Modernization of extrusion presses

Modernization of extrusion pressesIncreasing productivity, quality and production reliability

Service

• SMS GROUP TECHNICAL SERVICE

Greater quality you can depend onSolutions that offer lasting success

Our revamps make it possible: you can depend on your extrusion press to produce the desired quality in the required quantity. The following pages provide an overview of the solutions we have developed for just this purpose. These include our patented linear guide to minimize wear on your press, for example, and an active prefi ll valve for effi cient hydraulics. Automation systems, such as our eco-Draulic program, can be used to improve the energy balance. With CADEX, a direct extrusion software program, the optimum extruding process is fi rst simulated before it is implemented. This saves energy and material.

We offer the following renewal options: Revamp of the mechanical equipment, electrical and automation systems, and hydraulic equipment. Here the focus is always placed on improving quality, increasing production or making it more reliable. The symbols on the pages show you the goals that can be achieved in each case with the individual measures.

Our revamps are not just about making your plant and equipment state of the art. We also expand your product range and ensure a more fl exible production process with lower operating costs at the same time. We provide customized support with each and every project. Feel free to get in touch with us!

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Fewer shutdowns – higher availabilityKeeping your extrusion press up and running

SMS group Service provides support for the necessary upgrade work, after all a state-of-the-art the control system and hydraulic and mechanical equipment are what give you the edge over your competitors. From consulting services and the joint development of new ideas, through the engineering and manufacture of the hardware to the installation and commissioning, we are there for you every step of the way.

Why choose SMS group?

Our SMS group Service experts examine your plant from all angles before any planned revamp. We then offer profi t-making modernization proposals based on the results of this. At the

same time we incorporate all our manufacturing know-how and innovations from the design and construction of new plant and equipment. This helps you to meet growing demands in terms of quality and delivery times.

We offer you the latest in hardware design and technology to improve not only your plant‘s performance but its energy balance too.

What‘s more, we actively guide and support you throughout the entire project handling phase. That means you benefi t from the know-how of our service technicians.

Each individual service is marked with a symbol so that

the relevant focus becomes immediately evident.

Each individual service is marked with a symbol so that

the relevant focus becomes immediately evident.


Modernization of core componentsProviding the foundation for reliable productionSMS group performs regular inspections of the condition of your extrusion press. If key components, such as the cylinder crosshead, counter platen, moving crosshead, or container holder, are cracked, a replacement is often the only alternative that guarantees reliable, ongoing production.

SMS group replaces core components quickly and at a competitive price. We will take care of all project handling activities, from the latest technological design to the manufacture and assembly. Our innovations from the construction of new plant and equipment are also incorporated in the process. Our focus consistently remains on the optimization of your extrusion press.

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How you benefit from the replacement of core components

• No unscheduled shutdowns following core component failures

• We use our engineering know-how to design high-quality components at competitive prices

• Long service life of new components

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Designed for reliabilityPrecise guidance is what makes the differenceIncreasing the section quality while reducing the level of wear on your extrusion press at the same time is possible thanks to the advanced SMS linear guide system. No matter what guide your press has – fl at bed or X guide – the patented system reduces the need for maintenance, as the moving crosshead and container holder remain in a consistently aligned position. The quality of the sections is enhanced as a result. The costs of procuring spare parts and lubricants are lowered at the same time.

Changing the system to a linear guide involves adapting the moving crosshead and container holder and replacing the existing guideways with new linear guide ledges. SMS group has been successfully using its patented linear guide since 2003.

If you are interested in a revamp we would be happy to develop a concept tailored to your plant.

The advantages of a linear guide for you

• Non-wearing guide

• Minimal maintenance

• The press is constantly aligned, therefore wear on the other plant components is reduced.

• Laborious and time-consuming alignment

• Precise adjustment virtually impossible

• Optimized guidance

• Precise adjustments possible

• Less time required for alignment

• Wear-free

• Little lubrication required

• Linear guide minimizes the need for alignment, with less maintenance required

X-guide

since 1950

Flat guide

since 1980

Patented linear guide

from 2003


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Hydraulics - the heart of the machinePioneering technology, peak performance

… with the fully active prefill valve:

The prefill valve is the core component of the hydraulic system. The prefill valve is used to replace the volume of oil required for the main cylinder. In the case of the fully active prefill valve, the control circuit and flow geometry were improved by comparison with the standard variant. The new valve technology now enables you to enhance the performance of your entire hydraulic system.

The advantages of SMS valve blocks for you:

• The availability of spare parts is maintained

• Plant shutdowns are reduced

• The switching response is improved

… with valve technology that is quickly available:

The time and money spent on obtaining specific valves, pumps or other components are increasing all the time, and spare parts for some series are no longer offered. This is the case with Excentra valve technology, for example. To guarantee the supply of spare parts you need, SMS has developed valve blocks that can be replaced with little time or effort. They work with modern Rexroth cartridge technology and integrated pilot valves. This not only prevents outages, the improved switching characteristics of the plant also enhance its performance.

The advantages of a fully active prefill valve for you:

• Less cavitation

• Optimized flow geometry for maximum oil flow

• Fully active control for fast pressure build-up and rapid pressure relief

• Available in nominal sizes of up to 600

The drive unit in your extrusion press is operated by hydraulics. Even the smallest defects in the components can have a major impact on the plant‘s performance. To prevent this, it is important that the hydraulic system is updated at regular intervals.

We support you here ...

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… by upgrading assemblies:

The longer a plant is operated, the more it wears, including its hydraulic components. This increases the need for maintenance, results in leaks and adversely effects both performance and non-productive times. To ensure your plant continues to operate reliably, we offer partial or full upgrades of the hydraulic system. In other words, we replace either individual hydraulic blocks, including the valve technology, or the entire tank with the built-in hydraulic components. We work with you to find the right solution for all variants.

The advantages of a hydraulic system upgrade for you:

• Reduced non-productive times

• Shorter shutdowns and lower maintenance costs

• Higher productivity

Reconciling sustainability with economic growth is a particular challenge faced by the metal industry with its comparatively high energy consumption levels. SMS group has developed solutions for this. The plants carry the „ecoplants“ label. With our eco-Draulic program for extrusion applications you can save a great deal of energy with little effort. It works according to a simple principle: HP pumps that are not used for extrusion no longer run in idle mode, rather they are automatically switched on and off as and when required. That way you can operate your plant far most cost-effectively.

Calculations show the following: savings of up to 15 percent of the total energy required by the extrusion press can be made. CO2 emissions are also reduced.

We calculate the potential savings our eco-Draulic can offer your plant before the system is installed. And if you decide in favor of the program, we will take care of the entire installation – from planning through any necessary hardware or software modifi cations right up to commissioning.


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Cost-effi cient and eco-friendlyECO-Draulic – the energy-saving mode

The advantages of eco-Draulic for you:

• Energy savings with every extrusion procedure

• Reduced CO2 emissions from your extrusion press

Four pumps run in idle mode during the extrusion cycle, while two pumps are used for extrusion.

With an average press speed of < 7mm/s and a billet length of 1,400 mm, annual energy savings of up to 190,000 kWh/h (at 16.5 shifts per week) are achieved.

6 pumps under full load: 900 - 1,200 KW

4 pumps idling: 40 - 60 KW

2 pumps under full load: 300 - 400 KW

auxiliary time extrusion cycle

6 pumps under full load: 900 - 1,200 KW

Savings

2 pumps under full load: 300 - 400 KW

auxiliary time extrusion cycle

Stan

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(6 m

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Opt

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eco-

Dra

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driv

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Only the main pumps are used during extrusion.

0 Sec 14 Sec 100 Sec

0 Sec 14 Sec 100 Sec

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For us, extrusion press automation is about having a control system that lowers costs and enhances quality. Which makes our Process Information and Control System (PICOS) system the ideal choice, because it combines intuitive control with clear visualization of individual plant sections.

By upgrading to PICOS.NET, you can start benefi ting today from the system‘s continuous enhancement and avoid problems resulting from the discontinuation of after-sales support for older systems. PICOS.NET gives you the option of making customized modifi cations and extensions to screen forms and displays. The system lets you install updates, extend functions, and features rapid remote service support in the event of problems. By using standard PCs with up-to-date software, PICOS.NET guarantees low and cost-effective spare parts inventories.

Always up to dateMonitoring, operating and visualizing with PICOS.NET

The advantages of PICOS.NET for you:

• The latest software standard comes with all options for Windows operating systems and applications

• The software is subject to continuous further development

• Easy and intuitive operation

History

PICOS PICOS/2 PICOS.NET for Windows XP und Windows 7

PICOS.NET Windows 10

since 1990 since 1998 since 2003 since 2017


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Simulation first, then productionCADEX – raising the profile of extrusion

The CADEX (Computer Aided Direct Extrusion) automation program optimizes the direct extrusion process for aluminum alloys, improves the quality of the sections and boosts production volumes by up to 10 percent. The program simulates the extrusion process and calculates the ideal process parameters.

This ensures machine capacities are used efficiently. CADEX is based on measurement data that are calculated once for every extrusion tool and every type of material. It can therefore simulate the parameters for the entire product range of an extrusion press, meaning product quality is maintained at a consistently high level.

CADEX is an easy-to-operate, functional control system that has already been installed in over 130 plants worldwide.

History

CADEX 1 CADEX 2 CADEX 3

since 1988 since 2000 since 2016

The advantages of CADEX for you::

• Improved product quality

• Reduced extrusion times through optimal use of the machine’s capacities, resulting in higher productivity

• Optimized process database and thus reproducible product quality

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Product portfolioService that meets your needs every time

Whether it‘s spare parts, revamps, customized maintenance or specifi c training courses you are looking for: SMS group‘s Technical Service team are on hand at 50 locations around the world to offer you effective service packages right across the entire metallurgical process chain that are tailored to your needs. What‘s more, you also benefi t from the collective know-how of the SMS group, because our employees customize their services to meet your requirements in terms of deadlines, costs and quality.

That means: You can have full confi dence in the quality of our services and our worldwide presence when it comes to reducing downtimes, improving productivity and securing the value of your plant and equipment over the long term.

Spare Parts& Logistics

Upgrades &Modernization

Maintenance& Repairs

Consulting& Training

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.

SMS group GmbHTechnical Service

Ohlerkirchweg 66 41069 Mönchengladbach Germany

Tel.: +49 2161 350-2478Fax: +49 2161 350-1980

E-mail: [email protected]: www.sms-group.com

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Modernization of extrusion presses