Metal Forming Overview

The entire world of
metal forming
Components for sheet metal forming.
Table of contents / The entire world of metal forming
CONTENT.
The entire world of metal forming.
Welcome to the stamping plant.

Welcome to Schuler.
04
01 | Blanking lines
06
07 | Tryout systems
78
Cost-effective die startup with hydraulic and

mechanical tryout presses, tryout centers, die
turnover devices and simulators.
Individual solutions for your production.
08 | Lightweight technologies
02 | Hydraulic presses
14
86
Lines for press hardening (hot stamping), for cold and
Flexible presses for suppliers to the automobile
aluminum forming. For forming fiber-reinforced
industry, the household appliance industry and for
plastics and for hydroforming.
multiple metalforming applications.
09 | Die and forming technologies

03 | Mechanical presses
22
96
From simulation to series production.
Fast, flexible and cost-effective. C-frame presses,

blanking presses, knuckle-joint presses, transfer
10 | Systems large pipe manufacturing
and prog-die presses and servo presses.
Spiral pipe welding lines and system solutions for
100
longitudinally welded pipes.
04 | Automation of presses
50
Coil lines, roll feed units, tri-axis transfer systems
11 | Schuler Service
and destackers.
Technical customer service, components and
106
accessories, project business, special services and
05 | Press lines
60
used machines on your doorstep, worldwide.
Hydraulic, hybrid, mechanical or servo press lines
12 | TechCenter
are fully automated system solutions.
110
Experience Schuler products live and on the spot
06 | Automation of press lines
70
contact us.
Schuler press lines are equipped with the appropriate

mechanization concept for the range of parts,
13 | Sites
productivity and space requirements.
Production facilities, service sites, TechCenter and
114
agencies there for you in 40 countries.
Subject to technical modifications and amendments to content | 2014/15

3
TABLE OF CONTENTS
Welcome to the stamping plant.

Welcome to Schuler.
Transfer press with ServoDirect technology.

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TABLE OF CONTENTS
Welcome to Schuler / The entire world of metal forming
As a world market leader in the technology of metal forming, Schuler offers presses,
automation solutions, dies, process technology and service for the entire metal working
industry and lightweight automotive construction. Its customers include automobile
manufacturers and components suppliers as well as companies in the forging,
domestic appliances, packaging, energy and electrical industries. Schuler is a leader in
coin minting technology and produces system solutions for the aerospace, railway and
large pipe industries. 5,500 people work for the company worldwide. The Schuler Group
is present in 40 countries and is majority-owned by the Austrian Andritz-Group.
We support you in all phases of a project, in planning new stamping plants through
to integrating forming lines into existing structures. In close cooperation with your
planning departments, technical purchasing, stamping plant and maintenance, we
handle the installation, commissioning and production startup of lines and automation
components. In this process, you also benefit from the extensive know-how of our
project teams installations all over the world. We are also in daily contact with users
of mechanical and hydraulic press technology regarding modernization, rebuilding,
relocation and performance enhancements available for existing forming lines.
Together we can find solutions that improve the cost-effectiveness of the
stamping plant.
This book provides you with an overview of our range of products and services. We are
just right for the job wherever the highest parts quality, maximum plant availability and
reliable press engineering is required day-in, day-out. From blanking and the forming
process through stacking the finished components our lines offer the right answer to
future requirements including increased use of high and extra high-strength steels
or integration of additional process steps in the forming process.
Put us to the test.
SCHULER online
Would you like to find out more about our selections? Further information is available on the Internet at
www.schulergroup.com. You can also follow us on Facebook at www.facebook.com/schulergroup or on
Youtube at http://bit.ly/1gQpND8. There you will find interesting news and worthwhile information.
01
TABLE OF CONTENTS
TABLE OF CONTENTS
Blanking lines / The entire world of metal forming
AT A GLANCE
Blanking lines
Blanking lines from Schuler offer the complete process
BLANKING LINE WITH PRESS
10
BLANKING LINE WITH CROSS-CUT SHEAR
11
BLANKING LINE WITH LASER CELL
12
sequence from the coil through the blank stack from

a single source. You work with the latest safety and control
concepts. Their modular structure permits solutions that
are individually tailored to the user. All the components
of the line have been tested in practical operations, are
precisely adapted to one another and guarantee the
highest levels of availability and reliability. Expansions for
processing aluminum and high-strength steels can be easily
retrofitted. And it does not matter where the Schuler line
will be used our services are available worldwide.
SCHULER online
Would you like to find out more about our blanking lines? You can find our complete product range
at www.schulergroup.com/automotive. There, you will find extensive information about our system
solutions for large-scale mass production.
TABLE OF CONTENTS
Blanking lines
Individual solutions, flexible applications
Maximum productivity with ServoDirect presses

In addition to the use of conventional presses (mechanical
or hydraulic), lines for manufacturing shaped blanks
are preferably equipped with servo presses nowadays.
ServoDirect technology from Schuler enables movement
sequences of the press to be adapted individually to the
different blanking dies. This increases productivity and the
service lives of dies significantly. Also, lines with this
technology are configured for processing an extremely
wide range of materials such as aluminum or high-strength
steels. Material with a sensitive surface can also be
processed carefully, using a press blanking line with the
highest productivity.
All upstream and downstream automation components,
such as the roll feed unit driven directly by servomotors
or the flexible Stop2Drop stacker, support the impressive
Blanking line with servo press.
press performance and ensure powerful dynamic

properties in blanking. A high level of automation ensures
quick production changes and a smooth production
process.
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Blanking line with cross-cut shear.
Blanking line with laser cell.
Blanking with cross-cut shear the solution
This means there is no need, whatsoever, to invest in dies,
for straightforward blank shapes
die maintenance and die warehousing. The compact design
Schuler offers blanking lines equipped with cross-cut
of the line means it can be used even when space is
shears for manufacturing blanks with a rectangular,
limited and overhead heights are low. With their innovative
parallelogram or curved shape. If the manufacturing
DynamicFlow technology, they offer the most flexible
process is restricted to straightforward blank shapes, then
possible production conditions with comparatively low
cross-cut shears represent the ideal solution both with
investment costs. The laser cutting line processes an
regard to purchase costs and their productivity. Optionally,
extremely wide range of materials such as aluminum or
the shears can be equipped with an automatic die change.
high-strength steels, and guarantees high productivity

even with skin panels that have sensitive surfaces.
Laser cutting: Flexible production,

compact line design
Blanking lines with lasers are particularly suitable for
production sequences with frequent product changes
as well, because no tooling is used for laser cutting.
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Blanking lines
Blanking line with press
Blank shapes when using a press with die (max. stroke rate 105 spm).
Output rate of blanking line with servo press

Feed length [mm]
300
500
750
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
Servo press basic version [strokes/min]
75
73
66
61
51
43
38
31
28
27
24
Servo press with more powerful motor [strokes/min]
93
82
73
67
51
43
38
31
28
27
24
Advantages
Ideal for producing shaped blanks
Reducing die wear with ServoDirect technology
High output performance
Proven technology
High level of automation
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Blanking lines
Blanking line with cross-cut shear
Blank shapes when using a cross-cut shear (max. stroke rate 120 spm).
Output rate of blanking line with four-column cross-cut shear

Feed length [mm]
300
500
750
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
Cross-cut shear [strokes/min]
108
90
77
68
51
43
38
31
28
27
24
Advantages
Ideal for producing blanks with a rectangular,
parallelogram or curved shape
Attractive price/performance ratio

Proven technology
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Blanking lines
Blanking line with laser cell
Blank shapes when using laser cutting heads.
Output rate of a blanking line with laser

The productivity of a laser line must always be seen in the
context of sheet metal thickness, blank contour and laser
power. We would be happy to calculate the possible
productivity for you on the basis of your product data.
The advantages
Suitable for all blank shapes
Reduced material costs
No costs for dies and die warehousing
High energy efficiency
Fast product change, delivering a high level of availability
Reduced investment volume
Adaptation of blank contours after production startup
Space-saving line design
Simultaneous production of different blank shapes
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Blanking line with ServoDirect technology
In practice
Customer: Automotive supplier, People's Republic of China
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13
14
1.Decoiler
2. Coil infeed
3. Crop shear
4. Coil washing machine
5. Leveling machine
6. Loop pit
12
15
10
7. Roll feed unit

8. Telescopic roller train with
left-over coil feed
9. Blanking press with
ServoDirect technology
10. Cutting die
11. Telescopic conveyor

12. Vacuum blower for stacking
aluminum blanks
13. Blank stacker
14. Stack cart
15. Hydraulic unit
The requirements:
The solution:
Delivery of a blanking line for
Fully automated blanking line with
producing shaped blanks with
blanking press in ServoDirect
Loop equipment
the shortest downtimes during a
technology.
Roll feed unit with weld detection
coil change.
Coil loading cart for two coils
Blanking press with 8,000
Cutting steel, aluminum and
Moving decoiler for 35 tons
kilonewtons in ServoDirect
high-strength steels up to
Threading unit with dirt and
technology
1,200newtons/square millimeter
clean rolls
Leveling machine with crowning

function with 2 cassettes (17 rolls)
Stacker in Fly2Drop and Stop2Drop
Coil width: 2,150 millimeters
Cropping station
stacker technology (energy-efficient
Coil thickness: 0.5 to 2.5 millimeters
Coil washing machine
vacuum generation by blower)
Coil weight: 35 tonnes
13
02
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Hydraulic presses / The entire world of metal forming
AT A GLANCE
Hydraulic presses
You've got to be flexible. We've got the machines for this.
Hydraulic presses
16
Presses for the non-automotive

industry
19
Hydraulic transfer presses
21
Hydraulic press systems from Schuler are extraordinarily

versatile and make it possible for you to achieve efficient
series production of a wide range of components from
the blank through to the finished part. At the same time,
innovative hydraulic solutions ensure high output levels,
production reliability and the best quality. Whether in
classic metalforming, die tryout, die hardening, internal
high-pressure forming, precision blanking or processing
fiber-reinforced plastics: hydraulic presses from Schuler
can cope with any challenge round the clock, seven
days a week.
SCHULER online
Would you like to find out more about our hydraulic presses? You can find our complete selection at
www.schulergroup.com/hydraulic_press. In addition, you can download the Hydraulic press systems.
For the best component quality in the stamping plant brochure as a PDF file.
15
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Hydraulic presses
Flexible application with high

production reliability
Economical, flexible and for
reliable production
Because of their versatility, hydraulic presses offer a wide
range of applications in the stamping plant. They can be
used as a single press, automated press line, transfer press
or tryout press. In combination with a coil line, destacker or
tri-axis transfer, this creates turnkey system solutions for
economical parts production. These have a modular
structure and offer users a wide range of expansion options.
Equipped with a hydraulic bed cushion, impact shock
dampening, slide parallelism control and cylinder mode
switching, hydraulic presses provide all the prerequisites
for efficient production in the component supplier's
stamping plant. A data analysis system assists the press
operator in straightforward fault diagnosis of the entire
system, at the same time as increasing productivity
Hydraulic presses offer flexible applications.
by optimizing the process.
advantages
They can be used as a single press, in press lines or
as a transfer press
Production alternative for a wide range of parts
Increase in output by dynamic cylinder mode switching
Simple operation by sequence chart user interface
16
High flexibility through four-point impact shock

dampening and a hydraulic bed cushion
Parallelism control increases parts quality and
reduces die wear
Precise eight-way slide guidance
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Hydraulic press with a press force of 4,000 kilonewtons
1. Press cylinder
2. Adjustable eight-way precision slide guidance
with maintenance-free guide jaws

3. Hydraulic drawing cushion
4. Hydraulically operated slide locking in upper end position as per
UVV (safety codes and regulations)
5. AC drive motors designed to suit application

6. High-performance axial piston pumps with electronic pump control
7. Torsion-resistant press frame
8. Slide/piston connection
9. Impact shock dampening cylinder
10
10. Slide limitation/impact shock dampening
7
9
3
Model overview HYDRAULIC PRESSES 1,600 to 16,000 kilonewtons

Press force [kN]
2,500
3,150
4,000
5,000
6,300
8,000
10,000
12,500
16,000
1,000
1,300
1,600
1,300
1,600
1,300
1,600
1,300
1,600
2,000
2,500
1,600
2,000
2,500
1,600
2,000
2,500
1,600
2,000
2,500
1,600
2,000
2,500
1,600
2,000
2,500
2,000
2,500
2,500
2,500
2,500
2,500
3,000
2,500
3,000
2,500
3,000
2,500
3,000
2,500
3,000
2,500
3,000
2,500
3,000
Bed length [mm]
1,600
Daylight [mm]
Standard
Option
700
1,000
850
1,300
1,100
1,600
On request, hydraulic presses are available with alternative bed sizes and press forces up to 300,000 kN.
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Hydraulic drawing press for manufacturing side sill plates
In practice
Customer: Automotive components supplier, Czech Republic
Hydraulic press for producing side sill

plates and roof bows.
Maximum output rate of the line:

12strokes/minute.
Semi-automatic die change in 15 minutes.
The requirements:
Delivery of a production line for finish-processing of preformed side sill plates
and roof bows.
Perform pick-up
Component transfer through the press
Hole punching and forming of specified contours
The solution:
Hydraulic blanking and coining press with tri-axis gripper transfer, blanking
and forming dies.
Press force: 2,500 kilonewtons
Bed size: 2,500 1,300 millimeters
Slide parallelism control with screw adjustment
Roll-formed component pick-up by robot
Part transfer into the press and through the die stations
Semi-automatic die change in 15 minutes
Maximum output rate: 12 strokes/minute
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Hydraulic presses
Presses for the non-automotive industry
Hydraulic presses for the

non-automotive industry
Hydraulic presses also represent an efficient solution for a
wide range of production tasks in the domestic appliance
industry and for manufacturers of components made from
stainless steel. Both single presses and automated production systems increase users' competitiveness. The lines are
characterized by optimum reliability, high availability, fast
die changes as well as straightforward adaptation to
modified production conditions.
Pre-engineered press configurations in conjunction with a
wide variety of modular automation options and die change
techniques permit customer-specific manufacturing
solutions. The lines are also noted for their high degree
of user-friendliness.
Hydraulic presses for producing stainless steel sinks.
advantages
Reliable equipment with high levels of uptime
Maximum flexibility
Optimum line configuration using proven components
Maintenance-friendly because of easy accessibility

of all components
High part quality due to sturdy design
Process analyses with integrated data analysis system
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Hydraulic press for manufacturing heat exchanger plates
In practice
Customer: Manufacturer of heat exchanger plates, USA
Hydraulic coining press. Press force:

250,000 kN.
Fully automatic production system for

manufacturing heat exchanger plates.
Heat exchanger plates of various sizes.
The requirements:
The solution:
THE PRODUCTION SYSTEM:
High requirements apply to fully
The fully automated production system
Blanking system with coil line
automated forming of heat exchanger
has at its heart the hydraulic coining
Lifting bar transfer system for
plates: high stamping forces, many
press with multi-cylinder system in
different plate geometries, close
short-stroke technology. The system
Loading and unloading feeder
tolerances in stamping depth,
permits flexible adaptation of
Foil winding units
production process reliability and
press force ranges to the different
Fully automated die change system
high equipment availability.
geometries and as well as a uniform
Master controller
stamping depth by evenly distributed
Press for edge trimming and
force application without shimming.
transporting parts in the press
hole-punching for fluid outlets
advantages
Flexible automatic adjustment of the pressure circuits
according to various plate geometries
Optimal press force distribution by force application over a
large area and adjustment of individual cylinder pressures
20
Bowing or shimming of the dies no longer required

Deflection deviation between bed and slide reduced
to a minimum
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Hydraulic presses
Hydraulic transfer presses
Hydraulic transfer press. Press force: 25,000 kN.
Feeder loading station with blank singling.
Efficiency, step by step

Hydraulic transfer presses permit part production on
the capacity range for these presses is 5,000 to
multi-station transfer dies. High throughput rates can
30,000kilonewtons. The active electrohydraulic slide
be achieved due to hydraulic solutions such as the
parallelism control and hydraulic impact shock
Schuler ring valve technology and dynamic cylinder mode
dampening ensure superior part quality and reliability
switching. In single-slide or multi-slide design (with
in the forming process. Other auxiliary functions
options for one or more bed and/or slide cushions),
can be directly integrated into the die.
The advantages
Easy to adapt to different dies
Production of deep components by counter drawing
Freely programmable slide motion curves
Nominal capacity available over the entire stroke
Programmable pressure dwell in BDC
Simple die startup
High level of availability
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mechanical presses / The entire world of metal forming
AT A GLANCE
Mechanical presses
Blanking and forming systems from Schuler are used

successfully in a very wide range of industries. They permit
ServoDirect technology for

blanking and forming systems
24
C-frame presses
26
Automatic blanking presses
28
Blanking and forming systems

Servo presses
Presses with TwinServo technology
Transfer presses
Multiple-slide transfer presses
Knuckle-joint presses
32
32
38
40
41
42
Efficient process management
48
sheet metal parts to be produced flexibly and economically

with the best quality, and overcome challenges such as
large part quantities, complicated part geometries and
processing high-strength materials. The breadth of our
product range for economical series production of highquality components is matched only by the requirements
that exist in the various industries. Whether C-frame
presses, automatic blanking presses, knuckle-joint
presses, servo presses or conventional mechanical
transfer/ProgDie presses together, we can find the
right solution for your success.
SCHULER live
Your direct contact to the Servo TechCenter:
Gppingen | Tel.: +49 7161 66-214 | E-mail: stc-goeppingen@schulergroup.com
Erfurt | Tel.: +49 751 401-2606 | E-mail: stc-erfurt@schulergroup.com
Tianjin, China | Tel.: +49 7161 66-9011 | E-mail: stc-tianjin@schulergroup.com
SCHULER online
Would you like to find out more about mechanical single presses? You can find our complete selection at
www.schulergroup.com/stamping_cutting. In addition, you can download the At Home in Every Industry.
Blanking and Forming Systems from Schuler. brochure as a PDF file.
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Mechanical presses
ServoDirect technology for blanking

and forming systems
Operating panel of a servo press.
Production with optimally matched system components.
Success can be programmed

Presses with ServoDirect technology open completely new
systems are created for a broad range of parts. The presses
perspectives: maximum flexibility in production, economical
are driven directly by torque motors which permit highly
production of complex parts geometries and a high level of
dynamic forming processes thanks to their high torque.
productivity with optimum parts quality. In combination with
The lack of a flywheel and clutch/brake combination makes
highly dynamic Schuler roll feed units, coil lines, destackers
the presses flexible, energy efficient and cuts down the
or tri-axis transfer systems, fully automatic forming
maintenance required.
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FLEXIBILITY AND EFFICIENCY
max.
Stroke [mm]
max.
Stroke [mm]
Reduction in cycle time
Time [s]
Motion profile of conventionally driven eccentric press

Motion profile of the servo press with optimized performance
Operation in oscillating stroke
Time [s]
Oscillating mode, small stroke

Oscillating mode with rest position
Pass-through mode
Individual programming of the slide motion reduces the cycle time

whilst keeping the forming speed constant.
ServoDirect technology allows the slide motion to be programmed

individually.
Programmable slide motion curves
Oscillating stroke mode
The use of highly dynamic torque motors permits straight-
Oscillating stroke mode permits user-programmable slide
forward and rapid programming of different movement
stroke heights. The reversing movement of the torque motor
profiles in one press cycle. This means the slide kinematics
means that the eccentric drive of the slide has an oscillating
can be quickly and easily adapted to the process parameters
motion and alternates between forwards in one stroke and
of the die and the automation system, and optimized for a
backwards in the next stroke. This means the cycle count
high stroke rate.
and energy efficiency are improved significantly.
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Mechanical presses
C-frame presses
For universal application

C-frame presses provide small and medium-size companies
high product quality at low per unit cost. Innovative solutions
for equipment and controls ensure an integrated manufacturing process. The machines are configured for manual
loading (CB series) and either manual loading or automatic
mode (C series).
MODULAR FLEXIBLE ERGONOMIC
The C-FLEXline (CFL) series is based on a combination of
experience gained from users and more than 70 years
of experience in building C-frame presses. The modular
structure makes it possible to adapt to changing production
conditions at any time from straightforward manual
loading through to fully automatic production. The presses
are converted quickly and ergonomically. Two different
control concepts allow the presses to be adapted to
individual customer requirements.
C-FLEXline 630 kN comfort with foot pedal.
Model overview of C-frame presses
26
Model
CB-250
CB-400
C-400
CFL-630
CFL-1000
CFL-1600
CFL-2500
CS-1000
Press force [kN]
250
400
630
1,000
1,600
2,500
1,000
Bed dimensions [mm]
465 360
650 480
820 590
950 660
1,250 750
1,400 860
950 660
Slide dimensions [mm]
220 160
370 300
470 410
540 510
850 630
1,000 700
550 460
Shut height [mm]
270
240
320
370
440
470
371
Slide stroke [mm]
5 75
5 100
8 120
10 130
12 180
19 250
160
Slide adjustment [mm]
50
70
100
100
110
130
80
Stroke rate [rpm]
150
60 140
30 120
30 90
20 70
20 60
150
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The torque motor of the CS-1000 is located directly on a

simple knuckle joint drive, the design of which means that
slow slide speeds are achieved during the forming phase.
The additional individual adaptation of the slide kinematics
to the particular process requirements in conjunction with
a zero-play driveline guarantees high precision of the
components.
The space-saving and ergonomically built press additionally
impresses with its lower energy consumption, reduced
noise development and touchscreen operation that is both
straightforward and intuitive.
A die change can be carried out quickly and easily because
of the slide adjustment by an electric motor with quick-lift
function. Following that, die spotting ensures that production starts up smoothly and quickly.
C-frame press with ServoDirect drive CS-1000 with
1,000 kN press force.
The entire press drive does not need lubricating oil, something which is advantageous both for the production process
EFFICIENT PRECISE INNOVATIVE
and in terms of maintenance. The status-oriented mainte-
The newly developed CS-1000 C-frame press with
nance concept with integrated maintenance plan and
ServoDirect technology offers a boost in terms of produc-
innovative status monitoring via smart device increases
tivity and efficiency. Individual adaptation of the stroke
process security for the entire line.
height in conjunction with a reversing movement of the

torque motor (oscillating stroke) leads to a significant
increase in output. At the same time, optimum adaptation
of the slide kinematics to the process parameters
achieves greater product quality and a longer die life.
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Mechanical presses
Wide range of parts high output

Blanking presses (MC series) are standard machines with
extensive basic equipment for blanking classic sheet metal
components from the coil. In the range from 1,250 to 5,000
kilonewtons, they represent an optimally priced solution for
manufacturing components with high output rate.
The advantages:
Little bowing due to rigid welded construction
Long slideways ideally absorb off-center forces
Two transverse shafts compensate for rotational
forces without additional masses
Low-noise drive with helical gearing
Quick conversion to new die
Hydraulic overload protection protects the
machine and the die
Automatic blanking presses: the economical solution for
a wide range of parts.
Model overview AUTOMATIC BLANKING PRESSES (MC)

Model
MC-1250
MC-2000
Press force [kN]
1,250
2,000
Bed length [mm]

1,400
MC-3000
MC-4000
MC-5000
3,000
4,000
5,000
1,300
1,400
750
800
Bed width
1,000
1,800
1,100
2,200
1,300
3,000
Shut height [mm]
28
450
550
650
150
150
150
200
250
Slide stroke [mm]
20 180
20 220
40 315
40 315
40 315
Stroke rate [rpm]
30 150
30 130
25 100
20 80
20 70
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For small components with tight die clearances

The high-speed blanking press (MCF series) is designed for
producing components with output rates of up to 300
strokes/minute. The slide guidance system with preloaded,
play-free roller bearing units also guarantees the necessary
precision in the process: the best prerequisite for series
production of small components with tight die clearances.
The advantages:
Fast and reliable press type
Output rate up to 300 strokes/minute
Stress-relief annealed frame
Long die service lives
Longitudinal shaft machines with rotary mechanical
counterbalance
Linear roller bearings
Planetary gear unit ensures high available power,
even at low speeds
Automatic blanking press with up to 300 strokes per minute.
Fully automatic stroke and slide adjustment

reduces die change times
Infinitely variable overload protection for
die and machine
Model overview of high-speed BLANKING PRESSES (MCF)

Model
MCF-630
MCF-800
MCF-1000
MCF-1250
MCF-1600
MCF-2000
Press force [kN]
630
800
1,000
1,250
1,600
2,000
700
700
1,000
1,000
500
500
Bed length [mm]

1,000
Bed width
1,300
800
800
400
400
1,600
Shut height [mm]
350
350
70
70
100
100
100
100
Adjustable slide stroke [mm]
9 80
9 100
11 100
11 120
10 120
10 130
Stroke rate [spm]
30 300
30 300
30 280
30 280
30 260
30 260
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Mechanical presses

With ServoDirect technology
Automatic blanking press MSC-2000 with 2,000 kN press force.
12-way preloaded slide guide with zero play.
For maximum flexibility and economy
ServoDirect technology makes it possible both to adapt the
in production
slide movement to the workpiece and to increase the stroke
The new generation of ServoDirect technology makes it
rate with oscillating mode.
possible for a significant economy boost to be achieved with

MSC automatic banking presses. The new drive concept is
The drive concept without lubricating oil impresses across
based on an innovative drive module comprising highly
the board: it significantly improves process reliability
dynamic built-in torque motor, brake module, eccentric
because there is no longer any possibility of mixing process
shaft with connecting rod, two knuckle joints and slide. The
and press lubricants. As a result, this press generation is
two knuckle joints are synchronized by the drive control,
also ideal for use in the packaging and foodstuffs industry.
there is no mechanical connection.
30
TABLE OF CONTENTS
max.
Stroke [mm]
Time [s]
Drawing
Embossing
Crank
Pre-programmed slide movement profiles.
Control panel with touchscreen.
Precision and low-maintenance in harmony
Operation of the press by the touchscreen is intuitive and
The zero-play driveline increases precision and means the
simple. The menu can be individually configured and offers
possible die clearances can be even tighter, thereby also
both basket and a favorite functions.
reducing die wear.

The status-oriented maintenance concept with integrated
The pre-programmed slide motion curves are designed for
maintenance plan and innovative status monitoring via
various processes: Whether for punching, forming, blanking,
smart device increases process security for the entire line.
embossing, bending or drawing the press can be quickly

and flexibly adapted to meet any requirement.
31
TABLE OF CONTENTS
Mechanical presses

SERVO PRESSES IN MONOBLOCK AND TIE ROD DESIGN
Servo press MSD 250 in the Servo TechCenter at Gppingen

specifically for the requirements of the stamping operation.
Servo press MSD 630 with innovative Intra Trans transfer in the
ProTec Process and Technology Center, Lennestadt.
SCHULER SERVO DIRECT TECHNOLOGY
SERVO PRESSES IN MONOBLOCK DESIGN
The servo presses are driven directly and via torque motors,
The monoblock press body of the MSD series is implement-
which are the ideal drive for dynamic punching and forming
ed as a stress-free annealed welded structure. The eccen-
processes because of their high torque. The slide kinematics
tric gears have a double herringbone profile to provide axial
can be quickly and easily adapted to the process parameters
guidance and to reduce noise, and the slide roller guide is
of the die and automation functions, something which not
preloaded to eliminate play. All components are designed
only increases the die life but also improves component
to ensure a high level of machine availability.
quality. A freely programmable stroke height and dynamic

reversing movements of the motor (oscillating stroke)
ENERGY MANAGEMENT
significantly increases output and energy efficiency.
Energy accumulators can be used as an option in order

to reduce the connected load. These collect the energy
released during the braking phase in generator mode,
and make it available again during the subsequent
acceleration phase.
32
TABLE OF CONTENTS
Model overview of servo presses in monoblock design

Model
MSD250
MSD 400
MSD 630
MSD800
2,500
4,000
6,300
8,000
Press force [kN]

Bed length [mm]
2,000
Bed width
1,100
2,500
1,100
3,050
1,400
4,000
1,800
1,800
Shut height [mm]
550
600
700
1,000
1,000
Slide stroke [mm]
32 160
40 200
60 300
80 400
80 400
150
200
250
300
300
Stroke rate [rpm]*
3 160
3 140
3 90
3 60
3 60
All information for systems with two-conrod design.

* Stroke rate depending on programmed stroke height and kinematics.
advantages
Significant increase in productivity compared to
conventionally driven mechanical presses
Maximum production flexibility due to user-programmable
stroke heights and motion sequences
Increased parts quality and longer die lives due to motion
sequences optimally adapted to the particular forming
requirements
Greatest availability for production mode
Short delivery times and optimized spare part management

due to standardized modules
Shorter die tryout times because of setup and tryout
functions with hand wheel
Lower energy costs due to efficient drive solution
Easier maintenance compared to conventionally driven
mechanical presses, because there are fewer mechanical
components
Best suited for processing high-strength steels
33
TABLE OF CONTENTS
SERVO PRESSES IN TIE ROD DESIGN

The TSD/TSC series has a large number of tryout functions,
amongst other features, which use a hand wheel to reduce
setup times: the Quick-Lift function allows quick opening of
the die; the die is closed with a variable set-up speed while
in the die spotting function, the drive force can be preselected and the rest-in-rest movement can be reversed if
required. Short changeover times are achieved in combination with mature die change systems such as tandem
change cart or extendable bolster plates.
TSD 1100 servo press at the Servo TechCenter Erfurt.
Model overview of servo presses in tie rod design

Model
Press force [kN]
TSD 630
TSC 630
6,300
TSD 800
TSC 800
TSD 1000
TSC 1000
TSD 1100
TSC 1100
TSD 1250
TSC 1250
TSD 1600
TSC 1600
TSD 2000
TSC 2000
TSD 2500
TSC 2500
TSD 3200
TSC 3200
8,000
10,000
11,000
12,500
16,000
20,000
25,000
32,000
Bed length [mm]

4,000
Bed width
1,600
4,600
1,800
1,800
2,200*
1,800
5,000
2,200*
5,100
2,200*
1,800
2,200*
1,800
1,800
2,200*
1,800
2,500*
1,100
1,200
1,100
1,300
150600 120450 150600 150450 200600
6,000
2,500*
6,100
7,000
Shut height [mm]
Slide stroke [mm]
900
1,100
1,100
1,100
100350 120450 120500
120450
1,200
2,500*
2,500*
2,500*
2,500*
2,500*
2,500*
1,400
1,400
1,400
200700
230700
230700
Slide adjustment
[mm]
300
300
300
300
300
300
300
300
300
300
300
300
Stroke rate** [rpm]

TSD
TSC
3 70
3 60
3 50
3 50
3 50
3 45
3 36
3 45
3 38
3 40
3 34
3 40
3 32
3 36
3 34
3 30
3 30
34
All information for systems with two-conrod design. * Four-conrod design.

** Stroke rate depending on programmed stroke height and kinematics.
TABLE OF CONTENTS
Servo press in tie rod design with automation
10
11
13
12
LEGEND
1. Material feed (operation either with coil feed
line or destacker)
2. Decoiler
3. Leveling machine
4. Destacker, two destacker carts including
scissor-lift table and double-blank
depositing station
5. Roll feed unit

6. Coil or blank lubricating unit
7. Transfer and centering station
8. Servo press in tie rod design
9. Electronic, modular tri-axis transfer
10. Combined sequential or transfer die

11. Exit conveyor
12. Hydraulic, modular drawing cushion
13. Scrap disposal
35
TABLE OF CONTENTS
Servo presses
In practice
Blanking trials and process integration
Seat shell.
Component with welded nut.
Cylinder head gasket.
Integration of follow-on
make completely new working
as well as by providing rest times.
processes
methods possible here: Processes
The result: economical production
Frequently, component production
such as welding or lasering can be
of complex parts geometries and
involves several production steps
integrated reliably into the process
maximum output levels with the
which performed one after another
and with high productivity levels
highest quality. For extra efficiency.
take up time and productivity. Highly
thanks to the possibilities of user-
dynamic servomotors from Schuler
programmable time/travel sequences
36
Formed part
Operating mode
Component-specific
press force [kN]
Depth of draw
[mm]
Max. stroke rate

Conventional
Max. stroke rate

Servo
Increase
Flange
Progressive
1,200
30
30
56
+ 87 %
Gas generator holder
Progressive
1,300
60
25
40
+ 60 %
Holder
Progressive
2,000
40
30
60
+100%
Cage
Progressive
2,400
50
30
50
+ 67 %
Cross plate
Progressive
4,000
90
23
33
+ 43 %
Cover
Progressive
6,900
40
15
34
+ 126%
Center console
Transfer
6,000
190
12
17
+ 42 %
Insert cup
Transfer
6,600
130
15
+ 88%
Support
Transfer
7,190
67
14
30
+114%
Tank filler neck
Transfer
9,650
145
14
18
+ 29%
Side panel
Transfer
14,750
80
19
29
+ 53%
TABLE OF CONTENTS
Servo presses
In practice
Customer: Automotive components supplier, Germany and Austria
Servo press in monoblock design. Press force: 4,000 kN.
Servo press in tie rod design with 16,000 kN press force, coil feed
line and destacker combination.
The requirements:
The requirements:
Delivery of a servo press for producing a wide range
Delivery of a servo transfer press with complete automa-
of parts.
tion for manufacturing structural components in progressive

or transfer mode.
The solution:
Servo press in monoblock design with a maximum press
The solution:
force of 4,000 kilonewtons. Automated with coil line and
Servo press in tie rod design with a press force of 16,000
feed unit.
kilonewtons and Schuler automation components.
Monoblock design
Coil feed line/destacker combination
Bed surface: 2,500 1,100 millimeters
Roll feed unit
Slide stroke 300 millimeters
Electronic, modular tri-axis transfer
Maximum stroke rate in continuous operation:
Conveyor belt
80 strokes/minute
Bed surface: 6,000 2,500 millimeters

Slide stroke: 600 millimeters
Tie rod design
37
TABLE OF CONTENTS
Mechanical presses

Presses with TwinServo technology
Advanced thinking in servo technology

Following the market launch of ServoDirect technology, the
next milestone in a success story was set with TwinServo
technology. The new press generation is driven by decentralized TwinServo technology, which offers users additional
interesting possibilities in sheet metal forming. Schuler
impressively demonstrates the performance of the innovative press technology in the Servo TechCenter Erfurt on a
new transfer press. The new press system produces at a
press force of 16,000 kilonewtons and is fully automated
with components from Schuler.
TwinServo transfer press at the Servo TechCenter Erfurt.
Model overview of TwinServo presses

Press force [kN]
10,000
16,000
Bed length [mm]

5,000
20,000
25,000
30,000
35,000
Table width standard and option*

2,200
6,000
2,200*
2,500*/2,200*
3,000 / 2,500*
2,500
2,500*/2,200*
3,000/2,500*
3,000*/2,500*
3,000*
3,000 / 2,500*
3,000 / 2,500*
3,000*
3,000 / 2,500*
3,000
7,000
8,000
Slide stroke [mm]
600
600
600
750
750
750
300
300
300
300
300
300
Press force millimeters before BDT [mm]
Number of connection points
Stroke rate at max. stroke** and constant

speed [spm]/rated capacity [kJ]
40 / 400
35 / 500
40 / 900
30 / 1,200
25 / 1,500
25 / 1,500
Oscillating stroke rate 1/3 stroke**

[spm] /rated capacity [kJ]
50 / 250
50 / 250
60 / 400
40 / 650
35 / 700
30 / 900
* Option. ** Deviations possible depending on the motion curve and force profile.
38
TABLE OF CONTENTS
Automated transfer press with TwinServo technology
In practice
Servo TechCenter Erfurt
Coil line with decoiler and leveling machine.
Transfer press with TwinServo technology.

Press force: 16,000 kN.
Die change by moving bolster.
The requirements:
The solution:
In the ServoTech Center Erfurt,
Press
Destacker
the first transfer press with
Decentralized TwinServo drive
Destacker with removal feeder and
TwinServo technology has been
Press force: 16,000 kilonewtons
installed.
Main motors: 2 AC servo

torque motors 503 kilowatts
Four contact points
shuttle device in the press

Transfer
Electronic tri-axis rhombus transfer
Bed dimensions (L W):

5,000 2,200 millimeters
Slide stroke: 600 millimeters
Slide adjustment:
Additional equipment
Two moving bolsters and parts
outfeed belt
300 0.1 millimeter

Stroke rate: controllable
3 30/minute, in oscillating
mode without transfer
3 40/minute
Dimensions
Total length of the machine:
25 meters
Press height over floor:
6.50 meters
Coil feed line

Coil line with decoiler, leveling
Required foundation depth:

5.30 meters
machine, coil-end welding device,

PowerFeed roll feed unit and
spraying system, can be used with
aluminum
39
TABLE OF CONTENTS
Mechanical presses

Transfer presses
Individually adjustable forming stations

Multi-station presses differ from transfer presses mainly in
the ability to adjust individual forming stations. Another
difference in multi-station presses is the externally mounted
blanking slide for integrated blank production. Multi-station
presses are built both as single-slide and multi-slide
machines with a press force range from 2,500 kilonewtons
to 60,000 kilonewtons. Either mechanical or electronic rail
transfer systems are used for parts transport. The advantages are high output and high availability, individual station
adjustment in each station and, if necessary, the externally
mounted blanking slide for integrated blank production.
Mechanical multi-station press.
Multi-station press with externally mounted blanking slide

1. Crown with press drive
2. Press upright
3. Drawing slide
2
4. Transfer system
5. Die change cart
5
7
40
6. Blanking slide
7. Drawing cushion
TABLE OF CONTENTS
Mechanical presses

Multiple-slide transfer presses
Multifunctional mass production

Multi-slide transfer presses deliver impressive practical
performance as a functional unit comprising press, transfer
and material feed. The configuration is based on the parts
spectrum, die size and forming process. Single-slide,
double-slide or triple-slide machines are used, depending
on the parts spectrum, which also influences the size and
number of dies. Parts are transported by a rail transfer
system which can be equipped either with cam-controlled
or electronic drive.
Multi-slide transfer press.
Multi-slide transfer press

1
1. Destacker
2. Transfer press
4
3. Tie rod
4. Crown
5. Upright
6. Slide
7. Processed part unloading belt
8. Moving bolster
7
9. Damping element
10. Drawing cushion
10
41
TABLE OF CONTENTS
Mechanical presses

Knuckle-joint presses
Precise in operation
The very rigid press concept and the slide movement that
is characteristic of knuckle-joint presses guarantee
that ready-to-install precision parts can be manufactured
economically. Each machine permits efficient blanking,
drawing, embossing, punching and calibrating in one
operating sequence, while the various stations can also be
combined with one another. The optional use of ServoDirect
technology also ensures extra flexibility and productivity.
The new PSK and PSK PLUS series is the perfect solution
for components with increased requirements for precision
and smooth cutting proportion.
The versatile knuckle joint presses are simple to operate and

change over for high levels of availability and efficiency.
advantages
Optimized slide motion by modified knuckle-joint drive and
maximum production flexibility with user-programmable
High system rigidity for close component tolerances

and reduced cutting impact
stroke heights and motion sequences in knuckle-joint
Excellently suited for processing high-strength steels
presses with servo drive
Reliable repeat accuracies, even with fluctuating
Drawing, bending, cleaning, blanking and calibrating

operations in one press cycle
material thicknesses and strengths

Shorter die start-up times by precision setup using
hand wheel
42
TABLE OF CONTENTS
Stroke [mm]
max.
200
Eccentric curve
Knuckle joint curve

0
0
360
Time [s]
Structure of the knuckle joint system.
Motion characteristics of the eccentric and knuckle joint press.
Model overview of knuckle-joint presses (TMK)

Press force [kN]
2,000
2,500
3,150
1,500
1,000
1,000
2,000
1,000
1,000
1,100
1,100
2,500
1,000
1,000
1,100
1,100
Bed length [mm]
4,000
5,000
6,300
8,000
10,000
15,000
1,100
1,200
1,400
1,100
1,200
1,200
1,400
1,500
1,500
1,500
1,400
1,500
1,500
1,500
Bed width
3,000
3,660
Shut height [mm]
Stroke down
400
500
600
700
700
800
800
800
800
Adjustment up
500
600
700
800
800
900
900
1,100
1,100
150
150
150
150
150
200
200
200
200
with stroke adjustment
40 160
40 160
60 200
60 200
60 200
80 250
80 250
with fixed stroke
160
160
200
200
250
250
250
300
300
Stroke rate [rpm]
20 140
20 140
20 120
20 120
20 90
20 90
20 80
Slide stroke [mm]
43
TABLE OF CONTENTS
Mechanical presses

Knuckle joint presses with ServoDirect technology
Knuckle-joint press with servo drive. Press force: 8,000 kN.
Control panel of the overall machine.
Optimized overall process
EFFICIENT PROCESS TECHNOLOGY
User-programmable servomotors allow the tried-and-test-
The optimum design of the forming process with the servo
ed knuckle-joint kinematics to be exactly adapted to the
drive can be additionally expanded by integrating follow-on
requirements of the specific components. In addition, all
processes. This means a previously downstream process
components of the press peripherals such as coil feed,
such as welding a nut onto the formed component can be
transfer, drawing cushion and ejector are optimally inte-
integrated directly into the press cycle as part of a reliable
grated into the overall process. The results: increased
process with high output rates by providing rest times.
production quantities, higher component quality and
The result is highly efficient production of ready-to-install
longer die lives.
precision parts with the best quality.
Video
Find out more about knuckle-joint presses with servo drive.
Simply scan the QR code using the camera of your smartphone or tablet.
http://bit.ly/GR1EhR
44
TABLE OF CONTENTS
MODEL OVERVIEW OF KNUCKLE-JOINT PRESSES WITH SERVO DRIVE (MSK)

Model
MSK 250
MSK 400
MSK 630
MSK 800
MSK 1000
MSK 1500
Press force [kN]
2,500
4,000
6,300
8,000
10,000
15,000
1,300
1,300
1,300
Bed length [mm]

2,000
Bed width
1,000
2,500
1,100
3,500
1,300
Shut height [mm]
600
700
800
800
800
800
Slide stroke [mm]
40 160
50 200
75 300
75 300
75 300
75 300
150
150
200
200
200
200
Stroke rate [rpm]
3 160
3 120
3 80
3 70
3 60
3 50
All information for systems with two-conrod design. Further sizes are available on request.
* Stroke rate depending on programmed stroke height and kinematics.
advantages
conventionally driven knuckle-joint presses
Drawing, bending, cleaning, blanking and calibrating
Excellently suited for processing high-strength steels

Optimum adaptation of slide movement to the
automation concept
Shorter die start-up times by precision setup using
hand wheel
Compact and durable design with stable value
operations in one press cycle

Reliable repeat accuracy, even with fluctuating material
thicknesses and strengths
45
TABLE OF CONTENTS
Mechanical presses

Knuckle-joint press for precision blanking and forming processes
THE NEW PERFORMANCE CLASS

The PSK and PSK Plus series open up a new performance
class in production: Users in the normal blanking and
precision clamping quality range can significantly expand
their product range with the new PSK servo knuckle-joint
press, and produce better quality blanking in an economical
fashion with an increased straight cut proportion. However,
companies in the fine stamping sector can also improve
their efficiency with the PSK Plus: Components that do not
necessarily require fine stamping can now be manufactured
with lower production costs.
This extra quality and productivity is made possible by
significantly increased stiffness of the overall system
thereby permitting a minimum die clearance, as well
as by additional press functions for improved flatness,
positional accuracy, minimized pull-in and burrs.
Knuckle-joint press with servo drive for precision blanking and
forming processes, press force: 6,300 kN.
Model overview of knuckle joint presses for precision blanking and forming processes (PSK/PSK PLUS)
Model
PSK/PSK PLUS
250
PSK/PSK PLUS
400
PSK/PSK PLUS
630
PSK/PSK PLUS
800
PSK/PSK PLUS
1000
PSK/PSK PLUS
1500
Press force [kN]
2,500
4,000
6,300
8,000
10,000
15,000
Bed length [mm]
Bed width
2,000
1,000
1,100
2,500
1,000
1,100
3,000
1,100
3,500
46
1,300
1,300
1,300
1,300
1,300
1,300
1,300
1,300
1,300
1,300
Shut height [mm]
600
700
800
800
900
900
Slide stroke [mm]
40 160
50 200
75 300
75 300
75 300
75 300
150
150
200
200
200
200
Stroke rate [rpm]
3 160
3 140
3 100
3 80
3 70
3 60
TABLE OF CONTENTS
Overview of blanking processes
Normal blanking
Precision blanking
Precision blanking PLUS
Fine blanking
Conventional blanks
with straight cut proportion
of up to 30%
Precision blanks with higher

quality requirements
High-precision blanks
by additional functions
in the press
Fine blanks with straight

cut proportion of 100%
Blanking process
advantages
Outstanding parts quality with high straight cut proportions
conventionally driven knuckle-joint presses
Drawing, bending, embossing, blanking and calibrating

operations in one press operation in combined
sequential or transfer applications
Suitable for processing a wide range of materials
Optimum adaptation of the slide kinematics
Secure investment due to compact and durable
design that retains its value
47
TABLE OF CONTENTS
Mechanical presses
Process management
Efficiency across the line
Flexibility and efficiency by ServoDirect technology.
Digital simulation for optimum die configuration.
To achieve efficiency and economic strength in production,
accruing tooling costs. Schuler's personnel is at your side
it is not enough just to have the best machines. To enable all
with component calculations based on your individual
economic opportunities to be exploited to the full, the entire
component and tooling data.
process must be analyzed and all its aspects must be

optimally coordinated.
Optimum die configuration

The objective of any production company is to achieve the
Schuler is at your disposal as an expert partner with various
longest possible die service lives, at the same time as
services such as process consulting or training. First and
benefiting from the greatest possible stroke rates. We offer
foremost, each measure concentrates on boosting the
you advice in die configuration and design to ensure this is
economic performance of your company.
successful. We support you in defining press and transfer

movements in advance using simulations for optimum
Economical component and
output and clearance. This support is rounded off by training
manufacturing process
courses dealing with the topic of optimized die design
All production planning starts with the decision on which
adapted to the requirements of servo technology.
is the optimum production process. In this consideration,

it is necessary to take account of and calculate the material
costs and the output per component, as well as additionally
48
TABLE OF CONTENTS
Economical component
and manufacturing process
Maximum
efficiency
Optimum
die configuration
and simulation
Increasing
employee
qualification
Setup time
optimization
Increase in energy
efficiency
Flexibility and efficiency by
Noise reduction
Stroke rate optimization
Setup time optimization
Increase in energy efficiency
The current trend towards smaller and smaller batch
The greatest possible energy saving without impairing
sizes goes hand-in-hand with frequent die changes and
yield efficient machine technology from Schuler puts
increasing setup costs. Our setup workshop shows
you one step ahead of the competition here as well. We
you the ways to optimize setup times by standardized
offer you individual advice on optimum use of energy
processes and efficient working sequences.
in running machines, such as programming of energysaving stand-by operation as well as energy efficiency
Stroke rate optimization
programs for new machines. Furthermore, we are
It is only possible to achieve maximum stroke rates, and
ready to provide you with active support when it comes
thus a long-term boost in economic performance, if all
to training your operators.
process components are working together optimally.

Suitable methods for successful implementation are
revealed in our training course, Process optimization.
49
04
50
TABLE OF CONTENTS
TABLE OF CONTENTS
Automation of presses / The entire world of metal forming
AT A GLANCE
Automation of presses
Our automation ideally combines the press, automation
Destacker
52
coil feed lines
53
Roll feed unit
56
TRI-axis transfer
58
devices and die, offering impressive precision and

process reliability. With automation components from
Schuler, you benefit from a greater output rate even
when processing high-strength steels or aluminum.
SCHULER live
Your direct contact to the Automation TechCenter:
Hedorf | Telephone: +49 9135 715-264 | E-mail: atc-hessdorf@schulergroup.com
SCHULER online
Would you like to find out more about automating presses? You can find our complete offer at
www.schulergroup.com/Automation. In addition, you can download the Performance across
the line Automation from Schuler brochure as a PDF file.
51
TABLE OF CONTENTS
Destacker
Destacker with transfer system for blank destacking.
In order to automate transfer presses, Schuler not only

offers tried-and-tested destackers but also a special
solution. This consists of a mobile combination of coil line
in short design with a destacker. For the press owner, this
solution opens a wide range of options regarding material
and flexibility for efficient part production. It represents
a flexible solution for blank and coil processing on a
single line. The control is compatible with both the
press and transfer, and meets all production
requirements.
52
Integrated system solution. Destacker and coil line on a servo press.

Press force: 16,000 kN.
TABLE OF CONTENTS
Coil feed lines
Coil feed lines in short design

Our coil feed lines in short design have been specially
developed for the requirements of customers in the
components industry. They offer process reliability while
meeting the highest material requirements. The lines are
optimally suited for producing structural components and
processing high-strength materials even in the higher coil
thickness range. They are the ideal solution when space is
at a premium. Our product range includes coil feed lines
in various high-performance basic versions, and is adapted
to all press types. The modular concept permits flexible
configuration of the lines. With our extensive package of
options, you can react to new requirements at any time
while keeping control over your investments.
Reference data of the basic versions

Coil feed line in short design.
Coil width max. [mm]
1,850
Coil thickness max. [mm]
12
Coil weight max. [t]
27
53
TABLE OF CONTENTS
Coil feed lines in long design

Compact Line product line
The Compact Line from Schuler has been specially
developed for small coil widths and tonnages. It covers coil
widths up to 800 mm and tonnages up to 7.4 tons for
requirements with a straightforward level of automation.
Power Line product line
As an expansion of the Compact Line product line, Power
Line coil feed lines are available for large coil widths and
tonnages. These Schuler coil feed lines do full justice to
the requirements of the automotive and components
industry for material feed with the option of a high level of
automation for high-speed, prog-die and transfer presses.
Coil widths up to 1,850 millimeters and coil weights up to
27tons make it possible to prepare coil material for
structural and skin panels as well as blanks.
Schuler Power Line.
Technical data of the compact line

Compact Line
L-BS 0450
L-BS 0650
M-BS 0800
5.5
7.4
Coil width min. [mm]
110 [40]
110 [40]
110
450
650
800
Coil thickness min.

[mm]
0.5
0.5
0.5
Coil thickness max.

[mm]
Leveling rolls [mm]
70
70
70
Loop radius [mm]
1,000
1,000
1,300
Power Line model overview

Basic versions of coil feed lines in long design
Coil data for Light weight class
POWER LINE
L-BS 0650
L-BS 0800
L-BS 1050
L-BS 1300
L-BS 1600
5.5
12
12
14.5
17

Coil thickness min. [mm]
650
110 [80]
800
1,050
0.5
Leveling rolls [mm]
53
Loop radius [mm]
54
110 [40]
1,000
1,300
1,600
TABLE OF CONTENTS
Coil data for Medium weight class

POWER LINE
M-BS 0650
M-BS 0800
M-BS 1050
M-BS 1300
M-BS 1600
M-BS 1850
13.5
11.5
12.5
13.5
16
22
120
160
1,050
1,300
110
650
800
205
1,600
1.850
4.5
0.5
Leveling rolls [mm]
70
Loop radius [mm]
1,300
Coil data for Heavy weight class

POWER LINE
H-BS 0650
H-BS 0800
H-BS 1050
H-BS 1300
H-BS 1600
10
15
15
17
23
800
1,050
1,300

120
650
205

Leveling rolls [mm]
Loop radius [mm]
1,600
0.5
8
6
96
1,600
Advantages
Flexibility:
Attractive price/performance ratio:
Systems and components available on short notice
Significant cost advantage by modular line configuration and
Scalable weight classes>Light>Medium>Heavy
preconfigured components
Wide range of options can be retrofitted
Energy-efficient by optimum drive configuration
Can be configured for manufacturing structural
Very straightforward maintenance
and skin panels

Implementation of customer-specific requirements
User-friendly machine operation:
Rapid retrofitting
Intuitive operating concept
Flexible attachment to existing price systems
Online diagnosis
Variable level of automation:

Manual or motor-driven adjustment of the setup axes
Visualization
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Roll feed unit
Power Feed roll feed unit

The Power Feed roll feed unit shortens the automation
time, especially with highly dynamic presses. ServoDirect
drives provide greater dynamics and system accuracy, as
do the low-play and maintenance-free planetary gear
units. In the long term too, this makes it possible to achieve
a system accuracy of 0.05 millimeters. Furthermore,
there is an optimally configured roll coating which
transfers the high acceleration values to the material. The
Schuler Power Feed is divided into different weight classes
depending on the mass to be moved: Weight class L
(Light) with movable mass up to 100 kilograms, M
(Medium) with movable mass up to 180 kilograms or H
(Heavy) with movable mass up to 300 kilograms.
Power Feed.
Feed performance diagram, Power Feed (example)

Feed time [s]
Stroke rate [spm]
400
0,40
350
0,35
300
0,30
250
0,25
200
0,20
150
0,15
100
0,10
50
0,05
100
Feed length [mm]
56
200
300
400
500
600
0,00
Feed time
240,0
180,0
120,0
60,0
TABLE OF CONTENTS
Roll feed model overview

COIL DATA
POWER FEED
L-BP 0300
L-BP 0450
L-BP 0650
L-BP 0800
L-BP 1050
L-BP 1300
L-BP 1600
40
40
40
40
40
80
80
300
450
650
800
1,050
1,300
1,600
0.5
0.5
0.5
0.5
0.5
0.5
0.5
4.0
4.0
4.0
4.0
4.0
4.0
4.0
Coil cross section max. [mm]
750
1,125
1,300
1,600
2,100
2,600
3,200
Loop radius [mm]
1,000
1,000
1,000
1,000
1,000
1,000
1,000
POWER FEED
M-BP 0300
M-BP 0450
M-BP 0650
M-BP 0800
M-BP 1050
M-BP 1300
M-BP 1600
M-BP 1850
40
40
40
40
40
80
80
80
300
450
650
800
1,050
1,300
1,600
1,850
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6,0
1,350
2,025
2,600
2,800
3,150
3,900
4,800
7,200
Loop radius [mm]
1,300
1,300
1,300
POWER FEED
1,300
1,300
1,300
1,300
1,300
H-BP 0650
H-BP 0800
H-BP 1050
H-BP 1300
H-BP 1600
40
40
40
80
80
650
800
1,050
1,300
1,600
0.5
0.5
0.5
0.5
0.5
8.0
8.0
8.0
8.0
8.0
3,250
4,000
5,250
6,500
6,400
Loop radius [mm]
1,600
1,600
1,600
1,600
1,600
Advantages
Connection to all press types
Scalable in weight class and performance
Ideally usable within highly dynamic processes
Available on short notice
ServoDirect drive
Low maintenance requirement
System accuracy of 0.05 millimeters
Can be retrofitted at any time
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TABLE OF CONTENTS
Tri-axis transfer systems
Pro Trans
With its three motor versions L (Light), M (Medium)
and H (Heavy), Schuler Pro Trans covers low, medium
and high part weights and stroke rates. The heavy version
has twice the performance capability of the light version,
while the medium variant is situated in between. All the
transfers owe their significantly improved output
performance to having motor systems with direct advance
drive, featuring highly dynamic servo drives. Overall, the
Schuler Pro Trans has a modular principle: The three
defined standard models AT1, AT2 and AT3 can
quickly and easily be adapted to changed requirements.
Schuler offers a wide selection of options for this.
Power Trans
Schuler offers a high-end transfer solution for highperformance presses in the form of Schuler Power Trans
Schuler Pro Trans transfer.
and the S (Speed) motor system, the use of which

permits productivity to be increased even further and by a
The new modular transfer generation is a high-performance
significant amount. For example, the output rate with
addition to sheet metal forming presses. Designed with
Power Trans is up to 30% higher than with Pro Trans motor
three sizes, the transfer system covers a wide range of
systems. This additional performance is achieved in
applications. In all transfer solutions, active vibration
particular by using newly developed carbon rails with
damping AVD also guarantees reliable parts transport
aluminum profile functions combined with the ServoDirect
with the highest level of dynamic properties and at full load.
drive. The rails are very light and rigid, which means the
vibration levels are extremely low. As a result, they are
ideal for use in highly dynamic production processes.
Advantages
Can be retrofitted regardless of the press
Low tendency for vibration
Optimally adaptable to different applications
Short changeover times
Simple and cost-effective performance increase
Large clearances for attaching components for material

High rigidity in the overall system
58
feed and material unloading

Left-over strip processing regardless of material
TABLE OF CONTENTS
Intra Trans
The Schuler Intra Trans can be equipped with all motor
Overview of the sizes
variants from L (Light) to S (Speed), which means it is
Size
Support width [mm]
Press window/drive unit

width [mm]
suitable for use in presses ranging from conventional to
AT1
3,000
up to 1,600
AT2
6,000
up to 2,500
AT3
10,000
up to 5,500
high-performance. In Intra Trans, the transfer rails do not

operate through the press window, but are installed
between the press uprights. Parts feed in the working
direction is performed by movable slides mounted on the
transfer rails, with servo drives integrated in the rail. Each
Modular system
carriage of the Intra Trans can be moved individually so the
All models in the Pro Trans, Power Trans & Intra Trans
central joining of parts or even different distances between
series have gripper rail drive units that can be attached in
stations are possible. Using this compact transfer makes
the press (1), between the press uprights (2) or on the
it possible to manufacture larger parts with the same
outside of the press uprights (3). Furthermore, they can be
transfer press. The new transfer solution is also a genuine
installed above (hanging) or below (standing) the transport
alternative to progressive die manufacturing. Conventional
level, resulting in the highest level of flexibility both in
transfers require a larger press for the same maximum
project planning and for retrofitting to existing presses.
part size but the compact design of the Intra Trans means
it needs only the same space as the progressive die. The
transfer exploits its full benefit: less material is consumed,
because the parts are transported by the slides and not by
the coil material itself. Additional material is required in
combined sequential production, and the material has to
be cut off the finished pressed part as scrap. Intra Trans
is ideal for retrofitting to existing combined sequential
presses as a means of reducing unit costs. Access to the
Slide
die and the die change are possible without restrictions

as before, and as far as the operator is concerned there is
no difference from the Schuler transfers in the Pro Trans
and Power Trans series.
Gripper rail
drive units
Gripper rail
drive units
3
Moving bolster
Attachment variants of the transfer drive housings of the Schuler

transfer system on the press upright.
59
05
60
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TABLE OF CONTENTS
Press lines / The entire world of metal forming
AT A GLANCE
Press lines
The future starts with Schuler: with high-quality
Hydraulic press lines
62
Hybrid press lines
64
Mechanical high-speed press lines
65
Servo press lines
67
implementation and the technology of tomorrow, we are

taking measures today to ensure the greatest possible
productivity in mass production for the automotive
industry. Our results satisfy the most exacting
requirements and win over our customers worldwide.
Flexibility and quality are what we stand for. Our
innovations are unusual and practical. we create change
for the market, time and time again. Groundbreaking
new developments such as ServoDirect technology,
press automation with the crossbar feeder or crossbar
robot ensure the best component quality, high
availability and output.
SCHULER online
Would you like to find out more about our automotive press technology? You can find our complete selection
at www.schulergroup.com/automotive. In addition, the highlight on the page provides direct information
about the important aspect of High-Speed in the Stamping Plant.
61
TABLE OF CONTENTS
Press lines
Hydraulic press lines
Fully automated hydraulic press line.
Press automation with crossbar robot.
Reliable, flexible and economical

Hydraulic press lines are mainly used to manufacture a wide
developed by Schuler. The control and graphic display for
variety of parts in small to medium batch sizes. Depending
hydraulic press lines offer the operator uniform, user-
on the forming operations, the lines consist of four to six
friendly operation, efficient fault diagnostics and the
single presses. The production process is fully automated
management of all process and die data for all presses
from the blank to the finished component. To an increasing
and automation systems.
extent, automation is provided by the crossbar robot
advantages
Flexibility in the forming process
Precise slide guiding and rigid press frames
Energy-efficient drive systems
Uniform control concept
Dynamic cylinder mode switching and ring valve
User-friendly operation and efficient fault diagnostics
technology increase production rates

Automation for tooling and dies to ensure fast changeovers
62
Fast takeover of new die sets
TABLE OF CONTENTS
HYDRAULIC PRESS LINES
In practice
Customer: TRUCK MANUFACTURER, FRANCE
Existing and newly-developed dies will be used.
Automation with crossbar robot, one destacker and two

outfeed belts.
The requirements:
The solution:
With the Euro-6 exhaust standard, permitted nitrous oxide
Hydraulic lead press with 20,000 kilonewtons press force
emissions from trucks with a weight of more than 3.5 metric
Three hydraulic follow-up presses, each with
tons are reduced by 80 percent. Our customer took this
10,000kilonewtons press force
opportunity to thoroughly revise its entire model range. In
Destacker
future, for example, important components of the new
Press automation with crossbar robots
trucks will be produced on a high-performance hydraulic
Unloading with crossbar robot
press line from Schuler. High productivity combined with
Two outfeed belts
high flexibility proved to be convincing arguments.
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TABLE OF CONTENTS
Press lines
Hybrid press lines
Lead press hydraulic follow-up presses

mechanical
Hybrid press lines consist of a hydraulic lead press and
mechanical follow-up presses. They are a cost-effective
alternative when single-action and double-action dies will
be used on the same line. Modern hydraulic slide drives
put the output rate of hybrid lines in the region of
mechanical press lines. The slide cycle of hydraulic lead
presses is user-programmable, and the nominal press
force of the press is fully available at any time throughout
the press stroke.
Hybrid press line with hydraulic lead press and mechanical

follow-up presses.
advantages
One forming system for single and double-action dies
Flexible production alternative
Suitable for complex drawn parts because of the

modern bolster cushion technology
Quick and easy startup of new die sets
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Press lines
Crossbar feeder improves output performance

To increase the cost-effectiveness of mechanical press
lines, Schuler developed the crossbar feeder. In press
lines with crossbar feeder automation, the components
are transported directly from press to press without
intermediate stations. If required, the components can
also be repositioned before placement into the die. As
compared to mechanical press lines with robot or feeder
automation, it is possible to achieve production rates
as high as 15 strokes/minute.
In mechanical press lines with crossbar feeder automation,
both the loading of press 1 as well as unloading the
finished parts can be performed with the crossbar feeder.
Mechanical high-speed press line with crossbar feeder automation.
Advantages
One set of tooling for each press opening
Crossbar feeder with seven degrees of freedom
Short distances between presses
No intermediate stations required
Rapid die and tooling changes
65
TABLE OF CONTENTS
In practice
Customer: Automobile manufacturer, People's Republic of China
Mechanical high-speed press line.
End-of-Line-System.
The requirements:
The solution:
Delivery of a fully-automated mechanical high-speed
Schuler high-speed press line.
press line.
Destacker
Loading press 1 with crossbar feeder
Fast die change
Crossbar feeder press automation
End-of-Line-System with crossbar feeder and robot
Control station
66
TABLE OF CONTENTS
Press lines
Servo press lines
Quick, compact and flexible

Equipped with a Schuler destacker, crossbar feeder and
End-of-Line-System, servo press lines offer the greatest
possible flexibility, high output rates with a wide range of
parts as well as short die and tooling change times. Using
innovative drive technology, the slide movements of all
presses can be individually adapted for each component,
the forming process, the die and the parts transport. In
identical processes, this leads to higher output rates for
single, double or four-fold parts in steel, aluminum and
components made from higher-strength materials. The
combination of high output, short change times and high
flexibility contributes to reduction of part unit costs and
improvement to the productivity of press shops.
Six-station ServoLine18 XL with six die stations.
Advantages
Fully automatic die and tooling change in three minutes
High level of flexibility
One set of tooling per press opening
Reduction in part unit costs
Die tryout possible with hand wheel function
Slide movement freely programmable
User-friendly user interfaces
Optimum adaptation to various forming processes
Ergonomic parts outfeed
Automation with destacker and crossbar feeder
Easy-to-maintain technology, because the flywheel,
Compact design of the press line
clutch and brake are dispensed with
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TABLE OF CONTENTS
Servo press lines
In practice
Customer: Automobile manufacturer, Germany
ServoLine18 XL with six die stations.
Destacker.
Control station.
The requirements:
Delivery of three servo press lines for large-scale mass production of a wide
range of parts in three plants. Output performance: 17 strokes/minute.
The solution:
Fully automated servo press line with six die stations.
Destacker with lubricating unit and optical centering station
Loading press 1 with crossbar feeder
Crossbar feeder press automation
End-of-line system with robot and crossbar feeder
Control station
Crossbar feeder simulator
Die change in three minutes
68
TABLE OF CONTENTS
ServoLine23 L: With an output rate of 23 strokes per minute, it is the fastest press line in the world.
69
06
70
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TABLE OF CONTENTS
Automation of press lines / The entire world of metal forming
AT A GLANCE
Automation of press lines
From the single press to the complete press line: As a
Destacker for press lines
72
Blank washers and lubrication units
73
Robots
74
Crossbar robot
75
Crossbar feeder
76
Part racking systems
77
system supplier, we automate your forming systems

intelligently and practically. We boost the performance of
your production efficiently and economically. Whether it
comes to a broad portfolio of parts, high productivity or
the need for a compact space, automation solutions from
Schuler guarantee high efficiency and reliable production
processes. When it comes to modernizing existing lines,
we offer tried-and-tested practical solutions for efficient
production of components in the highest quality.
Automation solutions from Schuler deliver convincing
performance in all aspects of forming technology.
SCHULER live
Your direct contact to the Automation TechCenter:
Gemmingen | Telephone: +49 7267 809-141 | E-mail: atc-gemmingen@schulergroup.com
Hedorf | Telephone: +49 9135 715-264 | E-mail: atc-hessdorf@schulergroup.com
Canton, MI USA | Telephone: +1 734 207-7279 | E-mail: atc-canton@schulergroup.com
SCHULER ONLINE
Would you like to find out more about our stamping plant? You can find our High-Speed in the Stamping Plant
focus at www.schulergroup.com/automation. In addition, you can download the Performance along the line
Automation from Schuler brochure as a PDF.
71
TABLE OF CONTENTS
Destackers for press lines
Modular designed destacker concepts for mechanical and

hydraulic press lines are designed to suit downstream
forming systems. Schuler offers a selection of models
adapted to the required part size and contour, the type of
material, the blank weight and the loading speed. From the
simplest loader with one robot without centering station
for small parts and simple operations, up to destackers
with two destacking stations, optical or mechanical
centering station, blank washers and lubrication units for
large and/or heavy blanks we have it all. The blank
destacking is performed by the robot or feeder. To help
make full use of the capacities of large press lines, two
or even four blanks can be processed at the same time.
For press lines with crossbar automation, loading the
first die station can be performed by a crossbar robot or
crossbar feeder. In addition to handling conventional
steel sheet, these destackers can also process blanks
Optical centering station.
in aluminum, steel-aluminum mix, and higher-strength

steels.
components
One or two destacking stations for separating blanks
with a double blank monitor
Optical or mechanical centering station
Wash unit
72
Lubricating unit
Loading unit with robot, crossbar robot
or crossbar feeder
TABLE OF CONTENTS
Blank washers and lubrication units
Blank washer, lubrication unit and loading

robot in front of a hydraulic press line for
manufacturing aluminum components.
Blank washers provide a high and

consistent component quality.
Destacker with wash unit.
Blank washers and
In addition, blank washers also
Depending on requirements, the
lubrication units
provide significant reductions in
blank washers are designed to suit
Superior quality for outer skins and
downstream reworking and costs
variable blank lengths and widths.
structural parts requires blank
when it comes to body-in-white
A defined amount of oil provides
washing prior to processing to remove
assembly and painting. Blank
optimum preparation of the blank for
any dirt and deposits, and a final
washers are an integral part of
subsequent forming processes.
application of a defined amount of oil.
modern destackers and can, if
Flexibly programmable spraying
The effect of systematic washing and
required, be retrofitted to existing
heads in the lubrication unit ensure
a consistent application of oil prevents
lines.
superior part quality for forming
downtime for the entire process.
involving high drawing forces.
advantages
Superior, consistent surface quality of the components
Cost-savings for entire process
Best possible part quality, even with high drawing forces
Longer intervals between die cleaning
Increased productivity levels
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Robots
Press line with robot automation.
In addition to advanced automation solutions, such as

crossbar technology, there is still a place for conventional
solutions with robots. Robots are flexible since only one
robot is required per press opening. Automatic
changeover of robot tooling is easy.
74
Loading robots position the blanks accurately in the die

of the first press.
TABLE OF CONTENTS
CROSSBAR ROBOT 4.0

CONNECT FOR SUCCESS!
The crossbar robot combines proven robot technology with
the advantages of crossbar technology. This application uses
a conventional industrial robot. The robot is then expanded
by one feed axis and the crossbar beam provides a second
axis. The horizontal motion takes place along the x-axis that
is mounted on the press uprights. Programming is done at
the operator's panel for the robot. The crossbar robot can
be delivered with new lines or integrated into existing press
lines.
Connection to Industry 4.0.
The process data interface means the new Crossbar
Robot 4.0 is already optimally prepared for the Industry
4.0 age. Components such as personalization, networking
and resource efficiency will play an even more important
role; intelligent system components that actively intervene
in controlling the production process are central features.
In the Automation TechCenter Gemmingen, the crossbar robot
combines the advantages of robot technology with crossbar
technology in an innovative design.
advantages
20% more energy efficient due to innovative energy
management
50% weight reduction of the robot from about
2,800 to 1,400 kg
20% more dynamic, due amongst other things to modified
movement drive with two motors for high speed
Flexible parts orientation from die to die

No turning of components from die to die
User-programmable change in parts orientation
Full tooling compatibility with crossbar feeder
Complete solution including destacker and end-of-line
Can be used as destacker and unloader
Simply programmable with new robot controller
Single, double and four-fold parts production possible
Lighter, faster, higher performance
Suitable for steel and aluminum
Individual customer tooling interface
One set of tooling per opening
Direct parts transport from die to die
Rapid automatic tooling change
Press spacings from 4.5 to 10 meters, without idle station
Ease of maintenance due to free access to the gap

between the presses
75
TABLE OF CONTENTS
Crossbar feeder
Crossbar feeder within the press line.
Three rotating and four linear axes.
The crossbar feeder is the automation technology for
productivity of the stamping plant. The components are
high-speed mechanical and servo press lines. It increases
transported from die to die without intermediate stations
the line and process efficiency of mechanical press lines.
and can also be repositioned. The short, compact design
The crossbar feeder offers seven degrees of freedom,
makes the feeder extremely rigid.
three rotating and four linear axes, increasing the
Advantages
Seven degrees of freedom
One set of tooling per press opening
Variable press spacings
No intermediate stations required
Free access to the press opening
Optionally available with feed-direction rail for large
Compact construction possible
distances between presses
76
Fast die changes
TABLE OF CONTENTS
Part racking systems
Press line with ServoDirect technology

and automatic part racking system.
Part racking systems are reliable and fast, while ensuring
data is transferred to the robots. The robots thus pick up the
maximum part quality. A special suction-cup technology
finished parts in the correct orientation and stack them in
protects the highly sensitive surfaces of outer skin panels
parts containers. The automatic racking system allows
for downstream processing and preparation for subsequent
single, double and four-fold parts to be stacked. Up to four
body-in-white assembly.
robots are used with single parts, while there are up to eight
used with double and four-fold parts; in this case, the robots
Automatic part racking system for
operate in pairs and alternately stack the parts in the same
servo press lines
container in order to ensure a high output rate. Optionally,
The newly-developed, automatic, flexible part racking
the part racking system can be equipped with an automatic
systems from Schuler operates with hanging robots, which
quality control function.
can additionally be moved on a track. The position of the

finished parts is detected visually by a camera system.
Following that, the correction
Advantages
Stacking of single, double and four-fold parts
Compact, short design
Four-fold racking performance up to 68 parts/minute
Automatic quality control can be integrated
77
07
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Tryout systems / The entire world of metal forming
AT A GLANCE
Tryout systems
Tryout systems offer the highest level of flexibility for die

making and stamping plants. Depending on the
Hydraulic die-spotting and

tryout presses
80
Hydraulic Multicurve presses
81
Tryout centers
82
Tryout presses with

84
Die turnover devices and simulators
85
requirements, they contain various hydraulic or mechanical

press types, die turnover devices and turntables. The
time-consuming job of manually reworking the dies is
carried out outside the tryout presses. The individual
components of the tryout system are connected by moving
bolsters on a rail system.
SCHULER ONLINE
Would you like to find out more about our tryout systems? You can find our complete offer at
www.schulergroup.com/hydraulic_press. There you can find a complete overview of all our
system solutions.
79
TABLE OF CONTENTS
Tryout systems
Hydraulic die-spotting and tryout presses
Die tryout before the production startup

To keep the startup costs of new die sets low, it is important
to prepare them optimally for series production. Hydraulic
tryout presses ensure short startup phases under
near-to-production conditions. They are suitable for use
in die tryout and startup prior to production getting
underway. The line operator has the full press force
available at any time, and can lower the upper die
sensitively onto the lower die if required. In terms of sizes,
performance data and equipment details, die-spotting
and tryout presses are designed to meet the requirements
of die tryout and pilot-series production.
Tryout center with hydraulic tryout presses.
Advantages
Programmable speeds and forces
Slide return possible at any point
For double-action presses: operation possible in singleaction or double-action modes
Precise slide movements using a joystick
Rigidity like production presses
Maximum force available over the entire stroke
Bed cushion technology like in production lines ensures
Simple adjustment for varying die heights
80
optimum startup results
TABLE OF CONTENTS
Tryout systems
Hydraulic Multicurve presses
Precise simulation of forming processes

Hydraulic multicurve presses are used for starting up die
sets in the die shop, in tryout centers, in the stamping plant
and for verifying the method under production conditions.
Equipped with a hydraulic accumulator drive, they simulate
the slide motion characteristics of various hydraulic and
mechanical production presses. To properly represent the
forming processes of mechanical production lines, the
hydraulic multicurve press achieves working speeds up to
500 millimeters/second. Various user-programmable slide
motion curves are available to the user at any time, with
any desired adjustable stroke rate. Multi-point die cushion
technology ideally identical with the drawing station in
the production line ensures optimum breaking-in results.
Multicurve presses with moving bolster and die turnover device.
Advantages
Precise simulation of the slide movement curves of
all press types
Reduction in startup times on production lines

Bed cushion identical to that on the production press
Drawing speeds up to 500 millimeters/second

User-friendly management of the programmable
motion curves
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TABLE OF CONTENTS
Tryout systems
Tryout centers
Flexible system solution in the die shop

Tryout centers with a number of different press types offer
an extremely high degree of flexibility in the die shop.
Depending on the design, these centers may include
mechanical and hydraulic die-spotting and tryout presses,
die turnover devices and turntables. The time-intensive
manual die rework mainly takes place outside of the tryout
presses. The various pieces of equipment within the tryout
center are connected by moving bolsters on a rail system.
The dies can be moved into the optimum position for the
required work.
Tryout center with die-spotting and tryout press.
Advantages
High level of flexibility
Use of simple die-spotting presses for die-spotting work
Die startup on moving bolsters outside the presses
Optimum utilization of the equipment
Turning the upper dies with die turnover devices for

ergonomic reworking from above
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Hydraulic die-spotting and tryout presses in the die shop
In practice
Customer: Automobile manufacturer, Germany
Tryout center with hydraulic tryout presses.
The slide can be moved sensitively up and down using a joystick.
The requirements:
A hydraulic multicurve press, press force:
Tryout center for die startup of series production dies.
25,000kilonewtons
With multicurve accumulator technology
The solution:
Drawing cushion in eight-point design
Tryout center with a total of twelve hydraulic

tryout presses.
Three hydraulic multicurve presses, press force:

21,000kilonewtons each
Bed and slide dimensions: 4,500 2,500 millimeters
With multicurve accumulator technology
Each press with moving bolster to the front, hydraulic
Drawing cushion in eight-point design
drawing cushion, hydraulic slide cushion and hydraulic

impact shock dampening
Four hydraulic tryout presses, press force:

Four hydraulic tryout presses, press force:
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Tryout systems
Tryout presses with ServoDirect technology
Increasing the availability of

production presses
Tryout presses with ServoDirect technology are configured
as a duplicate of mechanical production lines. The bowing
and deflection properties of the line are consistently
simulated for the slide drive, connection point
arrangement, spacings between uprights and bed
cushions. This means the availability of production
operation can be increased even further. The hand wheel
function in particular offers the press operator new
possibilities when starting up new dies. The servo drive
allows optimum simulation of the movement properties
of an extremely wide range of presses.
Tryout presses increase availability in the press shop.
Advantages
Simulation of the production conditions of
mechanical presses
Increased availability in production
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Reduced parts costs per stroke

Slide tilting is identical to production presses
Takeover of die data
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Tryout systems
Die turnover devices and simulators
Die turnover device for easy turning of upper dies.
Simulator device for crossbar feeder.
Die turnover device Ergonomical DIE REWORK
Simulators precise setup of
For ergonomic rework of upper dies in the tryout phase, it
automation equipment
is preferable to turn them to an ergonomically favorable
At the interface between the die shop and stamping
position. Die turnover devices are used for safe opening and
plant, tryout presses and simulators both play a role
turning, and can be connected to the tryout presses using
in preparing dies and automation devices for series
moving bolsters. Die turnover devices simplify die
production while the production continues without
handling, so that the dies are subsequently available to
interruption. The component transport is simulated and
the production presses more quickly.
optimized in order to reduce cost-intensive setup phases

on the production presses.
THE ADVANTAGES
Simple opening and turning of the dies
THE ADVANTAGES
Ergonomic rework of the turned dies
Simulation of the automation while production continues
Integration into tryout centers using rail systems
Shortening of changeover and startup times
and moving bolsters
Increased press uptimes

Training of employees while production continues
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Lightweight technologies / The entire world of metal forming
AT A GLANCE
Lightweight construction technologies
Nowadays, it is technically feasible to build a light and safe
Press hardening with PCH technology
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Hot Stamping TechCenter
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Cold forming of high-strength steels
92
Aluminum forming
93
Forming of fiber-reinforced plastics
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Hydroforming
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car, but the manufacturing costs are a factor. Some

particularly light and low-consumption car models did not
attract enough buyers in the past, because they were too
expensive for customers. In the future, there cannot be
simply one basic approach to achieving greater efficiency.
What are called for are different concepts according to
individual customer requirements and vehicle categories.
It is only through the interplay of several processes and
the use of different materials that the required success
can be achieved in lightweight construction. Each material
has specific strengths, and is therefore suited to different
installation areas in the car.
SCHULER live
Your direct contact to the Hydroforming TechCenter:
Canton, MI USA | Telephone: +1 734 207-7279 | E-mail: hytc-canton@schulergroup.com
Your direct contact to the Hot Stamping TechCenter
Gppingen | Telephone: +49 7254 988-220 | E-mail: hstc-goeppingen@schulergroup.com
SCHULER ONLINE
Would you like to find out more about pressure-controlled hardening (PCH) in the forming process?
You can find further information at www.schulergroup.com/forming_systems. In addition, you
can download various brochures on the topic from there, or view an explanatory film.
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Press hardening with PCH technology
PCH Hardline Multi press hardening line.

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Sustainably successful
Schuler makes cars lighter. The results are: lower fuel
consumption and CO2 emissions. The greatest saving
potential available in today's passenger cars are to be

found in the bodywork and running gear, which together
comprise about 65 percent of the vehicle's mass. Perfectly
built, quality components for the chassis, engine and
bodywork not only make cars look attractive, they also
guarantee safety and comfort. Press hardening with
Pressure Controlled Hardening (PCH) technology is the
basis for higher body rigidity significantly improving
crash behavior. In press hardening, high-strength safety
components are manufactured by heating the blank, then
forming in a hydraulic press with rapid cooling in the die.
Steels with initial strengths of 500 to 700 newtons/
square millimeter achieve ultimate strengths of 1,300
to 1,600newtons/square millimeter.
Press hardening of safety components in large-scale production.
The component spectrum of press hardening:

Side impact elements and B-pillars
Side sill plates
Roof frames
Support parts
Tunnel
Door frame reinforcements
Bumpers
Advantages
Higher strengths with reduced component weight
Good repeat accuracy without spring-back
Higher rigidity of the bodywork
Less expensive material compared to high-strength steels
Improved crash behavior
No high press forces required
New possibilities in component design
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Press hardening
Today
Yesterday
Innovative press technology
Simple press technology
Presses with
cushion technology
Presses without cushion

technology
Fast die startup
Long die startup
No slide tilting
Slide tilting in multiple

production
Short cool-down times
Long cool-down times
High-speed transfer
automation
Average production rate 12 to
24 parts/minute
Bowing compensation
Robot or
feeder automation
Average production rate 4 to
6 parts/minute
Influences from bowing
Press hardening die for series production.
The press hardening performance range

Forming simulation
- Centering station
- Laser equipment
Die design and construction
- Robot or transfer automation
- Finished part handling
System engineering and installation
- Integration of furnace technology
- Master controller
- Destacker
- Blanking presses and dies
- Hydraulic press technology
- Soft-Shock technology
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Hot Stamping TechCenter Gppingen
Fully automated press hardening line with innovative

PCH bolster cushion concept.
Press hardening of safety components in large-scale production.
TechCenter with automated press hardening line opening
us to try out your series production dies at the TechCenter
in fall 2015. At the Hot Stamping TechCenter Gppingen,
under realistic conditions, so you can significantly reduce die
Schuler is bringing together all its expertise in press
tryout times on your premises. If you need initial prototypes
hardening along the entire added-value chain. As a system
or pilot series parts, we can manufacture them for you in
supplier, we are continuously developing machine, die and
our TechCenter.
process technology further. We are optimizing the applications in automotive series production so as to reduce cycle
Technological advice spanning processes:
times and cut costs per component. Take advantage of this
Extensive process and line expertise
decisivelead in experience when it comes to boosting
Further development in line and process technology
efficiency and optimizing stroke rates. The short distances
Die tryout and production of prototype parts
from our tool and die production facility enable
Training on the press hardening line

Backup possibility for Schuler customers
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Cold forming of high-strength steels
Innovative lightweight vehicle manufacture is now

inconceivable without high-strength steels, and
applications in mass production will increase in coming
years. It is possible to achieve further reductions in sheet
thicknesses by using new, high and extra high-strength
steels while maintaining the same component properties.
This means a lighter weight and reduced costs.
ServoDirect technology is pointing
the way to the future
Press lines, transfer and prog-die presses as well as
blanking systems with ServoDirect technology have
significantly changed stamping plants. They are
characterized by maximum flexibility, high output and
short die change times. The slide movement of each press
for each component can be individually adapted to the
forming process, the die and the automation. This
ServoDirect press for cold-forming high-strength steels.
is opening up new possibilities for cold forming of

high-strength steels.
New processes new possibilities
Using the advantages of ServoDirect technology, Schuler
is developing new production concepts for manufacturing
lighter components. For example, interdisciplinary teams
are looking into the possibility of integrating follow-on
processes or adopting new approaches for manufacturing
hybrid components. The objective is to develop new
production processes that can meet all the requirements of
series production despite the conflicting objectives of
reduced component weight, efficient production and high
safety requirements.
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Aluminum forming
Aluminum has now become a standard material in the area

of hang-on parts in many vehicle types. The material can
significantly reduce the weight of a body-in-white, even
if it is only rarely entirely made by forming aluminum.
Nowadays, about 40 percent of the overall weight of a car
is accounted for by the body. The trend for an increasing
variety of materials means aluminum is being used to an
increasing extent in automobile production.
From the skin through to the front wing and bonnet
aluminum is being used more and more frequently in
modern, reduced-weight vehicle manufacture because
these applications are often selected as a means of
replacing heavier materials. Thanks to its unique energy
absorption ability, it can also save lives in case of a
collision. Lower fuel consumption, greater comfort and
performance are further arguments alongside that of
Hydraulic press lines for manufacturing aluminum components.
increased safety for the use of aluminum as a material.

Schuler develops mechanical and hydraulic press lines as
turnkey solutions for processing aluminum skin panels.
We order suitable retrofit solutions for existing production
systems. Our turnkey machines have all of their
components designed for the materials they will process,
from automation through to the press and die.
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Forming of fiber-reinforced plastics
Fiber-reinforced plastics offer a great deal of design

freedom and a wide range of functions with minimum
component weight. They represent new, lightweight
concepts in vehicle architecture and in bodywork
manufacture. Schuler builds fully automated hydraulic
press systems for efficient and reliable series production
of fiber-reinforced components, that can withstand
even the most demanding component and production
requirements.
Hydraulic press systems from Schuler are suitable for
series production of SMC (sheet moulding compound)
components, GMT (glass mat thermoplastics) components,
LFT (long fiber-reinforced thermoplastics) components
and RTM (resin transfer moulding) components. Different
systems are used for these, depending on the component
requirements and the production process.
Hydraulic plastic presses for the series production.
The result is: Best parts quality and highest production

reliability for greater efficiency and maximum
productivity.
Hydraulic presses for fiber-reinforced plastics

Press force [kN]
12,500
16,000
21,000
25,000
30,000
36,000
Press force with max. parallel

control force [kN]
10,500
14,000
18,000
22,000
26,000
32,000
Bed size [mm]
2,8001,800
2,8001,800
3,0002,000
3,2002,200
3,4002,400
3,6002,400
Slide stroke [mm]
1,600
1,600
1,800
1,800
1,800
1,800
Shut height [mm]
2,200
2,200
2,600
2,600
2,600
2,600
Further sizes are available on request.

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Hydroforming
Automatic tubular hydroforming machine at an American

automobile manufacturer.
Tubular hydroforming of longitudinal members.
Tubular hydroforming offers a wide variety of
Schuler offers its partners not only elaborate systems
opportunities. Above all, however, it is used in series
and integration solutions but also component analyses,
production of automobiles, since this is where particularly
feasibility studies, prototype and die construction all
high requirements in terms of component composition
from a single source.
and component design need to be met. The process is used

for, among other things, forming exhaust, chassis and
structural parts.
Advantages
High component rigidity and strength
Maximum repeat accuracy
Low component weight by optimized design without
High component quality and long service life by avoiding
material duplications
Best exploitation of material
Integration of additional functions in the components
welds and having a geometry optimized with regard

to function
High freedom of design for complex components
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Die and forming technologies / The entire world of metal forming
Die and forming technologies
Consistent performance
Targeted support
To be prepared for the challenges of the future, we tackle
them with efficient structures. By establishing our own area,
we have reoriented ourselves strategically, and are now
capable of supporting you in an even more targeted and
consistent way. For example, we are excellently prepared to
expand our range of services and products to include new
ideas and innovative concepts. That is the basis for future
success together: after all, your success is our success! The
product development process is our key area of expertise.
Whether you are looking for a complete solution or a partial
one without knowledge of the entire process cycle, we can
offer you inestimable advantages for your production.
Stage set.
Successful together
Feasibility &
simulation
Methods &
production
concepts
Design
Mechanical
processing
Assembly
Tryout
Stamping
plants
Training &
startup
support
Component
in
Quality
Multi-disciplinary technological process team
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Success can be programmed. After all, perfectly matching

processes are required for producing components in the best
quality and with maximum output rates.
Transfer die for manufacturing disk carriers.
Engineering performance spectrum
Range of die services
Method planning /simulation
Body dies for
Feasibility analyses
Skin panels
Creation of methods and drawing systems
Structural parts
Process layout creation
Press hardening dies for series production
Deep-drawing simulation including simulation
Press hardening dies for prototypes
of the follow-up stations

Springback calculation
Powertrain dies for
Active surface creation
Disk carriers
Crowning and overpressure points
Spiders
Guide disks
Design
Thrust washers
Simulation of dies and press sequences

Drawing and forming dies
Modular dies for
Trimming/perforating dies
Friction modules
Progressive dies
Piercing nut modules
Mechanization systems
Sheet metal forming
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Die and forming technologies / The entire world of metal forming
New press generation TST TwinServo technology at the

Servo TechCenter Erfurt.
Prototype machine in Gppingen.
Parts production performance range
Servo TechCenter Tianjin

Disk carriers
Gppingen stamping plant
Guide disks
Skin panels
Spiders
Structural parts
Structural parts
Hot Stamping TechCenter Gppingen
At our sites in Gppingen and Erfurt, we offer you the
Press hardening parts/prototypes
following services in our stamping plants: Startup as

well as process and quality optimization, temporary
part pressing operations, small-series production and
Disk carriers
production of press hardening parts for prototypes
Guide disks
and small batches.
Spiders
Structural parts
From simulation through to series production

Thanks to our core expertise in engineering, method and die making as well as tryout, we meet the ever increasing needs
of the automotive and components industries with intelligent, complete solutions.
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Systems for large pipe manufacture / The entire world of metal forming
AT A GLANCE
Systems for large pipe manufacture
With Schuler, you lay the foundations for success with
SPIRAL PIPE PRODUCTION SYSTEMS
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System solutions for longitudinally

welded LARGE PIPES
104
economic, efficient and high-output production of spirally

and longitudinally welded large pipes. On your behalf, we
develop turnkey production lines for large pipes whether
pipelines for crude oil, natural gas, water or large pipes
in the petrochemicals industry, for use in wind turbines or
in the construction industry. Not only do we offer the
necessary experience, we also provide the appropriate
worldwide service for any required solution and projects
of all scales. We ensure that we maintain our position
of leadership in quality by permanent innovations and
investments in research and development.
At Schuler, we regard turnkey solutions for manufacturing
large pipes as a highly integrated overall concept:
From innovative layouts and designs through to intelligent
production principles. Our goal is for you to be able to
produce in an environmentally friendly way, minimizing
your use of resources. In this way, you can benefit during
every phase from our extensive, groundbreaking expertise
in large pipe manufacture and from our competence.
SCHULER online
Would you like to find out more about our system solutions for large pipe manufacture? You can
find our complete offer at www.schulergroup.com/Large_Pipes. In addition, you can download
the System solutions for manufacturing large pipe brochure as a PDF file.
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SPIRAL PIPE PRODUCTION MACHINES
Online process
Combined forming and welding machine
The pipe forming is directly followed by submerged arc
welding from the inside and outside.
Offline process
Separate forming and welding machine
After pipe forming and subsequent tack welding, the
submerged arc welding process is performed from the
inside and the outside on separate welding stands;
speeds up to 12 meters/minute
Modernization
Conversion of existing online machines to the
offline process
The objectives of such a conversion of existing machines
are to increase quality and productivity as well as
Spiral pipe production machine.
improving safety at work and energy efficiency.
We plan and implement complete production plants for
Suitable for spiral pipes with
manufacturing spirally welded large pipes, making them
Length up to 24 meters
turnkey for you. The machines meet the most demanding
Diameter from 450 to 3,500 millimeter (18"140")
requirements in terms of diameter tolerances or welding
Wall thickness from 6 to 25 millimeters (1/4"1")
gap, as well as impressing with maximum availability
Other dimensions possible on request.
Technical data
and productivity. Schuler offers progressive and highperformance solutions, precisely adapted to your
the advantages
requirement profile and tailor-made to your specific
Automation of important working steps
requirements from planning and consulting through
Increased safety at work
to startup.
Low downtimes
High process reliability
Reproducible, high product quality
Planning and implementation of complete
production lines
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Hydrotester.
Coil preparation stand.
End beveling machine.
Hydrotester
Coil preparation stand
End beveling machine
Ball head mounted inside sealing
Schuler ensures a significant
Automatic clamping with correct
or face sealing
force according to the diameter
simplification in handling during the
Water hydraulic control system
coil change at the same time as
Variable holding time
improving quality and optimizing
Connected to PID data system
procedures. Not only does this enable
Short changeover time
Automatic pipe positioning
you to reduce unproductive down-
Concentric clamping
Automatic test sequence
times, it also ensures consistently
Energy recovery by using the
Visualization with database for
higher efficiency throughout the
all pipe parameters
Infinitely coverage for all

diameter ranges
latest inverter technology
production process. Furthermore,
Full automatic pipe feeding
you sustainably increase the safety

of work on the stand.
Pipe diameter [inch]
18140
45
Pipe length [m]
824
Closing force max. [kN]
50,000*
External coil
diameter [mm]
1,300 2,200
Internal coil
diameter [mm]
720 800
Coil width [mm]
1,000 2,050
Coil thickness [mm]
6 25.4
Water pressure
max. [bar]
High-pressure control
range [liter/min]
* Higher closing forces on request.
400
33300
Coil unwinding
[m/min]
Plasma cutter
[m/min]
Cutting speed
max. [m/min]
90
Face plate feed speed

[mm/min]
550
Face plate drive servomotor

max. [kW AC]
200
0.3 6.0
0.1 3.0
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LONGITUDINALLY WELDED LARGE PIPES
formed either using a bending element or with a broad

bending shoe. This ensures fast and efficient production.
Process for high production output
U-O-presses primarily represent a solution when the
highest possible production output of a particular pipe
dimension range is to be achieved. As with the bending
presses, the C-press is also configured as the crimping
press for pipe forming; together with the tacking press
it ensures consistent pipe forming, while this concept
provides optimum passage through all the individual
pipe production stations.
Modernizations
Presses and machines from Schuler are particularly
suitable for complete modernization concepts or
exchanging individual system components in existing
Large pipe production machine.
pipe plants.
Regardless of whether your machine should be designed
Suitable for longitudinally welded large pipes with
Technical data
for longitudinally welded large pipes with a bending press
Length up to 18.3 meters (60')
or with U-O-presses Schuler provides you with the
Diameter from 406 to 1,625 millimeters (16"64")
innovative and forward-looking production technolgy. We
Wall thickness 12 to 70 millimeters (0.48" 2.76")
adapt and individually tailor our presses to your product
Other dimensions possible on request.
dimensions. Not only are we your expert for efficient

modernizations in order to optimize the performance of
the advantages
existing pipe plants, we are also the ideal technology
Planning and implementation of complete
partner for complete turnkey solutions. Whichever
production lines
approach you take the best idea is to get the expertise
Matching processes and process sequences
and experience of Schuler on your side right from
High process reliability
the outset.
Reproducible, high product quality

Step process for flexible production
Safeguarded high availability
Schuler bending presses (step process) are universally
Energy-efficient hydraulic drives EHF
applicable for pipes with diameters from 406 mm to
Global service network
1,625mm (16"64"). Pipes in this dimension range can be
Security of investment by turnkey solutions
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Longitudinal welding pipe presses.
U-O press.
LFJ pipe forming press
U-O presses
The modular LFJ pipe forming press is a further
The particular advantage of the U-O process is its high
development of the conventional pipe forming press. This
production output of pipes with one set of dimensions. The
unique development means that Schuler has an exclusive
individual forming steps are adapted to this in order to
and attractive product highlight in its portfolio. It is
produce a good quality open-seam pipe. In this way, the
characterized by an almost direct sheet feed, and bowing
subsequent production steps can be carried out optimally.
compensation is not required. The modular structure

ensures straightforward transport and input into the
the advantages
press without difficulty.
High productivity for set pipe dimension

Optimized die setting
the advantages
Simple integration into existing production lines
High productivity because the panel is loaded at the
Modernization option for existing machines
same time as the open-seam pipe is unloaded
Comprehensive, tried-and-tested operating concept
High productivity because bending shoes can be used

High flexibility by using the bending element
High process reliability by simplified press design
Simple transport and trouble-free integration into
existing production lines because of modular structure
Simple structure with scope for future uprating
by extension for bending longer pipes
Automatic die change and die adjustment available
as an option
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schuler service / The entire world of metal forming
schuler service
State-OF-the-art service for
more performance
Over 900 service employees worldwide provide expert
Components and Accessories:
support 24/7 in close cooperation with you our partners.
Spare parts and spare part packages
Our main priority is always to ensure the maximum
Maintenance kits
productivity and safety of your production equipment in
Repair parts
order to secure your companys continued success.
Replacement parts
With over 175 years of experience and expertise, we can
Project Business:
guarantee the best possible support for the operation of
Modernization
your machines and not only those supplied by Schuler, but
Retrofits
by all other manufacturers. Whatever the situation, Schuler
Refurbishment
Service has the right solution for your specific needs.
Machine relocations
Special Services:
Our services for you.
Service contracts
Hotline and remote service
Technical Customer Support:
Training
Machine inspections
Tailored customer training
Safety inspections
Optimizing plant & processes
Preventive maintenance
Consulting
Repair
Repair welding
Used Machinery:
Production support
Purchase and sale

Evaluation
Schuler Service ONLINE

Want to know more about our full range of services?
Simply scan the QR code with the camera of your smartphone or tablet.
www.schulergroup.com/service_en
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Schuler Service
Greater reliability, improved planning

capability, optimized efficiency
Our service contracts are tailored to your needs as users
of our machines. They offer you greater reliability, better
planning capability and optimized efficiency in the press
shop.
The BASIC service contract is used for maintaining the
operational reliability of your machine and offers both
quick and highly qualified assistance in case of problems,
thanks to our hotline and remote service center.
The STANDARD service contract improves your ability
to plan production. In addition, we support you on a
24/7 basis.
The ADVANCED service contract also contains many
consulting services to increase your efficiency in the
press shop.
SERVICE CONTRACTS BASIC I STANDARD I ADVANCED

The world your company works in today is full of challenges.
Schuler service contracts help you to overcome this
successfully.
ADVANCED
STANDARD
BASIC
The advantages:
Ensuring a high machine availability
Increasing the efficiency of your production
Complying with the latest safety standards
Better ability to plan budgets and deadlines
Reduction in the administrative overhead
for service activities
Cost benefits compared to individual orders
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schuler service / The entire world of metal forming
Schuler Service
Improved machine availability and

increased productivity
PROCESS OPTIMIZATIONS to exploit the full
potential of your machine
Increased productivity and OEE.
Schuler Service is available to you as an expert partner
for advice on your entire process. We always focus on
maximum productivity and availability of your machine.
Our activities:
Process analysis in your press shop
Taking account of the value stream
Availability consideration of your machine
Achieving optimization potential
Reduction in setup times
Increase in output performance
Reduction in downtimes
Needs analysis for staff training in the press shop
Quick and expert help over the phone as well as support via a
remote connection.
Increasing employee qualification

We show you the way to achieve significant optimizations
HOTLINE AND REMOTE SERVICE CENTER
in your overall process.
Our hotline and remote service center allow us to offer you

professional advice and remote diagnosis force move
production. By directly logging onto your machine controller,
we can carry out an initial diagnosis and in many cases
solve the problem remotely.
In more than 90% of all incidents, there is no need for
a service technician to be deployed.
That saves time and expense your machine downtimes are
significantly reduced. Software optimizations can be carried
out without a personal visit being required.
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Schuler TechCenter / The entire world of metal forming
Schuler TechCenter
Innovative forming technology

experience live
Welcome to the future. Welcome to the Schuler TechCenter.
Schuler live Explore Technology
For 175 years now, Schuler has been developing ground-
Servo TechCenter Gppingen
breaking system solutions, always with the goal of securing
long-term successes for our customers. All our activities
Servo TechCenter Tianjin, China
focus on the common goal of finding the best possible

answer to your challenges.
Automation TechCenter Gemmingen

Automation TechCenter Hedorf
Take new approaches with Schuler, and embark on intensive
Automation TechCenter Canton, MI USA
dialog with us. We have set up the latest machines and

systems for you at our new TechCenters in Germany, the
Hydroforming TechCenter Canton, MI USA
USA and China where you can try out production optimizations in a hands-on environment for employee qualification,
Hot stamping TechCenter Gppingen
short-term contract production or intensive familiarization.

As a result, we can tailor what we offer even more directly
to meet your individual requirements.
Come and see us in one of our TechCenters. We are looking
forward to your visit and many exciting experiences in all
aspects of the world of forming technology.
Your Schuler TechCenter team
SCHULER online
Would you like to find out more about our TechCenters?
Simply scan the QR code using the camera of your smartphone or tablet.
www.schulergroup.com/Techcenter
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Schuler TechCenter
Presentation of cutting-edge technology

and innovative potential at Schuler
Transfer press with TwinServo technology in the TechCenter Erfurt.
Exchange of experience on the automated transfer press

with ServoDirect technology.
The Schuler you know: as a technology and world market

leader in forming technology, our company is present at
all significant trade shows, congresses and technical
conferences as well as at university career fairs in
Germany and worldwide. Symposiums, workshops and
technology days are held regularly to provide an arena
for direct and personal dialog as well.
Now, we have taken the next step: at selected sites in
Germany, the USA and China, the new Schuler TechCenters
deliver a further decisive expansion to the possibilities for
intensive communication. With individual and tailor-made
demonstrations, tests and training courses directly on
the latest presses and automation equipment.
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Schuler TechCenter / The entire world of metal forming
Crossbar robot 4.0 in the Automation TechCenter Gemmingen.
Highly dynamic ServoDirect technology, presented live at the

Servo TechCenter Gppingen.
In intensive contact with the experts from Schuler, this
Technology events, training courses and on-site workshops
enables specific questions to be clarified even before
make Schuler TechCenters into beacons of knowledge and
series production starts and efficiency gains worked out
knowledge transfer. After all, highly competent employees
that are precisely tailored to your own production. Other
make a decisive contribution to a company's success and
main aspects include topics such as process and stroke rate
that goes for forming technology as well.
optimizations, die tryout, blanking and tooling tests as well

as process and module developments. This ensures that
Groundbreaking sector solutions can be seen here starting
systems from Schuler can deliver their full performance
from today. Experience the technology of the world market
potential and optimum output right from the word go.
leader in forming technology live, and keep in touch with

the future!
And yet the Schuler TechCenters have even more to offer:

depending on the system, it is possible for backup or
startup production to be carried out. This opens the
opportunity for carrying on production despite a machine
failure or in advance of commissioning.
113
13
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sites / The entire world of metal forming
At a glance
Production facilities, service sites,

TechCenter and agencies
Technologies, systems and machines from Schuler are at
Service sites
home in the following sectors: automotive, tiers 13,
Everything from a single source and that's worldwide:
drives & generators, railway, aerospace, appliances,
All round the world, our service network with more than
minting, packaging, industrial applications and large pipe.
900 service employees is working on your behalf. In this

way, we ensure that you can produce parts economically
For us, developing solutions for these sectors means
anywhere and at any time.
reducing good concepts to a common denominator. With

the objective of coming even closer to our customers
techcenter
and taking account of different industry requirements.
In opening the Schuler TechCenters, we have redefined
Therefore, we supply you with not only press technology
how systems and technologies are presented. Now, you
but also intelligent system solutions which meet the
can use this unique opportunity to experience cutting
requirements of the global competitive environment.
edge technology live; not only can you discover new
The individual requirements of users in the particular
approaches for your production, you can also optimize
market environment are the center of our attention.
your workflow and output rates, or access a backup
In this way, we convert technological leadership into
facility for ongoing production.
specific customer benefits, and together with you we

wish to take advantage of technological and growth
opportunities.
For this purpose, the Schuler Group employs about 5,500
people and has its own sites/agencies in 40 countries.
We are your partner who supports you reliably worldwide.
Benefit from the extensive expertise of our project teams
in installations all over the world.
We are there for you.
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Addresses
PARTNERS FOR SHEET METAL FORMING
15
Schuler Group headquarters, Gppingen.
Schuler AG
13
GERMANY
Bahnhofstrasse 41
73033 Gppingen | Germany
Phone +49 7161 66-0
Fax +49 7161 66-233
info@schulergroup.com
www.schulergroup.com
Schuler service
10
www.schulergroup.com/service
Schuler service and production sites

Schuler Service
Schuler TechCenter
SCHULER ONLINE
We employ about 5,500 people worldwide at our own sites and agencies in 40 countries, so we are always in your
vicinity. How to contact us. For an overview of all our sites and the most important address information, refer to
the Internet at www.schulergroup.com/plant_locations.
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sites / The entire world of metal forming
9
3
5
2
6
4
8
11
1. Germany
2. France
3. United Kingdom
4. Italy
5. Poland
6. Switzerland
7. Slovak Republic
8. Spain
9. Russian Federation
10. Brazil
11. People's Republic of China
12. India
13. Mexico
14. Thailand
15. USA
12
14
Social media
Current information about Schuler is available on Facebook, YouTube, Xing, Twitter and LinkedIn. The footer at the bottom
right of our webpage www.schulergroup.com contains links to our activities. You can visit us on the Internet. We are
looking forward to seeing you.
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The entire world of metal forming
Notes
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notes / The entire world of metal forming
Find out more. Simply scan the QR code using

the camera of your smartphone or tablet.
Schuler AG
Bahnhofstrae 41
73033 Gppingen | Germany
Phone +49 7161 66-0
Fax +49 7161 66-233
info@schulergroup.com
service@schulergroup.com
www.schulergroup.com/sheetforming
230EN-102014-WSP-2000 Copyright by Schuler AG

Metal Forming Overview

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Metal Forming Overview

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The entire world of

Components for sheet metal forming.

Table of contents / The entire world of metal forming

Welcome to the stamping plant.

Cost-effective die startup with hydraulic and

Individual solutions for your production.

Lines for press hardening (hot stamping), for cold and

Flexible presses for suppliers to the automobile

aluminum forming. For forming fiber-reinforced

industry, the household appliance industry and for

plastics and for hydroforming.

multiple metalforming applications.

09 | Die and forming technologies

From simulation to series production.

Fast, flexible and cost-effective. C-frame presses,

10 | Systems large pipe manufacturing

and prog-die presses and servo presses.

Spiral pipe welding lines and system solutions for

longitudinally welded pipes.

Coil lines, roll feed units, tri-axis transfer systems

Technical customer service, components and

accessories, project business, special services and

used machines on your doorstep, worldwide.

Hydraulic, hybrid, mechanical or servo press lines

are fully automated system solutions.

Experience Schuler products live and on the spot

06 | Automation of press lines

Schuler press lines are equipped with the appropriate

productivity and space requirements.

Production facilities, service sites, TechCenter and

agencies there for you in 40 countries.

Subject to technical modifications and amendments to content | 2014/15

Welcome to the stamping plant.

Transfer press with ServoDirect technology.

Welcome to Schuler / The entire world of metal forming

Blanking lines / The entire world of metal forming

Blanking lines from Schuler offer the complete process

BLANKING LINE WITH PRESS

BLANKING LINE WITH CROSS-CUT SHEAR

BLANKING LINE WITH LASER CELL

sequence from the coil through the blank stack from

Individual solutions, flexible applications

Maximum productivity with ServoDirect presses

press performance and ensure powerful dynamic

Blanking lines / The entire world of metal forming

Blanking line with cross-cut shear.

Blanking line with laser cell.

Blanking with cross-cut shear the solution

This means there is no need, whatsoever, to invest in dies,

for straightforward blank shapes

die maintenance and die warehousing. The compact design

Schuler offers blanking lines equipped with cross-cut

of the line means it can be used even when space is

shears for manufacturing blanks with a rectangular,

limited and overhead heights are low. With their innovative

parallelogram or curved shape. If the manufacturing

DynamicFlow technology, they offer the most flexible

process is restricted to straightforward blank shapes, then

possible production conditions with comparatively low

cross-cut shears represent the ideal solution both with

investment costs. The laser cutting line processes an

regard to purchase costs and their productivity. Optionally,

extremely wide range of materials such as aluminum or

the shears can be equipped with an automatic die change.

Fast product change, delivering a high level of availability

7. Roll feed unit

Roll feed unit with weld detection

Blanking press with 8,000

Cutting steel, aluminum and

Threading unit with dirt and

Leveling machine with crowning

Stacker in Fly2Drop and Stop2Drop

High flexibility through four-point impact shock

4. Hydraulically operated slide locking in upper end position as per

5. AC drive motors designed to suit application

10. Slide limitation/impact shock dampening