Task:
The production of rings directly from the production line is a common challenge. This applies in particular to the production of decorative and trim rings made of various materials for a wide range of applications such as case rings for watches, decorative and trim rings for pressure gauges and other instruments, pouring rims for saucepans, ball bearing cages, stove top rings, etc. The synchronization of decorative ring production with the manufacture of the end products requires precise solutions.
Solution:
Our automatic decorative ring machine masters this challenge effortlessly. It produces decorative, trim and housing rings from various malleable materials with flexible diameters and profiles. The changeover between minimum and maximum ring sizes is carried out simply by exchanging holders, and the Set-up time is only approx. 2 hours.
The entire production process is fully automatic. The machine monitors itself and switches off automatically in the event of faults. This makes it possible for one person to operate several machines or even operate one machine simultaneously in manual mode for intermediate sizes with smaller quantities (Klotz also offers interesting solutions here; see semi-automatic production).
Particularly noteworthy is the solution to the challenging problem of overlapping, which significantly influences the quality of the ring. The automatic decorative ring machine ensures precise overlapping of the ring ends and calibrates them during the welding process, resulting in a clean and even weld.
Workflow
The smooth-running rotary indexing table, controlled by a high-quality, precise indexing gear, transports the workpiece through the individual stations:
- The strip coming from the coil is precisely measured (approx. 0.05 mm), cut to length and transferred to the holder, which also serves as a forming tool for subsequent forming.
- The overlapped ring ends are welded in the welding station, whereby the ring is kept to size (calibrated) during welding. The upright ring is then tested. The welding system has a central water cooling system; decentralized cooling is also available as an option. As a supplement to the basic machine, Klotz offers a double decoiler and a strip deburrer on request.
- In station 3, the ring is given its final shape. This is usually done with a hydraulically-pneumatically controlled rolling device. Cam control is also possible for complex shapes.
- In the removal station, the ring is picked up by a gripper, removed from the working area of the machine and deposited:
a)Simple placement - the ring is placed on a mandrel.
b) Positioned depositing - the ring is deposited in a precise position to enable a downstream ring mounting machine.
As an alternative to this fully automatic production system, Klotz also offers a semi-automatic production system as well as various other systems for the household goods industry.
