The fully automatic machine is used for the fast and economical production of complete cake springform pans (without base) of consistently high quality.
Above all, this system solves the frequently occurring problem of quality fluctuations and the resulting production difficulties. The quality of the surface of the end product meets the highest standards. In addition, a significant increase in productivity is achieved thanks to the very high cycle time of up to 4 seconds.
Due to the short changeover times - only the tool set needs to be replaced - even small batch sizes can be produced economically.
The system is designed for 3-shift operation and can be operated by one person.
Task:
The production of cake springforms is very labor-intensive and places high demands on the quality of the surfaces of the end product.
In order to produce market-driven and therefore inexpensive springform pans, the cheapest possible material must be used. As a result, there are usually large fluctuations in the quality and dimensions of the raw material used. This repeatedly leads to production problems when forming the material.
The aim was to develop a system that produces economically and at the same time solves the above problems, i.e. above all takes material tolerances into account. The task included cutting the material to size, forming and assembling the lock. The target cycle time was 10 seconds.
Solution:
The production process is distributed across three interlinked systems, which can also be operated individually. This means there is no risk of complete production downtime in the event of malfunctions.
The system comprises a total of 16 workstations, each of which is interlinked.
In the first part of the system, the strip is unrolled from the coil, cut to length and perforated. A second version of the material feed offers the option of feeding sheets that have already been cut and/or printed from the stack.
The second part of the system is responsible for forming. It is important that the strip is handled without scratching and that it is tensioned for rolling. The rolling process is carried out using a special rolling tool coupled with a press.
The third part of the system is the assembly. The turnbuckle is fitted (riveted) to the ring and the bottom side is rolled up. The ring is removed fully automatically and placed on a conveyor belt. It is then packed together with the base.
In order to achieve the shortest possible cycle time, the drives had to be highly precise. In the end, a cycle time of 4 to 5 seconds was achieved.
Special clamping devices have been developed to prevent damage to the product.
The system is designed for 3-shift operation.
Operations:
- Cut to length (alternatively: feed from stack)
- Release
- Round off strips
- Flanging
- Feed lock
- Installing the lock
- Fastening the lock
- Roll up bottom side
- Removal and depositing on a conveyor belt
Technical data:
Cycle time: 4 to 5 sec.
Operating personnel: 1 person (for coil operation)
Sizes produced so far: 18, 20, 22, 24, 26, 28, 30 (others are possible)
Connected load: 380 V, 60 A
Control system: PLC
Space requirement: approx. 35 square meters
