WAVELINE PRESS LINE: A DECISIVE DEVELOPMENT FROM FAGOR ARRASATE

The WaveLine concept developed by KUKA Systems and FAGOR Arrasate  gives solution to the current problems of the conventional press tandem lines. In past and partially at present, press lines consist of individual presses which are operated in start/stop mode via the automation. This means that, as soon as the part has been loaded, a start signal is transmitted to the press by the automation. In that moment, the clutch on the flywheel is engaged and the press cycle begins. After the press has passed lower dead centre and has returned to upper dead centre, the clutch is disengaged and the press remains at upper dead centre. For every stroke performed the presses start and stop giving two consequences.
The parts per minute throughput is not highest possible since in every start and stop process a precious time is lost.
The energy costs and wear and tear caused by start/stop operation result in a considerable increase in the running costs (energy lost on clutch and break, energy lost since press must accelerate and break in every cycle, maintenance cost since abrasion of the clutch and brake discs).

The WaveLine is the first High-Speed Continuous Press Line with robotic automation on the market and combines the advantages of both Tandem and Transfer Press Lines in an ideal way.

The WaveLine concept allows a continuous and synchronized operation of Tandem Press Lines and, consequently, increases production volume compare to conventional tandem lines with a lower investment that transfer press lines. Single presses specially designed for continuous working production which are loaded and unloaded with the KUKA COBRA automation,  ensuring a higher number of strokes than conventional robot press lines. This operating mode reduces energy consumption (WaveLine technology uses approx. 30 % less energy than Press Lines operating in start/stop mode) and protects the press mechanics from wear, as the presses must not be break in each cycle and then clutched again. The Presses are at the same time controlled to ensure that the angle offset between them which is defined in the simulation is kept in an acceptable range. Too much angle offset gives time to the robot for reaching the downstream press for loading but at the same time reduces the time to go back on time to reach the unloading position synchronisation.