Space-saving line for hot stamping large components

One of the critical challenges faced by manufacturers in this field is space optimisation, especially when working with large machinery like roller hearth furnaces. Traditional roller hearth furnaces, while effective, require significant space, stretching up to 45 meters in length, which presents a challenge in modern manufacturing facilities where space and energy efficiency are paramount.

In response to this challenge, BSN Thermprozesstechnik and Schuler have teamed up to develop a compact rotary furnace designed specifically for the production of large components through hot stamping. This innovative furnace solution addresses not only the issue of space but also offers advantages in terms of energy efficiency, maintenance, and repeatability of component heating, which is crucial for ensuring high-quality production output.

Understanding the Hot Stamping Process

Hot stamping is a key technology in automotive manufacturing, especially for the production of lightweight, high-strength components that are crucial for improving vehicle safety and reducing overall weight to meet stringent fuel efficiency standards. In this process, metal blanks are heated to a specific temperature and then rapidly cooled and formed into the desired shape. Achieving and maintaining the correct temperature is critical because any variation can lead to defects in the final product.

Traditional roller hearth furnaces, which are commonly used in this process, require a significant amount of space, often up to 45 meters in length, to accommodate large components such as body sides or base assemblies. These furnaces also consume a considerable amount of energy, making them less than ideal for manufacturers seeking to reduce their environmental footprint. Recognising the need for a more efficient and space-saving solution, BSN Thermprozesstechnik and Schuler have innovated the compact rotary furnace.

Compact Rotary Furnace: A Breakthrough in Space and Energy Efficiency

The compact rotary furnace developed by BSN Thermprozesstechnik and Schuler represents a significant leap forward in terms of space utilisation and energy savings. With a total length of just 14 meters (including the loading unit and centering), a width of six meters (including heating and drives), and a height of seven meters, this furnace requires only about a quarter of the space needed by conventional roller hearth furnaces. This space reduction is particularly important for manufacturing plants where real estate is at a premium and floor space must be allocated for various other production processes.

One of the standout features of the compact rotary furnace is its ability to handle a minimum cycle time of just 12 seconds per part, which enhances throughput and overall efficiency. This is a significant improvement in the production of large automotive components where high-volume production is essential to meet demand.

Additionally, the furnace operates on both electricity and gas, offering flexibility in energy sourcing. This dual-energy capability not only improves energy efficiency but also allows for a more environmentally sustainable production process. By using this advanced furnace, manufacturers can save approximately 1,200 MWh of energy annually, which is a notable reduction in operational costs and environmental impact.

Precision and Reliability: Ensuring High-Quality Production

One of the critical aspects of the hot stamping process is maintaining precise and repeatable temperatures throughout the production cycle. Any deviation from the specified temperature can lead to inaccuracies in the formed parts, which in turn can cause problems during assembly, resulting in increased waste, rework, or even product recalls. The compact rotary furnace developed by BSN Thermprozesstechnik and Schuler ensures a repeatable and consistent temperature for heated parts, reducing the risk of production defects and enhancing overall product quality.

This level of precision is essential when working with large components, such as body sides for SUVs, where the dimensions of the blanks can reach up to 3,000 by 1,600 millimeters. To accommodate these large blanks, the furnace is paired with Schuler’s 1,800-ton hydraulic press, which has a table size of 3.60 by 2.50 meters. This powerful press is ideal for forming large components with complex geometries.

Furthermore, Schuler’s “Pressure Controlled Hardening” (PCH) technology plays a critical role in the process, ensuring shorter cooling times and better forming tolerances. This technology allows for more precise control over the cooling and hardening process, which is vital for maintaining the structural integrity and strength of the stamped components.

Schuler: A Pioneer in Hot Stamping Solutions

Schuler, a leading German manufacturer of metal forming equipment, has long been at the forefront of hot stamping technology. The company designed the first line for hot stamping complete side panels for a North American car manufacturer back in 2006. Since then, Schuler’s technology has been adopted worldwide, with around 12 million “double door rings” currently being produced annually using this process across the US, Europe, and China. This figure is expected to increase significantly, reaching an estimated 118 million by the end of the decade.

Schuler’s extensive experience in hot stamping and metal forming has made it a trusted partner for automotive manufacturers looking to enhance their production capabilities. The company’s solutions are known for their precision, durability, and ability to meet the high-volume production demands of the automotive industry.

Conclusion

The development of the compact rotary furnace by BSN Thermprozesstechnik and Schuler marks a significant advancement in the production of large automotive components. By reducing the space required for hot stamping, improving energy efficiency, and ensuring precise temperature control, this innovative furnace offers manufacturers a powerful tool to enhance their production processes while minimising environmental impact.

Schuler’s continued innovation in metal forming technology, combined with the expertise of BSN Thermprozesstechnik, is helping to drive the evolution of automotive manufacturing. As demand for lightweight, high-strength components continues to grow, solutions like the compact rotary furnace will play an increasingly important role in meeting the industry’s needs.