Klotz started out with systems for the manufacturers of house wares. Draw on technically mature solutions from our portfolio or let us know your testing and production requirements. We will find a solution. What applies on the “large scale”, namely in the automotive industry, can also be adapted to other sectors. Know-how and service included.
Producing rings off the conveyor belt – is that your problem?
The manufacture of ornamental and facing rings from various materials for a wide variety of applications:
case rings for timepieces, ornamental and facing rings for pressure gauges and other instruments, protective rims for cooking pots, ball bearing cages, cooker hotplate rings etc. This has certainly caused many a headache, because the producion of the rings must keep in step with that of the products they`re used for.
We`ve dealt with the problem once and for all – with our automatic ornamental ring machine.
The machine makes all formable materials into ornamental rings, facing rings and case rings for a wide variety of applications.
Between the minimum and the minimum and the maximum diameter (see specifications) all ring sizes can be produced with various profiles.
Resetting is achieved simply by changing the mountings.
Setting time is just 2 hours. The entire process is fully automatic.
The machine is selfmonitoring in the event of a fault.
So one person can operate several machines – or he can operate one machine and at the same time produce small runs of intermediate size in manual operation
(and here too we have an interesting proposal – ask for details).
The machine is easy to operate and permits shift working without problems.
The machine pays ist way quickly thanks to series production in large quantities with consistent quality.
Our fully automatic machine feature all the legally required accident prevention safeguards.
The automatic ornamental ring machine has the answer in particular to the tricky problem of overlap that has such a major effect on ring quality:
exact overlapping of the ring ends and calibration during the welding operation result in a clean and even weld.
Two vacant stations are provided in addition which can be installed anywhere in the production sequence. They permit additional work processes or interim checks to be implemented. Electrical Control of the Facility The control unit is of the stored-program type and meets every technical requirement of today. A step display permits transmission of error diagnoses. The control console is provided with a mimic diagram enabling even less qualified personnel to pinpoint faults. All switches are designed as illuminated push-buttons. Control console and machine are connected by plug-in leads.
The manufacture of high-quality yet inexpensive ornamental and facing rings for the pot and fitting industry and for other applications presented us with the problem of finding another solution in addition to the fully automatic facility we already produce. The machine had to be on a much lower technical level to permit an initial start to ring production with approximately equivalent quality. It was accepted here that the quality of the rings would partly depend on the skill of the operator. The facility was to be operable by one or two persons.
(see also the fully automatic solution)
The steel strip feeding device can be of the double-sided or single-sided type in order to ensure problem-free production.
It was assumed here that the skill of the operator should have no effect on the accuracy of the cutting operation. The length is preset exactly using an electronically powered intake unit, and the strip is cut to length without burr. The machine can be set to other sizes without difficulty simply by entering the appropriate numerical values. The entire control system has been accommodated in an 19″ module inside the base frame. This makes the facility very compact and suitable for even the most cramped conditions.
Two welding systems are possible: with the first variant more attention is devoted to the diameter of the welded ring, which is of major benefit when the ring is fitted. The second variant assumes that the overlap is adjustable and not dependent on the overall length of the strip. As a result the length tolerance of the cut strip has no effect on the weld overlap. The facility has a 40 kW transformer and a digital welding control unit. To change the ring size the clamping disc must be changed in the first variant. The welding tongs can be adjusted to the appropriate diameter in a guide slide. This permits a high degree of flexibility and adjustment to any ring size. For the unit to work self-sufficiently, it has its own cooling system accommodated in the base frame. Welding speed and electrode welding pressure can be precisely regulated. The entire unit has a stored-program control, installed like the power unit for the welding control in a 19″ module.
The welding control can also be provided with a pulse welding unit for precise welding work.
When constructing the facility, a modular design was assumed. The drive of the rolling tool is DC-controlled, so permitting the speed to be precisely adjusted to the strip quality and to the appropriate ring diameter. To minimise the resetting times, a tool is available as an alternative which already integrates the ejection device and the entire lower section of the rolling tool. By undoing a screw it is possible to carry out the tool change.
Ring ejection is fully automatic and can be controlled so that the ring is deposited in a container. Both the rollers and the rolling tool are made of high-quality nitrided steel to withstand the heavy wear. To comply with safety regulations the facility has a two-hand control, and it can be operated in both setup mode and in fully automatic mode.
The tool sets are not included in the general scope of supply, but are available separately. They comprise substantially the external and the internal ring and an efector device. Resetting the facility does not present problems because the roller plate and rolling tool can be changed over once a screw is loosened.
With the first station (cutting-to-length unit), its is possible to work directly into a container or discharge chute. From there, the operator takes the part and welds the strip into a ring. After welding, an intermediate position can be activated, depending on the numbers required, so that the profiling machine can be operated by a second person. If the numbers required are below a certain level, all three facilities can be operated by the same person.
It must be remembered that when the strip width changes the guides of the cutting-to-length unit are changed also. During welding the clamping disc and the clamping jaws are replaced additionally.
Fitting of ornamental and facing rings must be fully automatic since the systems developed so far have not optimally met the demands placed on our customers by the market.
The call for greater flexibility and increased productivity required from us a new development concept. In addition to an inexpensive solution, the necessity for high availability and loading capacity were the main requirements.
When designing this system, we could fall back on 20 years of experience in the field of ring fitting, particularly for highly sensitive product such as enamel.
This knowledge, an awareness of the changes in the market structure (e.g. small runs, high quality, optimum delivery readiness of the operator) were the aims of the new development.
With this product we have developed an automation module that is proving its worth in production. The entire facility has been modified in a manner that points the way ahead for the future.
The main factor considered was simple operation of the machine and a high degree of automation of the operating process. This however is not sufficient on its own to comply with the parameters set by the customer.
For this reason, the facility was designed so that up to six pot and lid sizes – i.e. diameters – can be produced, with five options available
The machine can be operated from directly in front of the appropriate station in setup mode. The necessary control consoles are provided at the workplaces. When the safety grille is closed the consoles become inoperative.
As previously mentioned, the feed unit is provided with an adjusted half-dish that takes the part with its manually fitted rings from the conveyor belt and supplies it to the rotary table. The alternatives assume that the tool automatically adjusts to the sizes.
The enamelled part (pot or lid) arrives from the furnace chain, is removed manually, and checked.
The ring is then placed manually onto the part. The parts are placed in this condition onto the conveyor belt, which is of the backup type so that certain quantity can be positioned.
The separation of the transfer unit is already fully automatic. For rolling up or pressing on the rings, the parts are introduced by a pulling plate. This pulling plate has three no-load stations which can be used if required for knob fitting.
The fitted part is removed by a gripper that deposits the workpiece on a conveyor belt. There is an optional possibility of placing the parts in a carton.
When the safety grille is closed only automatic operation is possible.
After Emergency Off, each station can be moved to the starting position at the push of a button using the control panel on the switch-gear cabinet.
Cycle time: 6 to 7.5 sec
Width: 3.7 m
Length: 5.0 m
Height: 2.2 m
Weight: 2800 kg
Pneumatic connection: 6 bars, 1/2″
Connection load: 380 V, 25 A
Control voltage: 24 V
Min. diameter: 90 mm
Min. diameter: 300 mm
(other dimensions on request)
Siemens S5-115U electric/electronic freely programmable and pneumatic-hydraulic
Semi-automatic (automatic run of a station)
The demand placed on the rim protection rings on enamelled pots have changed considerably in recent years. The protective rings have become a design element of the pot, and this means that the problems involved in fitting have also shifted in emphasis. It is no longer possible to crimp on the rings, as the reject rates are then too high and the appearance is not up to date. A new process therefore had to be developed.
The pot holder is seated on a vertical shaft driven by a variable-speed motor. The vertical motion necessary for the roll-in operation is supplied by a pneumatic / hydraulic cylinder. Precision in positioning (0.02 mm) is of central importance here. The signal is given by a proximity-type sensor. The travel distance is adjustable. The twin slide with top and bottom sections supports the rolling tool. With afine adjustment feature the rolling tool guide can be pressed into contact with the pot. This fine adjustment is necessary in order not to deform the ornamental ring or damage the enamel finish of the pot. The rolling-in process is achieved with a vertical stroke. This combination process ensures perfect fitting of the protective ring. A powerful electronic stored-program control unit (free programmable) is used to operate the facility. The control unit is accommodated in an insulated switchgear box and is thereby protected from environmental effects. All positions can be approached manually during the setting procedure. This optimizes the setup process, i.e. resetting takes less time and the reject rate is minimized. Furthermore, a cycle can be run fully automatically. A two-hand safety control feature ensures safe operation. The facility is designed for three-shift operation. The electronic speed control meets international standards.
Time per cycle: appr. 4 s. without operation
Connected lesd: 220 V
Air connection: 1/2″, min. 5 bars
Pot an lid diameter: 120 – 280 mm
Pot and lid heigth: 10 – 300 mm
(other dimensions on request)
Overall height: 1.80 m
Height up to working level: 0.75 m
Width: 0.80 m
Length: 1.40 m
Weight: appr. 400 kg