using
hand wheel
42
Stroke [mm]
max.
200
Eccentric curve
Knuckle joint curve
0
0 360
Time [s]
Structure of the knuckle joint system. Motion characteristics of the eccentric and knuckle joint press.
Model overview of knuckle-joint presses (TMK)

Press force [kN] 2,000 2,500 3,150 4,000 5,000 6,300 8,000 10,000 15,000
1,500 1,000 1,000
2,000 1,000 1,000 1,100 1,100
2,500 1,000 1,000 1,100 1,100 1,200 1,400
3,000 1,100 1,100 1,200 1,400 1,500 1,500 1,500
3,660 1,200 1,400 1,500 1,500 1,500
Shut height [mm]
Stroke down 400 500 600 700 700 800 800 800 800
Adjustment up 500 600 700 800 800 900 900 1,100 1,100
Slide adjustment [mm] 150 150 150 150 150 200 200 200 200
Slide stroke [mm]
with stroke adjustment 40 160 40 160 60 200 60 200 60 200 80 250 80 250
with fixed stroke 160 160 200 200 250 250 250 300 300
Stroke rate [rpm] 20 140 20 140 20 120 20 120 20 90 20 90 20 80
43
TABLE OF CONTENTS
Mechanical presses

Knuckle joint presses with ServoDirect technology
Knuckle-joint press with servo drive. Press force: 8,000 kN. Control panel of the overall machine.
Optimized overall process EFFICIENT PROCESS TECHNOLOGY

User-programmable servomotors allow the tried-and-test- The optimum design of the forming process with the servo
ed knuckle-joint kinematics to be exactly adapted to the drive can be additionally expanded by integrating follow-on
requirements of the specific components. In addition, all processes. This means a previously downstream process
components of the press peripherals such as coil feed, such as welding a nut onto the formed component can be
transfer, drawing cushion and ejector are optimally inte- integrated directly into the press cycle as part of a reliable
grated into the overall process. The results: increased process with high output rates by providing rest times.
production quantities, higher component quality and The result is highly efficient production of ready-to-install
longer die lives. precision parts with the best quality.
Video
Find out more about knuckle-joint presses with servo drive.

Simply scan the QR code using the camera of your smartphone or tablet.
http://bit.ly/GR1EhR
44
MODEL OVERVIEW OF KNUCKLE-JOINT PRESSES WITH SERVO DRIVE (MSK)

Model MSK 250 MSK 400 MSK 630 MSK 800 MSK 1000 MSK 1500
Press force [kN] 2,500 4,000 6,300 8,000 10,000 15,000
2,000 1,000
2,500 1,100
3,500 1,300 1,300 1,300 1,300
Shut height [mm] 600 700 800 800 800 800
Slide stroke [mm] 40 160 50 200 75 300 75 300 75 300 75 300
Stroke rate [rpm] 3 160 3 120 3 80 3 70 3 60 3 50
All information for systems with two-conrod design. Further sizes are available on request.
* Stroke rate depending on programmed stroke height and kinematics.
advantages
Significant increase in productivity compared to Excellently suited for processing high-strength steels
conventionally driven knuckle-joint presses Optimum adaptation of slide movement to the
Maximum production flexibility due to user-programmable automation concept
stroke heights and motion sequences Shorter die start-up times by precision setup using
High system rigidity for close component tolerances hand wheel
and reduced cutting impact Long die service lives
Drawing, bending, cleaning, blanking and calibrating Compact and durable design with stable value
operations in one press cycle
Reliable repeat accuracy, even with fluctuating material
thicknesses and strengths
45
TABLE OF CONTENTS
Mechanical presses

Knuckle-joint press for precision blanking and forming processes
THE NEW PERFORMANCE CLASS

The PSK and PSK Plus series open up a new performance
class in production: Users in the normal blanking and
precision clamping quality range can significantly expand
their product range with the new PSK servo knuckle-joint
press, and produce better quality blanking in an economical
fashion with an increased straight cut proportion. However,
companies in the fine stamping sector can also improve
their efficiency with the PSK Plus: Components that do not
necessarily require fine stamping can now be manufactured
with lower production costs.
This extra quality and productivity is made possible by

significantly increased stiffness of the overall system
thereby permitting a minimum die clearance, as well
as by additional press functions for improved flatness,
positional accuracy, minimized pull-in and burrs.
Knuckle-joint press with servo drive for precision blanking and
forming processes, press force: 6,300 kN.
Model overview of knuckle joint presses for precision blanking and forming processes (PSK/PSK PLUS)
Model PSK/PSK PLUS PSK/PSK PLUS PSK/PSK PLUS PSK/PSK PLUS PSK/PSK PLUS PSK/PSK PLUS
250 400 630 800 1000 1500
Press force [kN] 2,500 4,000 6,300 8,000 10,000 15,000

2,000 1,000 1,100
2,500 1,000 1,100 1,300 1,300
3,000 1,100 1,300 1,300 1,300 1,300
3,500 1,300 1,300 1,300 1,300
Shut height [mm] 600 700 800 800 900 900
Slide stroke [mm] 40 160 50 200 75 300 75 300 75 300 75 300
Stroke rate [rpm] 3 160 3 140 3 100 3 80 3 70 3 60
46
Overview of blanking processes
Normal blanking Precision blanking Precision blanking PLUS Fine blanking

Conventional blanks Precision blanks with higher High-precision blanks Fine blanks with straight
with straight cut proportion quality requirements by additional functions cut proportion of 100%
of up to 30% in the press
Blanking process
advantages
Outstanding parts quality with high straight cut proportions Drawing, bending, embossing, blanking and calibrating
Significant increase in productivity compared to operations in one press operation in combined
conventionally driven knuckle-joint presses sequential or transfer applications
Maximum production flexibility due to user-programmable Suitable for processing a wide range of materials
stroke heights and motion sequences Optimum adaptation of the slide kinematics
High system rigidity for close component tolerances Long die service lives
and reduced cutting impact Secure investment due to compact and durable
design that retains its value
47
TABLE OF CONTENTS
Mechanical presses
Process management
Efficiency across the line
Flexibility and efficiency by ServoDirect technology. Digital simulation for optimum die configuration.
To achieve efficiency and economic strength in production, accruing tooling costs. Schuler's personnel is at your side
it is not enough just to have the best machines. To enable all with component calculations based on your individual
economic opportunities to be exploited to the full, the entire component and tooling data.
process must be analyzed and all its aspects must be
optimally coordinated. Optimum die configuration
The objective of any production company is to achieve the
Schuler is at your disposal as an expert partner with various longest possible die service lives, at the same time as
services such as process consulting or training. First and benefiting from the greatest possible stroke rates. We offer
foremost, each measure concentrates on boosting the you advice in die configuration and design to ensure this is
economic performance of your company. successful. We support you in defining press and transfer
movements in advance using simulations for optimum
Economical component and output and clearance. This support is rounded off by training
manufacturing process courses dealing with the topic of optimized die design
All production planning starts with the decision on which adapted to the requirements of servo technology.
is the optimum production process. In this consideration,
it is necessary to take account of and calculate the material
costs and the output per component, as well as additionally
48
Economical component
and manufacturing process
Maximum
efficiency
Optimum
die configuration
and simulation
Increasing
employee
qualification
Setup time
optimization
Increase in energy
efficiency
Flexibility and efficiency by

ServoDirect technology
Noise reduction
Stroke rate optimization
Setup time optimization Increase in energy efficiency

The current trend towards smaller and smaller batch The greatest possible energy saving without impairing
sizes goes hand-in-hand with frequent die changes and yield efficient machine technology from Schuler puts
increasing setup costs. Our setup workshop shows you one step ahead of the competition here as well. We
you the ways to optimize setup times by standardized offer you individual advice on optimum use of energy
processes and efficient working sequences. in running machines, such as programming of energy-
saving stand-by operation as well as energy efficiency
Stroke rate optimization programs for new machines. Furthermore, we are
It is only possible to achieve maximum stroke rates, and ready to provide you with active support when it comes
thus a long-term boost in economic performance, if all to training your operators.
process components are working together optimally.
Suitable methods for successful implementation are
revealed in our training course, Process optimization.
49
04
TABLE OF CONTENTS
50
TABLE OF CONTENTS Automation of presses / The entire world of metal forming
AT A GLANCE
Automation of presses
Our automation ideally combines the press, automation Destacker 52

devices and die, offering impressive precision and
process reliability. With automation components from coil feed lines 53
Schuler, you benefit from a greater output rate even
when processing high-strength steels or aluminum. Roll feed unit 56
TRI-axis transfer 58
SCHULER live
Your direct contact to the Automation TechCenter:

Hedorf | Telephone: +49 9135 715-264 | E-mail: atc-hessdorf@schulergroup.com
SCHULER online
Would you like to find out more about automating presses? You can find our complete offer at
www.schulergroup.com/Automation. In addition, you can download the Performance across
the line Automation from Schuler brochure as a PDF file.
51
TABLE OF CONTENTS
Destacker
Destacker with transfer system for blank destacking. Integrated system solution. Destacker and coil line on a servo press.
Press force: 16,000 kN.
In order to automate transfer presses, Schuler not only

offers tried-and-tested destackers but also a special
solution. This consists of a mobile combination of coil line
in short design with a destacker. For the press owner, this
solution opens a wide range of options regarding material
and flexibility for efficient part production. It represents
a flexible solution for blank and coil processing on a
single line. The control is compatible with both the
press and transfer, and meets all production
requirements.
52
Coil feed lines
Coil feed lines in short design

Our coil feed lines in short design have been specially
developed for the requirements of customers in the
components industry. They offer process reliability while
meeting the highest material requirements. The lines are
optimally suited for producing structural components and
processing high-strength materials even in the higher coil
thickness range. They are the ideal solution when space is
at a premium. Our product range includes coil feed lines
in various high-performance basic versions, and is adapted
to all press types. The modular concept permits flexible
configuration of the lines. With our extensive package of
options, you can react to new requirements at any time
while keeping control over your investments.
Reference data of the basic versions

Coil feed line in short design. Coil width max. [mm] 1,850
Coil thickness max. [mm] 12
Coil weight max. [t] 27
53
TABLE OF CONTENTS
Coil feed lines in long design

Compact Line product line
The Compact Line from Schuler has been specially
developed for small coil widths and tonnages. It covers coil
widths up to 800 mm and tonnages up to 7.4 tons for
requirements with a straightforward level of automation.
Power Line product line

As an expansion of the Compact Line product line, Power
Line coil feed lines are available for large coil widths and
tonnages. These Schuler coil feed lines do full justice to
the requirements of the automotive and components
industry for material feed with the option of a high level of
automation for high-speed, prog-die and transfer presses.
Coil widths up to 1,850 millimeters and coil weights up to
27tons make it possible to prepare coil material for
structural and skin panels as well as blanks.
Schuler Power Line.
Technical data of the compact line

Compact Line L-BS 0450 L-BS 0650 M-BS 0800
Coil weight max. [t] 3 5.5 7.4
Coil width min. [mm] 110 [40] 110 [40] 110
Coil width max. [mm] 450 650 800
Coil thickness min.
0.5 0.5 0.5
[mm]
Coil thickness max.
4 4 6
[mm]
Leveling rolls [mm] 70 70 70
Loop radius [mm] 1,000 1,000 1,300
Power Line model overview

Basic versions of coil feed lines in long design
Coil data for Light weight class
POWER LINE L-BS 0650 L-BS 0800 L-BS 1050 L-BS 1300 L-BS 1600
Coil weight max. [t] 5.5 12 12 14.5 17
Coil width min. [mm] 110 [40] 110 [80]
Coil width max. [mm] 650 800 1,050 1,300 1,600
Coil thickness min. [mm] 0.5
Coil thickness max. [mm] 4
Leveling rolls [mm] 53
Loop radius [mm] 1,000
54
Coil data for Medium weight class

POWER LINE M-BS 0650 M-BS 0800 M-BS 1050 M-BS 1300 M-BS 1600 M-BS 1850
Coil weight max. [t] 13.5 11.5 12.5 13.5 16 22
Coil width min. [mm] 110 120 160 205
Coil width max. [mm] 650 800 1,050 1,300 1,600 1.850
Coil thickness max. [mm] 6 4 4.5
Coil data for Heavy weight class

POWER LINE H-BS 0650 H-BS 0800 H-BS 1050 H-BS 1300 H-BS 1600
Coil weight max. [t] 10 15 15 17 23
Coil width min. [mm] 120 205
Coil width max. [mm] 650 800 1,050 1,300 1,600
Coil thickness max. [mm] 8 6
Advantages
Flexibility: Attractive price/performance ratio:

Systems and components available on short notice Significant cost advantage by modular line configuration and
Scalable weight classes>Light>Medium>Heavy preconfigured components
Wide range of options can be retrofitted Energy-efficient by optimum drive configuration
Can be configured for manufacturing structural Very straightforward maintenance
and skin panels
Implementation of customer-specific requirements User-friendly machine operation:
Rapid retrofitting Intuitive operating concept
Flexible attachment to existing price systems Online diagnosis
Variable level of automation:

Manual or motor-driven adjustment of the setup axes
Visualization
55
TABLE OF CONTENTS
Roll feed unit
Power Feed roll feed unit

The Power Feed roll feed unit shortens the automation
time, especially with highly dynamic presses. ServoDirect
drives provide greater dynamics and system accuracy, as
do the low-play and maintenance-free planetary gear
units. In the long term too, this makes it possible to achieve
a system accuracy of 0.05 millimeters. Furthermore,
there is an optimally configured roll coating which
transfers the high acceleration values to the material. The
Schuler Power Feed is divided into different weight classes
depending on the mass to be moved: Weight class L
(Light) with movable mass up to 100 kilograms, M
(Medium) with movable mass up to 180 kilograms or H
(Heavy) with movable mass up to 300 kilograms.
Power Feed.
Feed performance diagram, Power Feed (example)
Stroke rate [spm] Feed time [s]
400 0,40
350 0,35
300 0,30
250 0,25
200 0,20
150 0,15
Feed time
100 0,10 240,0
180,0
50 0,05
120,0
0 0,00 60,0
0 100 200 300 400 500 600
Feed length [mm]
56
Roll feed model overview

COIL DATA
POWER FEED L-BP 0300 L-BP 0450 L-BP 0650 L-BP 0800 L-BP 1050 L-BP 1300 L-BP 1600
Coil width min. [mm] 40 40 40 40 40 80 80
Coil width max. [mm] 300 450 650 800 1,050 1,300 1,600
Coil thickness min. [mm] 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Coil thickness max. [mm] 4.0 4.0 4.0 4.0 4.0 4.0 4.0
Coil cross section max. [mm] 750 1,125 1,300 1,600 2,100 2,600 3,200
Loop radius [mm] 1,000 1,000 1,000 1,000 1,000 1,000 1,000
POWER FEED M-BP 0300 M-BP 0450 M-BP 0650 M-BP 0800 M-BP 1050 M-BP 1300 M-BP 1600 M-BP 1850
Coil width min. [mm] 40 40 40 40 40 80 80 80
Coil width max. [mm] 300 450 650 800 1,050 1,300 1,600 1,850
Coil thickness min. [mm] 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Coil thickness max. [mm] 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6,0
Coil cross section max. [mm] 1,350 2,025 2,600 2,800 3,150 3,900 4,800 7,200
Loop radius [mm] 1,300 1,300 1,300 1,300 1,300 1,300 1,300 1,300
POWER FEED H-BP 0650 H-BP 0800 H-BP 1050 H-BP 1300 H-BP 1600
Coil width min. [mm] 40 40 40 80 80
Coil width max. [mm] 650 800 1,050 1,300 1,600
Coil thickness min. [mm] 0.5 0.5 0.5 0.5 0.5
Coil thickness max. [mm] 8.0 8.0 8.0 8.0 8.0
Coil cross section max. [mm] 3,250 4,000 5,250 6,500 6,400
Loop radius [mm] 1,600 1,600 1,600 1,600 1,600
Advantages
Connection to all press types Scalable in weight class and performance

Ideally usable within highly dynamic processes Available on short notice
ServoDirect drive Low maintenance requirement
System accuracy of 0.05 millimeters Can be retrofitted at any time
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TABLE OF CONTENTS
Tri-axis transfer systems
Pro Trans
With its three motor versions L (Light), M (Medium)
and H (Heavy), Schuler Pro Trans covers low, medium
and high part weights and stroke rates. The heavy version
has twice the performance capability of the light version,
while the medium variant is situated in between. All the
transfers owe their significantly improved output
performance to having motor systems with direct advance
drive, featuring highly dynamic servo drives. Overall, the
Schuler Pro Trans has a modular principle: The three
defined standard models AT1, AT2 and AT3 can
quickly and easily be adapted to changed requirements.
Schuler offers a wide selection of options for this.
Power Trans
Schuler offers a high-end transfer solution for high-
performance presses in the form of Schuler Power Trans
Schuler Pro Trans transfer. and the S (Speed) motor system, the use of which
permits productivity to be increased even further and by a
The new modular transfer generation is a high-performance significant amount. For example, the output rate with
addition to sheet metal forming presses. Designed with Power Trans is up to 30% higher than with Pro Trans motor
three sizes, the transfer system covers a wide range of systems. This additional performance is achieved in
applications. In all transfer solutions, active vibration particular by using newly developed carbon rails with
damping AVD also guarantees reliable parts transport aluminum profile functions combined with the ServoDirect
with the highest level of dynamic properties and at full load. drive. The rails are very light and rigid, which means the
vibration levels are extremely low. As a result, they are
ideal for use in highly dynamic production processes.
Advantages
Can be retrofitted regardless of the press Low tendency for vibration

Optimally adaptable to different applications Short changeover times
Simple and cost-effective performance increase Large clearances for attaching components for material
High output performance feed and material unloading
High rigidity in the overall system Left-over strip processing regardless of material
58
Intra Trans Overview of the sizes

The Schuler Intra Trans can be equipped with all motor
Press window/drive unit
Size Support width [mm]
variants from L (Light) to S (Speed), which means it is width [mm]
suitable for use in presses ranging from conventional to AT1 3,000 up to 1,600
high-performance. In Intra Trans, the transfer rails do not AT2 6,000 up to 2,500
operate through the press window, but are installed AT3 10,000 up to 5,500
between the press uprights. Parts feed in the working
direction is performed by movable slides mounted on the
transfer rails, with servo drives integrated in the rail. Each Modular system
carriage of the Intra Trans can be moved individually so the All models in the Pro Trans, Power Trans & Intra Trans
central joining of parts or even different distances between series have gripper rail drive units that can be attached in
stations are possible. Using this compact transfer makes the press (1), between the press uprights (2) or on the
it possible to manufacture larger parts with the same outside of the press uprights (3). Furthermore, they can be
transfer press. The new transfer solution is also a genuine installed above (hanging) or below (standing) the transport
alternative to progressive die manufacturing. Conventional level, resulting in the highest level of flexibility both in
transfers require a larger press for the same maximum project planning and for retrofitting to existing presses.
part size but the compact design of the Intra Trans means
it needs only the same space as the progressive die. The
transfer exploits its full benefit: less material is consumed,
because the parts are transported by the slides and not by
the coil material itself. Additional material is required in
combined sequential production, and the material has to
be cut off the finished pressed part as scrap. Intra Trans
is ideal for retrofitting to existing combined sequential
presses as a means of reducing unit costs. Access to the
Slide
die and the die change are possible without restrictions
as before, and as far as the operator is concerned there is
no difference from the Schuler transfers in the Pro Trans
3 2 2 3
and Power Trans series.
Gripper rail Gripper rail
drive units drive units
3 2 1 1 2 3
Moving bolster
Attachment variants of the transfer drive housings of the Schuler

transfer system on the press upright.
59
05
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60
TABLE OF CONTENTS Press lines / The entire world of metal forming
AT A GLANCE
Press lines
The future starts with Schuler: with high-quality Hydraulic press lines 62
implementation and the technology of tomorrow, we are
taking measures today to ensure the greatest possible Hybrid press lines 64
productivity in mass production for the automotive
industry. Our results satisfy the most exacting Mechanical high-speed press lines 65
requirements and win over our customers worldwide.
Flexibility and quality are what we stand for. Our Servo press lines 67
innovations are unusual and practical. we create change
for the market, time and time again. Groundbreaking
new developments such as ServoDirect technology,
press automation with the crossbar feeder or crossbar
robot ensure the best component quality, high
availability and output.
SCHULER online
Would you like to find out more about our automotive press technology? You can find our complete selection
at www.schulergroup.com/automotive. In addition, the highlight on the page provides direct information
about the important aspect of High-Speed in the Stamping Plant.
61
TABLE OF CONTENTS
Press lines
Hydraulic press lines
Fully automated hydraulic press line. Press automation with crossbar robot.
Reliable, flexible and economical

Hydraulic press lines are mainly used to manufacture a wide developed by Schuler. The control and graphic display for
variety of parts in small to medium batch sizes. Depending hydraulic press lines offer the operator uniform, user-
on the forming operations, the lines consist of four to six friendly operation, efficient fault diagnostics and the
single presses. The production process is fully automated management of all process and die data for all presses
from the blank to the finished component. To an increasing and automation systems.
extent, automation is provided by the crossbar robot
advantages
Flexibility in the forming process Precise slide guiding and rigid press frames
Energy-efficient drive systems Uniform control concept
Dynamic cylinder mode switching and ring valve User-friendly operation and efficient fault diagnostics
technology increase production rates Fast takeover of new die sets
Automation for tooling and dies to ensure fast changeovers
62
HYDRAULIC PRESS LINES
In practice
Customer: TRUCK MANUFACTURER, FRANCE
Existing and newly-developed dies will be used. Automation with crossbar robot, one destacker and two
outfeed belts.

With the Euro-6 exhaust standard, permitted nitrous oxide Hydraulic lead press with 20,000 kilonewtons press force
emissions from trucks with a weight of more than 3.5 metric Three hydraulic follow-up presses, each with
tons are reduced by 80 percent. Our customer took this 10,000kilonewtons press force
opportunity to thoroughly revise its entire model range. In Destacker
future, for example, important components of the new Press automation with crossbar robots
trucks will be produced on a high-performance hydraulic Unloading with crossbar robot
press line from Schuler. High productivity combined with Two outfeed belts
high flexibility proved to be convincing arguments.
63
TABLE OF CONTENTS
Press lines
Hybrid press lines
Lead press hydraulic follow-up presses

mechanical
Hybrid press lines consist of a hydraulic lead press and
mechanical follow-up presses. They are a cost-effective
alternative when single-action and double-action dies will
be used on the same line. Modern hydraulic slide drives
put the output rate of hybrid lines in the region of
mechanical press lines. The slide cycle of hydraulic lead
presses is user-programmable, and the nominal press
force of the press is fully available at any time throughout
the press stroke.
Hybrid press line with hydraulic lead press and mechanical

follow-up presses.
advantages
One forming system for single and double-action dies Suitable for complex drawn parts because of the
Flexible production alternative modern bolster cushion technology
Quick and easy startup of new die sets
64
Press lines
Mechanical high-speed press lines
Crossbar feeder improves output performance

To increase the cost-effectiveness of mechanical press
lines, Schuler developed the crossbar feeder. In press
lines with crossbar feeder automation, the components
are transported directly from press to press without
intermediate stations. If required, the components can
also be repositioned before placement into the die. As
compared to mechanical press lines with robot or feeder
automation, it is possible to achieve production rates
as high as 15 strokes/minute.
In mechanical press lines with crossbar feeder automation,

both the loading of press 1 as well as unloading the
finished parts can be performed with the crossbar feeder.
Mechanical high-speed press line with crossbar feeder automation.
Advantages
Output rate up to 15 strokes/minute One set of tooling for each press opening
Crossbar feeder with seven degrees of freedom Short distances between presses
No intermediate stations required Rapid die and tooling changes
65
TABLE OF CONTENTS
Mechanical high-speed press lines
In practice
Customer: Automobile manufacturer, People's Republic of China
Mechanical high-speed press line. End-of-Line-System.

Delivery of a fully-automated mechanical high-speed Schuler high-speed press line.
press line.
Destacker
Loading press 1 with crossbar feeder
Fast die change
Crossbar feeder press automation
End-of-Line-System with crossbar feeder and robot
Control station
66
Press lines
Servo press lines
Quick, compact and flexible

Equipped with a Schuler destacker, crossbar feeder and
End-of-Line-System, servo press lines offer the greatest
possible flexibility, high output rates with a wide range of
parts as well as short die and tooling change times. Using
innovative drive technology, the slide movements of all
presses can be individually adapted for each component,
the forming process, the die and the parts transport. In
identical processes, this leads to higher output rates for
single, double or four-fold parts in steel, aluminum and
components made from higher-strength materials. The
combination of high output, short change times and high
flexibility contributes to reduction of part unit costs and
improvement to the productivity of press shops.
Six-station ServoLine18 XL with six die stations.
Advantages
Output rate up to 23 strokes/minute Fully automatic die and tooling change in three minutes
High level of flexibility One set of tooling per press opening
Reduction in part unit costs Die tryout possible with hand wheel function
Slide movement freely programmable User-friendly user interfaces
Optimum adaptation to various forming processes Ergonomic parts outfeed
Automation with destacker and crossbar feeder Easy-to-maintain technology, because the flywheel,
Compact design of the press line clutch and brake are dispensed with
67
TABLE OF CONTENTS
Servo press lines
In practice
Customer: Automobile manufacturer, Germany
ServoLine18 XL with six die stations. Destacker. Control station.
The requirements:
Delivery of three servo press lines for large-scale mass production of a wide
range of parts in three plants. Output performance: 17 strokes/minute.
The solution:
Fully automated servo press line with six die stations.
Destacker with lubricating unit and optical centering station

Loading press 1 with crossbar feeder
Crossbar feeder press automation
End-of-line system with robot and crossbar feeder
Control station
Crossbar feeder simulator
Die change in three minutes
68
ServoLine23 L: With an output rate of 23 strokes per minute, it is the fastest press line in the world.
69
06
TABLE OF CONTENTS
70
TABLE OF CONTENTS Automation of press lines / The entire world of metal forming
AT A GLANCE
Automation of press lines
From the single press to the complete press line: As a Destacker for press lines 72
system supplier, we automate your forming systems
intelligently and practically. We boost the performance of Blank washers and lubrication units 73
your production efficiently and economically. Whether it
comes to a broad portfolio of parts, high productivity or Robots 74
the need for a compact space, automation solutions from
Schuler guarantee high efficiency and reliable production Crossbar robot 75
processes. When it comes to modernizing existing lines,
we offer tried-and-tested practical solutions for efficient Crossbar feeder 76
production of components in the highest quality.
Automation solutions from Schuler deliver convincing Part racking systems 77
performance in all aspects of forming technology.
SCHULER live
Your direct contact to the Automation TechCenter:

Gemmingen | Telephone: +49 7267 809-141 | E-mail: atc-gemmingen@schulergroup.com
Hedorf | Telephone: +49 9135 715-264 | E-mail: atc-hessdorf@schulergroup.com
Canton, MI USA | Telephone: +1 734 207-7279 | E-mail: atc-canton@schulergroup.com
SCHULER ONLINE
Would you like to find out more about our stamping plant? You can find our High-Speed in the Stamping Plant
focus at www.schulergroup.com/automation. In addition, you can download the Performance along the line
Automation from Schuler brochure as a PDF.
71
TABLE OF CONTENTS
Destackers for press lines
Modular designed destacker concepts for mechanical and

hydraulic press lines are designed to suit downstream
forming systems. Schuler offers a selection of models
adapted to the required part size and contour, the type of
material, the blank weight and the loading speed. From the
simplest loader with one robot without centering station
for small parts and simple operations, up to destackers
with two destacking stations, optical or mechanical
centering station, blank washers and lubrication units for
large and/or heavy blanks we have it all. The blank
destacking is performed by the robot or feeder. To help
make full use of the capacities of large press lines, two
or even four blanks can be processed at the same time.
For press lines with crossbar automation, loading the
first die station can be performed by a crossbar robot or
crossbar feeder. In addition to handling conventional
steel sheet, these destackers can also process blanks
Optical centering station. in aluminum, steel-aluminum mix, and higher-strength
steels.
components
One or two destacking stations for separating blanks Lubricating unit

with a double blank monitor Loading unit with robot, crossbar robot
Optical or mechanical centering station or crossbar feeder
Wash unit
72
Blank washers and lubrication units
Blank washer, lubrication unit and loading Blank washers provide a high and Destacker with wash unit.
robot in front of a hydraulic press line for consistent component quality.
manufacturing aluminum components.
Blank washers and In addition, blank washers also Depending on requirements, the
lubrication units provide significant reductions in blank washers are designed to suit
Superior quality for outer skins and downstream reworking and costs variable blank lengths and widths.
structural parts requires blank when it comes to body-in-white A defined amount of oil provides
washing prior to processing to remove assembly and painting. Blank optimum preparation of the blank for
any dirt and deposits, and a final washers are an integral part of subsequent forming processes.
application of a defined amount of oil. modern destackers and can, if Flexibly programmable spraying
The effect of systematic washing and required, be retrofitted to existing heads in the lubrication unit ensure
a consistent application of oil prevents lines. superior part quality for forming
downtime for the entire process. involving high drawing forces.
advantages
Superior, consistent surface quality of the components Cost-savings for entire process
Best possible part quality, even with high drawing forces Longer intervals between die cleaning
Increased productivity levels
73
TABLE OF CONTENTS
Robots
Press line with robot automation. Loading robots position the blanks accurately in the die
of the first press.
In addition to advanced automation solutions, such as

crossbar technology, there is still a place for conventional
solutions with robots. Robots are flexible since only one
robot is required per press opening. Automatic
changeover of robot tooling is easy.
74
CROSSBAR ROBOT 4.0

CONNECT FOR SUCCESS!
The crossbar robot combines proven robot technology with

the advantages of crossbar technology. This application uses
a conventional industrial robot. The robot is then expanded
by one feed axis and the crossbar beam provides a second
axis. The horizontal motion takes place along the x-axis that
is mounted on the press uprights. Programming is done at
the operator's panel for the robot. The crossbar robot can
be delivered with new lines or integrated into existing press
lines.
Connection to Industry 4.0.

The process data interface means the new Crossbar
Robot 4.0 is already optimally prepared for the Industry
4.0 age. Components such as personalization, networking
and resource efficiency will play an even more important
role; intelligent system components that actively intervene
in controlling the production process are central features.
In the Automation TechCenter Gemmingen, the crossbar robot
combines the advantages of robot technology with crossbar
technology in an innovative design.
advantages
20% more energy efficient due to innovative energy Flexible parts orientation from die to die
management No turning of components from die to die
50% weight reduction of the robot from about User-programmable change in parts orientation
2,800 to 1,400 kg Full tooling compatibility with crossbar feeder
20% more dynamic, due amongst other things to modified Complete solution including destacker and end-of-line
movement drive with two motors for high speed Can be used as destacker and unloader
Simply programmable with new robot controller Single, double and four-fold parts production possible
Lighter, faster, higher performance Suitable for steel and aluminum
Individual customer tooling interface One set of tooling per opening
Direct parts transport from die to die Rapid automatic tooling change
Press spacings from 4.5 to 10 meters, without idle station Ease of maintenance due to free access to the gap
between the presses
75
TABLE OF CONTENTS
Crossbar feeder
Crossbar feeder within the press line. Three rotating and four linear axes.
The crossbar feeder is the automation technology for productivity of the stamping plant. The components are
high-speed mechanical and servo press lines. It increases transported from die to die without intermediate stations
the line and process efficiency of mechanical press lines. and can also be repositioned. The short, compact design
The crossbar feeder offers seven degrees of freedom, makes the feeder extremely rigid.
three rotating and four linear axes, increasing the
Advantages
Seven degrees of freedom One set of tooling per press opening

Output rate up to 23 strokes/minute Variable press spacings
No intermediate stations required Free access to the press opening
Optionally available with feed-direction rail for large Compact construction possible
distances between presses Fast die changes
76
Part racking systems
Press line with ServoDirect technology

and automatic part racking system.
Part racking systems are reliable and fast, while ensuring data is transferred to the robots. The robots thus pick up the
maximum part quality. A special suction-cup technology finished parts in the correct orientation and stack them in
protects the highly sensitive surfaces of outer skin panels parts containers. The automatic racking system allows
for downstream processing and preparation for subsequent single, double and four-fold parts to be stacked. Up to four
body-in-white assembly. robots are used with single parts, while there are up to eight
used with double and four-fold parts; in this case, the robots
Automatic part racking system for operate in pairs and alternately stack the parts in the same
servo press lines container in order to ensure a high output rate. Optionally,
The newly-developed, automatic, flexible part racking the part racking system can be equipped with an automatic
systems from Schuler operates with hanging robots, which quality control function.
can additionally be moved on a track. The position of the
finished parts is detected visually by a camera system.
Following that, the correction
Advantages
Stacking of single, double and four-fold parts Compact, short design

Four-fold racking performance up to 68 parts/minute Automatic quality control can be integrated
77
07
TABLE OF CONTENTS
78
TABLE OF CONTENTS Tryout systems / The entire world of metal forming
AT A GLANCE
Tryout systems
Tryout systems offer the highest level of flexibility for die Hydraulic die-spotting and 80
making and stamping plants. Depending on the tryout presses
requirements, they contain various hydraulic or mechanical
press types, die turnover devices and turntables. The Hydraulic Multicurve presses 81
time-consuming job of manually reworking the dies is
carried out outside the tryout presses. The individual Tryout centers 82
components of the tryout system are connected by moving
bolsters on a rail system. Tryout presses with 84
ServoDirect technology
Die turnover devices and simulators 85
SCHULER ONLINE
Would you like to find out more about our tryout systems? You can find our complete offer at
www.schulergroup.com/hydraulic_press. There you can find a complete overview of all our
system solutions.
79
TABLE OF CONTENTS
Tryout systems
Hydraulic die-spotting and tryout presses
Die tryout before the production startup

To keep the startup costs of new die sets low, it is important
to prepare them optimally for series production. Hydraulic
tryout presses ensure short startup phases under
near-to-production conditions. They are suitable for use
in die tryout and startup prior to production getting
underway. The line operator has the full press force
available at any time, and can lower the upper die
sensitively onto the lower die if required. In terms of sizes,
performance data and equipment details, die-spotting
and tryout presses are designed to meet the requirements
of die tryout and pilot-series production.
Tryout center with hydraulic tryout presses.
Advantages
Programmable speeds and forces For double-action presses: operation possible in single-
Slide return possible at any point action or double-action modes
Precise slide movements using a joystick Rigidity like production presses
Maximum force available over the entire stroke Bed cushion technology like in production lines ensures
Simple adjustment for varying die heights optimum startup results
80
Tryout systems
Hydraulic Multicurve presses
Precise simulation of forming processes

Hydraulic multicurve presses are used for starting up die
sets in the die shop, in tryout centers, in the stamping plant
and for verifying the method under production conditions.
Equipped with a hydraulic accumulator drive, they simulate
the slide motion characteristics of various hydraulic and
mechanical production presses. To properly represent the
forming processes of mechanical production lines, the
hydraulic multicurve press achieves working speeds up to
500 millimeters/second. Various user-programmable slide
motion curves are available to the user at any time, with
any desired adjustable stroke rate. Multi-point die cushion
technology ideally identical with the drawing station in
the production line ensures optimum breaking-in results.
Multicurve presses with moving bolster and die turnover device.
Advantages
Precise simulation of the slide movement curves of Reduction in startup times on production lines
all press types Bed cushion identical to that on the production press
Drawing speeds up to 500 millimeters/second
User-friendly management of the programmable
motion curves
81
TABLE OF CONTENTS
Tryout systems
Tryout centers
Flexible system solution in the die shop

Tryout centers with a number of different press types offer
an extremely high degree of flexibility in the die shop.
Depending on the design, these centers may include
mechanical and hydraulic die-spotting and tryout presses,
die turnover devices and turntables. The time-intensive
manual die rework mainly takes place outside of the tryout
presses. The various pieces of equipment within the tryout
center are connected by moving bolsters on a rail system.
The dies can be moved into the optimum position for the
required work.
Tryout center with die-spotting and tryout press.
Advantages
High level of flexibility Use of simple die-spotting presses for die-spotting work
Die startup on moving bolsters outside the presses Optimum utilization of the equipment
Turning the upper dies with die turnover devices for
ergonomic reworking from above
82
Hydraulic die-spotting and tryout presses in the die shop
In practice
Customer: Automobile manufacturer, Germany
Tryout center with hydraulic tryout presses. The slide can be moved sensitively up and down using a joystick.
The requirements: A hydraulic multicurve press, press force:

Tryout center for die startup of series production dies. 25,000kilonewtons
With multicurve accumulator technology
The solution: Drawing cushion in eight-point design
Tryout center with a total of twelve hydraulic
tryout presses. Three hydraulic multicurve presses, press force:
21,000kilonewtons each
Bed and slide dimensions: 4,500 2,500 millimeters With multicurve accumulator technology
Each press with moving bolster to the front, hydraulic Drawing cushion in eight-point design
drawing cushion, hydraulic slide cushion and hydraulic
impact shock dampening Four hydraulic tryout presses, press force:
Four hydraulic tryout presses, press force:

83
TABLE OF CONTENTS
Tryout systems
Tryout presses with ServoDirect technology
Increasing the availability of

production presses
Tryout presses with ServoDirect technology are configured
as a duplicate of mechanical production lines. The bowing
and deflection properties of the line are consistently
simulated for the slide drive, connection point
arrangement, spacings between uprights and bed
cushions. This means the availability of production
operation can be increased even further. The hand wheel
function in particular offers the press operator new
possibilities when starting up new dies. The servo drive
allows optimum simulation of the movement properties
of an extremely wide range of presses.
Tryout presses increase availability in the press shop.
Advantages
Simulation of the production conditions of Reduced parts costs per stroke

mechanical presses Slide tilting is identical to production presses
Increased availability in production Takeover of die data
84
Tryout systems
Die turnover devices and simulators
Die turnover device for easy turning of upper dies. Simulator device for crossbar feeder.
Die turnover device Ergonomical DIE REWORK Simulators precise setup of

For ergonomic rework of upper dies in the tryout phase, it automation equipment
is preferable to turn them to an ergonomically favorable At the interface between the die shop and stamping
position. Die turnover devices are used for safe opening and plant, tryout presses and simulators both play a role
turning, and can be connected to the tryout presses using in preparing dies and automation devices for series
moving bolsters. Die turnover devices simplify die production while the production continues without
handling, so that the dies are subsequently available to interruption. The component transport is simulated and
the production presses more quickly. optimized in order to reduce cost-intensive setup phases
on the production presses.
THE ADVANTAGES
Simple opening and turning of the dies THE ADVANTAGES
Ergonomic rework of the turned dies Simulation of the automation while production continues
Integration into tryout centers using rail systems Shortening of changeover and startup times
and moving bolsters Increased press uptimes
Training of employees while production continues
85
08
TABLE OF CONTENTS
86
TABLE OF CONTENTS Lightweight technologies / The entire world of metal forming
AT A GLANCE
Lightweight construction technologies
Nowadays, it is technically feasible to build a light and safe Press hardening with PCH technology 88
car, but the manufacturing costs are a factor. Some
particularly light and low-consumption car models did not Hot Stamping TechCenter 91
attract enough buyers in the past, because they were too
expensive for customers. In the future, there cannot be Cold forming of high-strength steels 92
simply one basic approach to achieving greater efficiency.
What are called for are different concepts according to Aluminum forming 93
individual customer requirements and vehicle categories.
It is only through the interplay of several processes and Forming of fiber-reinforced plastics 94
the use of different materials that the required success
can be achieved in lightweight construction. Each material Hydroforming 95
has specific strengths, and is therefore suited to different
installation areas in the car.
SCHULER live
Your direct contact to the Hydroforming TechCenter:

Canton, MI USA | Telephone: +1 734 207-7279 | E-mail: hytc-canton@schulergroup.com
Your direct contact to the Hot Stamping TechCenter
Gppingen | Telephone: +49 7254 988-220 | E-mail: hstc-goeppingen@schulergroup.com
SCHULER ONLINE
Would you like to find out more about pressure-controlled hardening (PCH) in the forming process?
You can find further information at www.schulergroup.com/forming_systems. In addition, you
can download various brochures on the topic from there, or view an explanatory film.
87
TABLE OF CONTENTS
Press hardening with PCH technology
PCH Hardline Multi press hardening line.

88
Sustainably successful
Schuler makes cars lighter. The results are: lower fuel
consumption and CO2 emissions. The greatest saving
potential available in today's passenger cars are to be
found in the bodywork and running gear, which together
comprise about 65 percent of the vehicle's mass. Perfectly
built, quality components for the chassis, engine and
bodywork not only make cars look attractive, they also
guarantee safety and comfort. Press hardening with
Pressure Controlled Hardening (PCH) technology is the
basis for higher body rigidity significantly improving
crash behavior. In press hardening, high-strength safety
components are manufactured by heating the blank, then
forming in a hydraulic press with rapid cooling in the die.
Steels with initial strengths of 500 to 700 newtons/
square millimeter achieve ultimate strengths of 1,300
to 1,600newtons/square millimeter.
Press hardening of safety components in large-scale production.
The component spectrum of press hardening:
Side impact elements and B-pillars
Side sill plates
Roof frames
Support parts
Tunnel
Door frame reinforcements
Bumpers
Advantages
Higher strengths with reduced component weight Good repeat accuracy without spring-back
Higher rigidity of the bodywork Less expensive material compared to high-strength steels
Improved crash behavior No high press forces required
New possibilities in component design
89
TABLE OF CONTENTS
Press hardening
Today Yesterday
Innovative press technology Simple press technology
Presses with Presses without cushion

cushion technology technology
Fast die startup Long die startup
Slide tilting in multiple

No slide tilting
production
Short cool-down times Long cool-down times
High-speed transfer Robot or

automation feeder automation
Average production rate 12 to Average production rate 4 to

24 parts/minute 6 parts/minute
Bowing compensation Influences from bowing
Press hardening die for series production.
The press hardening performance range
Forming simulation - Centering station - Laser equipment

Die design and construction - Robot or transfer automation - Finished part handling
System engineering and installation - Integration of furnace technology - Master controller
- Destacker - Blanking presses and dies
- Hydraulic press technology - Soft-Shock technology
90
Hot Stamping TechCenter Gppingen
Fully automated press hardening line with innovative Press hardening of safety components in large-scale production.
PCH bolster cushion concept.
TechCenter with automated press hardening line opening us to try out your series production dies at the TechCenter
in fall 2015. At the Hot Stamping TechCenter Gppingen, under realistic conditions, so you can significantly reduce die
Schuler is bringing together all its expertise in press tryout times on your premises. If you need initial prototypes
hardening along the entire added-value chain. As a system or pilot series parts, we can manufacture them for you in
supplier, we are continuously developing machine, die and our TechCenter.
process technology further. We are optimizing the applica-
tions in automotive series production so as to reduce cycle Technological advice spanning processes:
times and cut costs per component. Take advantage of this Extensive process and line expertise
decisivelead in experience when it comes to boosting Further development in line and process technology
efficiency and optimizing stroke rates. The short distances Die tryout and production of prototype parts
from our tool and die production facility enable Training on the press hardening line
Backup possibility for Schuler customers
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TABLE OF CONTENTS
Cold forming of high-strength steels
Innovative lightweight vehicle manufacture is now

inconceivable without high-strength steels, and
applications in mass production will increase in coming
years. It is possible to achieve further reductions in sheet
thicknesses by using new, high and extra high-strength
steels while maintaining the same component properties.
This means a lighter weight and reduced costs.
ServoDirect technology is pointing

the way to the future
Press lines, transfer and prog-die presses as well as
blanking systems with ServoDirect technology have
significantly changed stamping plants. They are
characterized by maximum flexibility, high output and
short die change times. The slide movement of each press
for each component can be individually adapted to the
forming process, the die and the automation. This
ServoDirect press for cold-forming high-strength steels. is opening up new possibilities for cold forming of
high-strength steels.
New processes new possibilities

Using the advantages of ServoDirect technology, Schuler
is developing new production concepts for manufacturing
lighter components. For example, interdisciplinary teams
are looking into the possibility of integrating follow-on
processes or adopting new approaches for manufacturing
hybrid components. The objective is to develop new
production processes that can meet all the requirements of
series production despite the conflicting objectives of
reduced component weight, efficient production and high
safety requirements.
92
Aluminum forming
Aluminum has now become a standard material in the area

of hang-on parts in many vehicle types. The material can
significantly reduce the weight of a body-in-white, even
if it is only rarely entirely made by forming aluminum.
Nowadays, about 40 percent of the overall weight of a car
is accounted for by the body. The trend for an increasing
variety of materials means aluminum is being used to an
increasing extent in automobile production.
From the skin through to the front wing and bonnet

aluminum is being used more and more frequently in
modern, reduced-weight vehicle manufacture because
these applications are often selected as a means of
replacing heavier materials. Thanks to its unique energy
absorption ability, it can also save lives in case of a
collision. Lower fuel consumption, greater comfort and
performance are further arguments alongside that of
Hydraulic press lines for manufacturing aluminum components. increased safety for the use of aluminum as a material.
Schuler develops mechanical and hydraulic press lines as

turnkey solutions for processing aluminum skin panels.
We order suitable retrofit solutions for existing production
systems. Our turnkey machines have all of their
components designed for the materials they will process,
from automation through to the press and die.
93
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Forming of fiber-reinforced plastics
Fiber-reinforced plastics offer a great deal of design

freedom and a wide range of functions with minimum
component weight. They represent new, lightweight
concepts in vehicle architecture and in bodywork
manufacture. Schuler builds fully automated hydraulic
press systems for efficient and reliable series production
of fiber-reinforced components, that can withstand
even the most demanding component and production
requirements.
Hydraulic press systems from Schuler are suitable for

series production of SMC (sheet moulding compound)
components, GMT (glass mat thermoplastics) components,
LFT (long fiber-reinforced thermoplastics) components
and RTM (resin transfer moulding) components. Different
systems are used for these, depending on the component
requirements and the production process.
Hydraulic plastic presses for the series production.
The result is: Best parts quality and highest production
reliability for greater efficiency and maximum
productivity.
Hydraulic presses for fiber-reinforced plastics

Press force [kN] 12,500 16,000 21,000 25,000 30,000 36,000
Press force with max. parallel

10,500 14,000 18,000 22,000 26,000 32,000
control force [kN]
Bed size [mm] 2,8001,800 2,8001,800 3,0002,000 3,2002,200 3,4002,400 3,6002,400

Slide stroke [mm] 1,600 1,600 1,800 1,800 1,800 1,800
Shut height [mm] 2,200 2,200 2,600 2,600 2,600 2,600
Further sizes are available on request.

94
Hydroforming
Automatic tubular hydroforming machine at an American Tubular hydroforming of longitudinal members.

automobile manufacturer.
Tubular hydroforming offers a wide variety of Schuler offers its partners not only elaborate systems
opportunities. Above all, however, it is used in series and integration solutions but also component analyses,
production of automobiles, since this is where particularly feasibility studies, prototype and die construction all
high requirements in terms of component composition from a single source.
and component design need to be met. The process is used
for, among other things, forming exhaust, chassis and
structural parts.
Advantages
High component rigidity and strength Maximum repeat accuracy

Low component weight by optimized design without High component quality and long service life by avoiding
material duplications welds and having a geometry optimized with regard
Best exploitation of material to function
Integration of additional functions in the components High freedom of design for complex components
95
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96
TABLE OF CONTENTS Die and forming technologies / The entire world of metal forming
Die and forming technologies
Consistent performance
Targeted support
To be prepared for the challenges of the future, we tackle
them with efficient structures. By establishing our own area,
we have reoriented ourselves strategically, and are now
capable of supporting you in an even more targeted and
consistent way. For example, we are excellently prepared to
expand our range of services and products to include new
ideas and innovative concepts. That is the basis for future
success together: after all, your success is our success! The
product development process is our key area of expertise.
Whether you are looking for a complete solution or a partial
one without knowledge of the entire process cycle, we can
offer you inestimable advantages for your production.
Stage set.
Successful together
Feasibility & Methods & Design Mechanical Assembly Tryout Stamping Training &
Component
simulation production processing plants startup
concepts support in
Quality
Multi-disciplinary technological process team
97
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Success can be programmed. After all, perfectly matching Transfer die for manufacturing disk carriers.
processes are required for producing components in the best
quality and with maximum output rates.
Engineering performance spectrum Range of die services
Method planning /simulation Body dies for

Feasibility analyses Skin panels
Creation of methods and drawing systems Structural parts
Process layout creation Press hardening dies for series production
Deep-drawing simulation including simulation Press hardening dies for prototypes
of the follow-up stations
Springback calculation Powertrain dies for
Active surface creation Disk carriers
Crowning and overpressure points Spiders
Guide disks
Design Thrust washers
Simulation of dies and press sequences
Drawing and forming dies Modular dies for
Trimming/perforating dies Friction modules
Progressive dies Piercing nut modules
Mechanization systems Sheet metal forming
98
TABLE OF CONTENTS Die and forming technologies / The entire world of metal forming
New press generation TST TwinServo technology at the Prototype machine in Gppingen.
Servo TechCenter Erfurt.
Parts production performance range Servo TechCenter Tianjin

Disk carriers
Gppingen stamping plant Guide disks
Skin panels Spiders
Structural parts Structural parts
Hot Stamping TechCenter Gppingen At our sites in Gppingen and Erfurt, we offer you the
Press hardening parts/prototypes following services in our stamping plants: Startup as
well as process and quality optimization, temporary
Servo TechCenter Erfurt part pressing operations, small-series production and
Disk carriers production of press hardening parts for prototypes
Guide disks and small batches.
Spiders
Structural parts
From simulation through to series production
Thanks to our core expertise in engineering, method and die making as well as tryout, we meet the ever increasing needs
of the automotive and components industries with intelligent, complete solutions.
99
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100
TABLE OF CONTENTS Systems for large pipe manufacture / The entire world of metal forming
AT A GLANCE
Systems for large pipe manufacture
With Schuler, you lay the foundations for success with SPIRAL PIPE PRODUCTION SYSTEMS 102
economic, efficient and high-output production of spirally
and longitudinally welded large pipes. On your behalf, we System solutions for longitudinally 104
develop turnkey production lines for large pipes whether welded LARGE PIPES
pipelines for crude oil, natural gas, water or large pipes
in the petrochemicals industry, for use in wind turbines or
in the construction industry. Not only do we offer the
necessary experience, we also provide the appropriate
worldwide service for any required solution and projects
of all scales. We ensure that we maintain our position
of leadership in quality by permanent innovations and
investments in research and development.
At Schuler, we regard turnkey solutions for manufacturing

large pipes as a highly integrated overall concept:
From innovative layouts and designs through to intelligent
production principles. Our goal is for you to be able to
produce in an environmentally friendly way, minimizing
your use of resources. In this way, you can benefit during
every phase from our extensive, groundbreaking expertise
in large pipe manufacture and from our competence.
SCHULER online
Would you like to find out more about our system solutions for large pipe manufacture? You can
find our complete offer at www.schulergroup.com/Large_Pipes. In addition, you can download
the System solutions for manufacturing large pipe brochure as a PDF file.
101
TABLE OF CONTENTS
SPIRAL PIPE PRODUCTION MACHINES
Online process
Combined forming and welding machine
The pipe forming is directly followed by submerged arc
welding from the inside and outside.
Offline process
Separate forming and welding machine
After pipe forming and subsequent tack welding, the
submerged arc welding process is performed from the
inside and the outside on separate welding stands;
speeds up to 12 meters/minute
Modernization
Conversion of existing online machines to the
offline process
The objectives of such a conversion of existing machines
are to increase quality and productivity as well as
Spiral pipe production machine. improving safety at work and energy efficiency.
Technical data
We plan and implement complete production plants for Suitable for spiral pipes with
manufacturing spirally welded large pipes, making them Length up to 24 meters
turnkey for you. The machines meet the most demanding Diameter from 450 to 3,500 millimeter (18"140")
requirements in terms of diameter tolerances or welding Wall thickness from 6 to 25 millimeters (1/4"1")
gap, as well as impressing with maximum availability Other dimensions possible on request.
and productivity. Schuler offers progressive and high-
performance solutions, precisely adapted to your the advantages
requirement profile and tailor-made to your specific Automation of important working steps
requirements from planning and consulting through Increased safety at work
to startup. Low downtimes
High process reliability
Reproducible, high product quality
Planning and implementation of complete
production lines
102
Hydrotester. Coil preparation stand. End beveling machine.
Hydrotester Coil preparation stand End beveling machine

Ball head mounted inside sealing Schuler ensures a significant Automatic clamping with correct
or face sealing simplification in handling during the force according to the diameter
Water hydraulic control system coil change at the same time as Infinitely coverage for all
Variable holding time improving quality and optimizing diameter ranges
Connected to PID data system procedures. Not only does this enable Short changeover time
Automatic pipe positioning you to reduce unproductive down- Concentric clamping
Automatic test sequence times, it also ensures consistently Energy recovery by using the
Visualization with database for higher efficiency throughout the latest inverter technology
all pipe parameters production process. Furthermore,
Full automatic pipe feeding you sustainably increase the safety
of work on the stand.
Pipe diameter [inch] 18140 Coil weight max. [t] 45 Cutting speed
90
Pipe length [m] 824 max. [m/min]
External coil
1,300 2,200
Closing force max. [kN] 50,000* diameter [mm]
Face plate feed speed
550
[mm/min]
Water pressure Internal coil
400 720 800
max. [bar] diameter [mm]
Face plate drive servomotor
200
Coil width [mm] 1,000 2,050 max. [kW AC]
High-pressure control
33300
range [liter/min] Coil thickness [mm] 6 25.4
* Higher closing forces on request. Coil unwinding

0.3 6.0
[m/min]
Plasma cutter
0.1 3.0
[m/min]
103
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LONGITUDINALLY WELDED LARGE PIPES
formed either using a bending element or with a broad

bending shoe. This ensures fast and efficient production.
Process for high production output

U-O-presses primarily represent a solution when the
highest possible production output of a particular pipe
dimension range is to be achieved. As with the bending
presses, the C-press is also configured as the crimping
press for pipe forming; together with the tacking press
it ensures consistent pipe forming, while this concept
provides optimum passage through all the individual
pipe production stations.
Modernizations
Presses and machines from Schuler are particularly
suitable for complete modernization concepts or
exchanging individual system components in existing
Large pipe production machine. pipe plants.
Technical data
Regardless of whether your machine should be designed Suitable for longitudinally welded large pipes with
for longitudinally welded large pipes with a bending press Length up to 18.3 meters (60')
or with U-O-presses Schuler provides you with the Diameter from 406 to 1,625 millimeters (16"64")
innovative and forward-looking production technolgy. We Wall thickness 12 to 70 millimeters (0.48" 2.76")
adapt and individually tailor our presses to your product Other dimensions possible on request.
dimensions. Not only are we your expert for efficient
modernizations in order to optimize the performance of the advantages
existing pipe plants, we are also the ideal technology Planning and implementation of complete
partner for complete turnkey solutions. Whichever production lines
approach you take the best idea is to get the expertise Matching processes and process sequences
and experience of Schuler on your side right from High process reliability
the outset. Reproducible, high product quality
High level of automation
Step process for flexible production Safeguarded high availability
Schuler bending presses (step process) are universally Energy-efficient hydraulic drives EHF
applicable for pipes with diameters from 406 mm to Global service network
1,625mm (16"64"). Pipes in this dimension range can be Security of investment by turnkey solutions
104
Longitudinal welding pipe presses. U-O press.
LFJ pipe forming press U-O presses

The modular LFJ pipe forming press is a further The particular advantage of the U-O process is its high
development of the conventional pipe forming press. This production output of pipes with one set of dimensions. The
unique development means that Schuler has an exclusive individual forming steps are adapted to this in order to
and attractive product highlight in its portfolio. It is produce a good quality open-seam pipe. In this way, the
characterized by an almost direct sheet feed, and bowing subsequent production steps can be carried out optimally.
compensation is not required. The modular structure
ensures straightforward transport and input into the the advantages
press without difficulty. High productivity for set pipe dimension
Optimized die setting
the advantages Simple integration into existing production lines
High productivity because the panel is loaded at the Modernization option for existing machines
same time as the open-seam pipe is unloaded Comprehensive, tried-and-tested operating concept
High productivity because bending shoes can be used
High flexibility by using the bending element
High process reliability by simplified press design
Simple transport and trouble-free integration into
existing production lines because of modular structure
Simple structure with scope for future uprating
by extension for bending longer pipes
Automatic die change and die adjustment available
as an option
105
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106
TABLE OF CONTENTS schuler service / The entire world of metal forming
schuler service
State-OF-the-art service for
more performance
Over 900 service employees worldwide provide expert Components and Accessories:
support 24/7 in close cooperation with you our partners. Spare parts and spare part packages
Our main priority is always to ensure the maximum Maintenance kits
productivity and safety of your production equipment in Repair parts
order to secure your companys continued success. Replacement parts
With over 175 years of experience and expertise, we can Project Business:
guarantee the best possible support for the operation of Modernization
your machines and not only those supplied by Schuler, but Retrofits
by all other manufacturers. Whatever the situation, Schuler Refurbishment
Service has the right solution for your specific needs. Machine relocations
Special Services:
Our services for you. Service contracts
Hotline and remote service
Technical Customer Support: Training
Machine inspections Tailored customer training
Safety inspections Optimizing plant & processes
Preventive maintenance Consulting
Repair
Repair welding Used Machinery:
Production support Purchase and sale
Evaluation
Schuler Service ONLINE
Want to know more about our full range of services?

Simply scan the QR code with the camera of your smartphone or tablet.
www.schulergroup.com/service_en
107
TABLE OF CONTENTS
Schuler Service
Greater reliability, improved planning

capability, optimized efficiency
Our service contracts are tailored to your needs as users

of our machines. They offer you greater reliability, better
planning capability and optimized efficiency in the press
shop.
The BASIC service contract is used for maintaining the

operational reliability of your machine and offers both
quick and highly qualified assistance in case of problems,
thanks to our hotline and remote service center.
The STANDARD service contract improves your ability

to plan production. In addition, we support you on a
24/7 basis.
The ADVANCED service contract also contains many

consulting services to increase your efficiency in the
press shop.
SERVICE CONTRACTS BASIC I STANDARD I ADVANCED

ADVANCED
The world your company works in today is full of challenges.
Schuler service contracts help you to overcome this STANDARD
successfully.
BASIC
The advantages:
Ensuring a high machine availability
Increasing the efficiency of your production
Complying with the latest safety standards
Better ability to plan budgets and deadlines
Reduction in the administrative overhead
for service activities
Cost benefits compared to individual orders
108
TABLE OF CONTENTS schuler service / The entire world of metal forming
Schuler Service
Improved machine availability and

increased productivity
PROCESS OPTIMIZATIONS to exploit the full

potential of your machine
Increased productivity and OEE.

Schuler Service is available to you as an expert partner
for advice on your entire process. We always focus on
maximum productivity and availability of your machine.
Our activities:
Process analysis in your press shop
Taking account of the value stream
Availability consideration of your machine
Achieving optimization potential
Reduction in setup times
Increase in output performance
Reduction in downtimes
Needs analysis for staff training in the press shop
Quick and expert help over the phone as well as support via a Increasing employee qualification
remote connection.
We show you the way to achieve significant optimizations

HOTLINE AND REMOTE SERVICE CENTER in your overall process.
Our hotline and remote service center allow us to offer you
professional advice and remote diagnosis force move
production. By directly logging onto your machine controller,
we can carry out an initial diagnosis and in many cases
solve the problem remotely.
In more than 90% of all incidents, there is no need for

a service technician to be deployed.
That saves time and expense your machine downtimes are

significantly reduced. Software optimizations can be carried
out without a personal visit being required.
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110
TABLE OF CONTENTS Schuler TechCenter / The entire world of metal forming
Schuler TechCenter
Innovative forming technology

experience live
Welcome to the future. Welcome to the Schuler TechCenter. Schuler live Explore Technology
For 175 years now, Schuler has been developing ground- Servo TechCenter Gppingen
breaking system solutions, always with the goal of securing Servo TechCenter Erfurt
long-term successes for our customers. All our activities Servo TechCenter Tianjin, China
focus on the common goal of finding the best possible
answer to your challenges. Automation TechCenter Gemmingen
Automation TechCenter Hedorf
Take new approaches with Schuler, and embark on intensive Automation TechCenter Canton, MI USA
dialog with us. We have set up the latest machines and
systems for you at our new TechCenters in Germany, the Hydroforming TechCenter Canton, MI USA
USA and China where you can try out production optimiza-
tions in a hands-on environment for employee qualification, Hot stamping TechCenter Gppingen
short-term contract production or intensive familiarization.
As a result, we can tailor what we offer even more directly
to meet your individual requirements.
Come and see us in one of our TechCenters. We are looking

forward to your visit and many exciting experiences in all
aspects of the world of forming technology.
Your Schuler TechCenter team
SCHULER online
Would you like to find out more about our TechCenters?

Simply scan the QR code using the camera of your smartphone or tablet.
www.schulergroup.com/Techcenter
111
TABLE OF CONTENTS
Schuler TechCenter
Presentation of cutting-edge technology

and innovative potential at Schuler
Transfer press with TwinServo technology in the TechCenter Erfurt. Exchange of experience on the automated transfer press
with ServoDirect technology.
The Schuler you know: as a technology and world market

leader in forming technology, our company is present at
all significant trade shows, congresses and technical
conferences as well as at university career fairs in
Germany and worldwide. Symposiums, workshops and
technology days are held regularly to provide an arena
for direct and personal dialog as well.
Now, we have taken the next step: at selected sites in

Germany, the USA and China, the new Schuler TechCenters
deliver a further decisive expansion to the possibilities for
intensive communication. With individual and tailor-made
demonstrations, tests and training courses directly on
the latest presses and automation equipment.
112
TABLE OF CONTENTS Schuler TechCenter / The entire world of metal forming
Crossbar robot 4.0 in the Automation TechCenter Gemmingen. Highly dynamic ServoDirect technology, presented live at the
Servo TechCenter Gppingen.
In intensive contact with the experts from Schuler, this Technology events, training courses and on-site workshops
enables specific questions to be clarified even before make Schuler TechCenters into beacons of knowledge and
series production starts and efficiency gains worked out knowledge transfer. After all, highly competent employees
that are precisely tailored to your own production. Other make a decisive contribution to a company's success and
main aspects include topics such as process and stroke rate that goes for forming technology as well.
optimizations, die tryout, blanking and tooling tests as well
as process and module developments. This ensures that Groundbreaking sector solutions can be seen here starting
systems from Schuler can deliver their full performance from today. Experience the technology of the world market
potential and optimum output right from the word go. leader in forming technology live, and keep in touch with
the future!
And yet the Schuler TechCenters have even more to offer:
depending on the system, it is possible for backup or
startup production to be carried out. This opens the
opportunity for carrying on production despite a machine
failure or in advance of commissioning.
113
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114
TABLE OF CONTENTS sites / The entire world of metal forming
At a glance
Production facilities, service sites,

TechCenter and agencies
Technologies, systems and machines from Schuler are at Service sites

home in the following sectors: automotive, tiers 13, Everything from a single source and that's worldwide:
drives & generators, railway, aerospace, appliances, All round the world, our service network with more than
minting, packaging, industrial applications and large pipe. 900 service employees is working on your behalf. In this
way, we ensure that you can produce parts economically
For us, developing solutions for these sectors means anywhere and at any time.
reducing good concepts to a common denominator. With
the objective of coming even closer to our customers techcenter
and taking account of different industry requirements. In opening the Schuler TechCenters, we have redefined
Therefore, we supply you with not only press technology how systems and technologies are presented. Now, you
but also intelligent system solutions which meet the can use this unique opportunity to experience cutting
requirements of the global competitive environment. edge technology live; not only can you discover new
The individual requirements of users in the particular approaches for your production, you can also optimize
market environment are the center of our attention. your workflow and output rates, or access a backup
In this way, we convert technological leadership into facility for ongoing production.
specific customer benefits, and together with you we
wish to take advantage of technological and growth
opportunities.
For this purpose, the Schuler Group employs about 5,500

people and has its own sites/agencies in 40 countries.
We are your partner who supports you reliably worldwide.
Benefit from the extensive expertise of our project teams
in installations all over the world.
We are there for you.
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TABLE OF CONTENTS
Addresses
PARTNERS FOR SHEET METAL FORMING
15
Schuler Group headquarters, Gppingen. 13
Schuler AG GERMANY
Bahnhofstrasse 41
73033 Gppingen | Germany
Phone +49 7161 66-0
Fax +49 7161 66-233
1
info@schulergroup.com
www.schulergroup.com
Schuler service
10
www.schulergroup.com/service
Schuler service and production sites

Schuler Service
Schuler TechCenter
SCHULER ONLINE
We employ about 5,500 people worldwide at our own sites and agencies in 40 countries, so we are always in your
vicinity. How to contact us. For an overview of all our sites and the most important address information, refer to
the Internet at www.schulergroup.com/plant_locations.
116
TABLE OF CONTENTS sites / The entire world of metal forming
1. Germany
2. France
3. United Kingdom
4. Italy
9
5. Poland
3 6. Switzerland
5 7. Slovak Republic
2 6 8. Spain
7
4 9. Russian Federation
8 10. Brazil
11. People's Republic of China
11 12. India
13. Mexico
14. Thailand
15. USA
12
14
Social media
Current information about Schuler is available on Facebook, YouTube, Xing, Twitter and LinkedIn. The footer at the bottom
right of our webpage www.schulergroup.com contains links to our activities. You can visit us on the Internet. We are
looking forward to seeing you.
117
TABLE OF CONTENTS
The entire world of metal forming
Notes
118
TABLE OF CONTENTS notes / The entire world of metal forming
230EN-102014-WSP-2000 Copyright by Schuler AG
www.schulergroup.com www.schulergroup.com/sheetforming
Find out more. Simply scan the QR code using
the camera of your smartphone or tablet.
Schuler AG
Bahnhofstrae 41
73033 Gppingen | Germany
Phone +49 7161 66-0
Fax +49 7161 66-233
info@schulergroup.com
service@schulergroup.com
www.schulergroup.com

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The entire world of

Welcome to the stamping plant. 04 07 | Tryout systems 78

Subject to technical modifications and amendments to content | 2014/15

Welcome to the stamping plant.

Transfer press with ServoDirect technology.

Put us to the test.

Individual solutions, flexible applications

Maximum productivity with ServoDirect presses

All upstream and downstream automation components,

Blanking line with press

Output rate of blanking line with servo press

Blanking line with cross-cut shear

Output rate of blanking line with four-column cross-cut shear

Ideal for producing blanks with a rectangular, High output performance

Blanking line with laser cell

Blank shapes when using laser cutting heads.

Output rate of a blanking line with laser

Suitable for all blank shapes Reduced material costs

Blanking line with ServoDirect technology

1.Decoiler 7. Roll feed unit 11. Telescopic conveyor

The requirements: The solution: Leveling machine with crowning

Flexible application with high

Economical, flexible and for

Equipped with a hydraulic bed cushion, impact shock

Hydraulic press with a press force of 4,000 kilonewtons

10 2 9. Impact shock dampening cylinder

Model overview HYDRAULIC PRESSES 1,600 to 16,000 kilonewtons

1,000 1,300 1,300 1,300

1,300 1,600 1,600 1,600 1,600 1,600 1,600

1,600 2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,500

Hydraulic drawing press for manufacturing side sill plates

Press force: 2,500 kilonewtons

Presses for the non-automotive industry

Hydraulic presses for the

Pre-engineered press configurations in conjunction with a

Hydraulic presses for producing stainless steel sinks.

Hydraulic press for manufacturing heat exchanger plates

The requirements: The solution: THE PRODUCTION SYSTEM:

Hydraulic transfer presses

Efficiency, step by step

Easy to adapt to different dies Production of deep components by counter drawing

Efficient process management 48

Your direct contact to the Servo TechCenter:

ServoDirect technology for blanking

Success can be programmed

FLEXIBILITY AND EFFICIENCY

Stroke [mm] Stroke [mm]

0 Reduction in cycle time Time [s] 0 Time [s]

Programmable slide motion curves Oscillating stroke mode

For universal application

MODULAR FLEXIBLE ERGONOMIC

Model overview of C-frame presses

Model CB-250 CB-400 CFL-630 CFL-1000 CFL-1600 CFL-2500 CS-1000

The torque motor of the CS-1000 is located directly on a

The space-saving and ergonomically built press additionally

A die change can be carried out quickly and easily because

Automatic blanking presses

Wide range of parts high output

Automatic blanking presses: the economical solution for

Model overview AUTOMATIC BLANKING PRESSES (MC)

For small components with tight die clearances

Model overview of high-speed BLANKING PRESSES (MCF)

Automatic blanking presses

Ideal for producing blanks with a rectangular, High output performance

1.Decoiler 7. Roll feed unit 11. Telescopic conveyor

The requirements: The solution: Leveling machine with crowning

Connection to all press types Scalable in weight class and performance