production lines

This line’s task is to produce blanks required by lines G1, G2 and G3, having a production capacity of 60 tones per shift. Blanking line is equipped with a mechanical press of 500 tones and automated coil feeding system, and also an oscillating shear system. Its able to cut a variety of coils and transform them to blanks with different geometric dimensions (rectangle, trapezoid,…) or blanks with shape or curvature (contoured), required for pressing operations.

This line is equipped with a washing machine for sheets and a coil straightener ( Leveler ) , when coil feeding for cutting operations and its blanking press has quick mold change system, automatic clamps and trolleys in dimensions 4500 mm * 2200m.

Blanked sheets pack, is stacked automatically on two stacker tables with automatic system. Rated speed of this press is between 20 and 60 beats per minute, able to produce sheets with thickness of 0.5 to 2 mm and minimum of 800 to maximum of 1800 coil width, that maximum tonnage of pack is 5 tons and maximum tonnage of coil is 15 tons.

SaipaPress CO. pressing hall (Press Shop) is located in an area over 23000 square meters, on the northwest side of the company, comprising blanking lines , G1, G2 and G3 pressing lines, cut to length and progressive, which were satisfied by Spanish company FAGOR. Also waste products (bailing) and hydraulic press (Die Spotting), blank turnover machine, CMM and portable CMM devices are located in this hall.

G1 pressing line:

This line is used for production of large and heavy parts with deep an complex deformations, and its production capacity is 8.28 parts per minute. Parts made in this line are mainly related to external car’s body, usually includes largest pressing parts of a car. It includes sheet washing machine, and vision system in order to put blanks on the mold, in correct position.

According to this system, it has the possibility of feeding two blanks simultaneously for molds with two cavities. This line established from 6 pressing devices , equipped with 9 robots manufactured by ABB, to transfer between press devices. All these robots are equipped with a filter carbon arm ( to reduce weight and vibration of tools when parts move) and replacing molds provided very quickly cause of having two trolleys for each press.

Trolleys dimensions in first press are 4300 mm * 2300 mm and 4200 mm * 2300 mm in others. Large tables and high tonnage pressing devices provide opportunity to use big molds. Line G1 presses are mechanical and link drive type, equipped with pneumatic cushion. The first press of this line, being the heaviest too, is a double action press device of 2000 tons, with 800 tons blank holder and 1200 tons punch press. Then two 800 tons and three 600 tons presses, which are all single action.

This line has production management system to control and program lines, and operators are not required, except at the beginning and end of the line. Sheet lesion are transmitted below the salon surface, on the conveyor while other lines are working, and transferred to bailing press. There is a monitoring system in line for reporting and counting stops. In order to better control.

G2 pressing line:

Press devices in this line, with production capacity of 8.95 parts per shift, are used to produce large parts, likely to G1, although cover parts and internal body parts are made here too.

This line has washing machine system for sheets, and also vision system to locate blanks on the molds, in correct position. G2 comprises 5 press devices, equipped with 8 robots manufactured by ABB to transfer parts between trolleys. Table’s dimensions in all presses are 4200 mm * 2200 mm suitable for using large molds. Similar to G1, presses are mechanical and link drive type, equipped with pneumatic cushion system. The first place of this line as its heaviest press , is a double action press of 1300 tons with 500 tons blank holder and 800 tons punch press. Then four 630 tons presses which are all single action. Like G1, this line has production management and monitoring system too.

G3 pressing line:

In this line, smaller parts are produced, that mostly are a car’s internal body parts and require less tonnage for pressing operations. Its has 5 pressing devices, that the first press is a double action 650 tons device, and four single action presses besides it. All these pressing devices are mechanical, eccentric type with pneumatic cushion system, with production capacity of 6.34 parts per minute.

G3 pressing devices are semi-automatic, carrying parts between them is done manually by the operators. For operator’s safety, system uses electronic eye, not allowing the operator to approach press table excessive. Also its necessary to press four pedals to set up and start pressing operations , which increases safety factor. Tables dimensions are 300 mm * 1500 mm in all devices and each press is equipped with trolleys.

Cut to length line:

Having ability of produce 60 tons per shift, task of this line is producing required blanks for G1 , G2 and G3. This production line makes rectangular blanks and sheet with thickness between 0.5 to 2 mm and minimum of 500 mm and maximum of 1500 coil width, minimum of 1000 mm and maximum of 3000 mm cutting length, maximum packed tonnage of 5 tones, maximum coil tonnage of 15 tons, and maximum production speed is 90 meters per minute.

Progressive line:

This pressing line, with tonnage of 630 tons and quick mold change system (two trolleys with dimensions: 3100 mm*2200 mm), is a very efficient machine to produce small size parts with high circulation, and it has a production capacity of 25 to 90 parts per minute.

Unlike conventional press machines that use blanks, inputs of the progressive press are coils, which are maintained on coil keeper axis, through a bogie equipped with coil lift, and adjusted automatically. After that, coil passes the leveler and sheets surface becomes completely smooth, then continues its way into the mold.

Progressive molds act multi-stage and do all pressing processes continuously, such as drilling, shaping and cutting. Number of these stages reaches even to 25, is some molds. Device feeding system is controlled by CNC, while PLC controls pressing operations. Since the two processes are synchronized, this ensures that the opening speed of the coil plate is exactly equal to speed of sheet entry into molds. After different mold stages, sheet exits as a perfect part, and after exporting the first part, device maintains in automatic mode and production press continues without operator. Thus, instead of using a press line and blanking line, complete part is produced only by means of a press and coil opener, using less meanpower.

Bailing:

This press is used for bailing lesion (scrap) from pressing operations. (collected lesion transferred by conveyor bellow lines). Device specifications include:

Bale dimensions : 300 * 300 * variable ( width * height * length )

Capacity : 8.9 to 9.5 tons per hour

Bale number : approximately 120 bales per hour

Bale weight : approximately 74.2 to 79.5 kg

Hydraulic press ( Die spotting ):

This pressing device with tonnage of 200 tones, manufactured by south Korean company SIMPAC, is installed to repair and seal the molds used in pressing lines. Its equipped with micro inching system and able to precise motion control of slides, through hydraulic valve (servo) and position GPS sensor. Dimensions of table and slides are 4500 mm * 2500 mm and slides moving speed is about 10 to 82 mm per second.

Blank turnover:

Blank turnover machine, manufactured by SIMPAC , has been installed coincide with hydraulic spotting press. This system is used for turning over packs which are blank molded and shaping operation for left and right side parts, by a mold in every press beat.

In such a mold, blank’s mold is designed only to produce left or right parts, so the opposite blank is supplied by rotating produced pack, 180 degrees. Specifications of rotatable pack made by this machine are:

Maximum pack length : 3500 mm

Maximum pack width : 1800 mm

Maximum pack weight (with pallet) : 7000 kg

CMM :

CMM is a gateway device, manufactured by LK England. It includes three axes x, y and z which are perpendicular to each other, each is equipped with a system that defines axis position. Three dimensional measurement is done by device’s prob, under operator’s manual control, or automatically , as planned.

Measurement range for CMM is 4000 mm * 2000 mm * 2000 mm, with accuracy of 0.500 mm.

Portable CMM:

Its manufactured by French company ROMER, and has ability of appropriate quality control, comparison of parts with 3D model, measuring with minimum limitations, suitable for transposition among production stages (cause of being light weighted and silent), and its measuring accuracy is 0.20 mm.

Heming hall , as one of the most equipped halls in automotive body parts production, has front and rear door sets, front and rear door linings, trunk door set and motor door set production lines for all PRIDE family, as well as front and rear fenders for Tiba.

Buildings and warehouses area of the company was 25750 square meters at its establishment, which 32000 square meters have been added ( at high altitude ) to it, as needed.

This hall is located in an area approximately 5800 square meters. On the western side o company, and its second production hall in SaipaPress. It includes front and rear, left and right door sets for Pride, production line of motor door set for Pride and also trunk lid.

PRIDE door sets production line:

Front and rear, left and right doors set production lines include 7 stages. At the beginning, all lining and skein reinforcement parts are assembled by spot welding operations in two stages. Then for sealing, glue operations are done in front doors, as sealer work in rear.

In next stage, cover is assembled to lining through hydraulic press, and after closing hinges, brass welding is carried out to remove all gapes between components, as well as positioning skein on lining part and cover. Finally, to dispel any scratches, finishing operations are carried out. These lines have three work shifts with a production capacity of 520 parts per shift.

Pride trunk door set line:

Has 5 stages, first of all reinforcement parts and hinges are assembled on lining, though spot welding operations. In the next step, sealing operations are done manually on trunk doors lining, then glue is added.

After placing the pads on the covers, set is directed into the press for Heming operation. Finally, in order to dispel deformations and scratches, finishing operations are done.

Pride motor door set line:

This line has 4 stages and its similar to trunk door set line, however, glue stage isn’t in the line. This line has three work shifts, and production capacity of 520 parts per shift.

Mechatronic workshop:

Mechatronic workshop in SaipaPress, always tries to provide appropriate context, to develop goals in areas of repair (repairing needed dissipation and returning it to production cycle or the equipment with a target of return on investment), internalization of vital and unique needed parts and equipment, improving and developing projects to increase production capacity and better control, service activities (advice to other units and technical support to prodive technical specifications and commissioning of production lines , if necessary), training courses (in the fields of industrial automation, industrial mechanics, robotics, mining equipment and electrical and mechanical installations with internal methods presentable in Saipa group, creating knowledge, new functionality and… , according to potentials and capacities of department of technical support, and attracting cooperation from other units in the company.