Automation of a production line for flashless precision forging

Automation is an important approach to achieving more economical production systems. But most automated production lines are inflexible. Flexibility is an essential topic for manufacturing lines which have high machine costs and whose various products are made on variably combined aggregates such as forging lines for example. For the innovative technology of flashless precision forging an automated production line has been developed at the IPH-Institut fur Integrierte Produktion Hannover to demonstrate a new concept of flexible automation in forging. With the flashless forging process gearwheels are produced in one forming step with such precision that only final grinding after forging is necessary. All aggregates needed for the complete process chain such as material handling, heating system, forging piece handling, die cooling and lubrication system, forging press, heat treatment and clipping press are inter-connected via a field bus and controlled by decentralised CAN-Bus-components located directly at the machines. One advantage of the decentralised CAN-Bus-technology compared to conventional central control is the possibility of fast changes of manufacturing aggregates without new wiring of sensors and actors. Another advantage is the possibility of integrating the existing machine controls. Both factors contribute a deal to a flexible production line at a favourable price. All process parameters are controlled in almost real-time by an on-line monitoring system since they have to be maintained in a very small range of tolerances for the demanded precision. The visualisation and data processing of the process parameters and process steps allow fast reaction to problems and enable an effective quality assurance.