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Synopsis of Sheet Hydroforming Press Controls Project

  • Situation: A Big 3 automotive manufacturer purchased a new sheet hydroforming press line from a Japanese OEM for installation at one of the automotive manufacturer's production plants in the United States.
  • Press Description: The hydroforming cell consists of a Front-of-Line consisting of 2 stationary pallet stations plus centering station; 1—Fluid Forming Press; 2—Servo Link mechanical presses; 5 GE Fanuc destacking, load, and unload robots complete with tooling; 3 Die Carriers (one set for each press); 5 Tool Change Stands; 1 Scrap conveyor system for removing scrap from presses 2 and 3; 1 End-of-Line system for transporting finished parts;4 Main Operator Stations (MOS) containing the HMIs and controls; 1 Main Operator Console (MOC) for supervisory/maintenance functions.
  • Requirement: A complete automation (controls and software) system (includes 57 electrical control panels) to run press operations.
Sheet Hydroforming Screenshot
  • Brock Solutions' Role: Design, develop, and implement the complete electrical, control, and automation system, complete with a customized Line Supervisor (LSV) to monitor line production plus provide a platform for maintenance and diagnostics activities.
  • Main Technology Components: Allen-Bradley ControlLogix PLCs, RSView HMIs, Siemens’ IP20, InterlinkBT IP67 I/O hardware, DeviceNet, Ethernet, custom software.
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