At Hatebur, we have been working hard for several years to develop and optimize SAM technology (servohydraulic ejector module). Various tests have been carried out with a prototype on a dedicated testing station and on the AMP 30 in the demonstration center. The results are overwhelmingly positive, meaning SAM technology is now ready for productive use by our customers.
The technical solution in detail
Using servohydraulic ejector components makes the mechanical ejector components superfluous to requirements. A further advantage of this local approach is that the axes can be individually controlled and optimally adjusted to production requirements. For example, the ejector forces can be monitored or new processing possibilities can be created. This is possible because the ejector return can be powerfully braked or blocked at the required moment, which in turn enables
an intermediate forming step to be executed. But more on that later.
The electronic control for the ejectors allows all settings to be loaded and modified on the HMI at the touch of a button, leading to significantly reduced retooling times, since the manual tasks for the ejector are no longer required. Previously, the ejector functions were tied to fixed curve laws. With SAM, many of the previous restrictions are already a thing of the past.
The ejection process for forgings from the die with the servo‑hydraulic ejector modules takes place in two phases: Loosening the part with a strong force and pushing out the part at high speed. A sophisticated cylinder design means that energy consumption for these movements has been successfully reduced to a minimum, thereby developing an energy‑ saving solution in keeping with the spirit of the times. Regulating the oil flow in the cylinder ensures a constant wear‑free braking
function for the ejector.
Combined processing possibilities
The valve technology makes it possible to modify the oil flow very quickly to suit the current requirements. This means, for example, that the ejector can be fully braked while a blank is being inserted into the die. Through successful tests and test runs with SAM technology, we were able to optimize familiar processes and even lay the foundations for completely new processes. For example, sheared cut‑offs can be descaled in the press using a SAM module in the first station, and can even be made into the required shape in a die in the same forming process.
Thanks to part geometry, it is possible to achieve a very slim slug, particularly when manufacturing combination rings. For this process, the ejector is braked until stationary in an intermediate position on the return. Since the slug is formed in position and not at the forward dead center of the press movement, the slug thickness can be significantly reduced owing to the freer material flow. As material is the greatest cost driver in the production of forgings, this method results in considerable cost benefits for operators.
Forming stations in which several process steps are combined are nothing new in and of themselves. Hatebur has thus already been offering the piercing/separating method for several decades. Yet with a SAM module, this can be simplified yet further, whereby the parts can be discharged even more softly and the whole sequence of movements for the ejector can be monitored.All these combined processes are based on flexible control for the ejector function, which allows retention in an intermediate position with great supporting forces. This not only simply saves tool costs as the steps need not be divided into several stations, but also allows challenging parts to be produced with comparatively low production resources.
Hatebur HOTmatic HM 35: Integration into the machine range
In addition to automotive parts, production of bearing components is also a focus for the HM 35 product launch. In view of the ever increasing price pressure in the bearing sector, the new SAM technology creates pioneering potential for material‑saving and therefore cost‑effective production. In addition to these cost advantages, a variety of other quality requirements are met, such as a descaling station, which does not generate any additional tool costs and is independent of body deflection during bar transitions. A user‑friendly surface on the HMI completes these new options, which allows for rapid retooling, making the Hatebur HOTmatic HM 35 an ideal production resource for bearing components up to 68 mm over four forming stations.
- Cost savings thanks to process combinations
- Faster retooling
- Ejector timing can be freely selected
- Integrated wear-free braking function
- Integrated electronic overload protection without shear bolts