Precision in series

The company Ideal-Werk C. + E. Jungblodt GmbH has automated resistance welding machines for bandsaws using end-to-end control and drive technology from Siemens.
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Challenge

Ideal conditions

A single weld can have an enormous impact on the quality of an end-product. This is particularly true of bandsaws, whose saw blades are welded to form a continuous ring.

The seam must not be allowed to rupture or break under even the highest levels of stress – for instance, in bandsawing timber or plastics. The company Ideal Werk Jungblodt GmbH creates the ideal conditions for reliable sawing with its series of flash butt welding machines. These ensure a consistently high standard of quality in each and every welded seam as well as providing a high yield.

As a leading manufacturer of resistance welding machines, Ideal attaches enormous value to quality, development and progress. The company’s core business has traditionally included standardized flash butt welding machines for bandsaws. To improve its future flexibility and productivity, and enhance the operating convenience of its BAS 300 machine series, Ideal-Werk relies on end-to-end control and drive technology from Siemens.

Solution

A first complete and integrated system

To further improve the utilization, handling and flexibility of its machines, the company decided to equip its long-established BAS 300 machine series with integrated control and drive technology from Siemens – not, as previously, only in parts, but from the bottom up.

The core component of the new automation solution is a compact central processing unit SIMATIC S7-1200, as well as a single-axis SINAMICS S110 converter, a SIMOTICS S-1FK7 servomotor with pre-mounted gearbox, and a SIMATIC KTP700 Basic touch/key panel. These additions enable not only the carriage movement but also the annealing process to be flexibly controlled and monitored.

Freely programmable and flexible
Thanks to a new, patented combination of mechanics and automation, Ideal is also able to meet demands for greater flexibility. Instead of using a rigid mechanical cam disk, carriage movement is now controlled by a simple linear cam disk driven by servo motor. Its movement can be freely programmed using a programmable logic controller (PLC), allowing individual adjustment of the welding, forging and flashing processes. As this SIMATIC controller also supports interrupt modules, in addition to the normal control sequence it is also possible to initiate precisely-timed asynchronous processes, allowing a rapid user response to process requirements.  

Benefits

Engineering and servicing made easy

The Lippstadt-based machine builder also benefits from the possibilities offered by the Totally Integrated Automation Portal (TIA Portal), which it introduced some time ago.

This allows required automation components to be simply and efficiently engineered, parameterized, linked and programmed. As even the compact variant of the SIMATIC S7-1200 comes with an Ethernet port, the commissioning or servicing engineer only needs to connect to the controller using a simple network cable to begin work. Ideal is so delighted with the new modular automation system that the concept has already been transferred to other machine series.

References

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