Together with GEDIA, AP&T has created what is probably the world’s most advanced production line for manufacturing press-hardened automotive components.

AP&T’s latest press-hardening production solution lays the groundwork for providing car manufacturers with lighter, safer and more flexible designs that are cost- and energy-efficient. The solution includes AP&T’s proprietary servo-hydraulic press, boasting up to 70% lower energy consumption than conventional hydraulic presses, and TemperBox, which enables the combination of soft and hard zones in the same finished component.

The first commercial production line containing both innovations became operational at GEDIA in Germany in the fall of 2019, with subsequent installation of the same equipment at the company’s facilities in Spain and the US. It is no coincidence that GEDIA and AP&T are pioneering the future of press hardening in the industry: it is a result of a deeply rooted collaboration between the two companies that has lasted a decade.

Jörgen Theander, AP&T’s person responsible for the project, says: “Together with GEDIA, we have now developed what is probably the world’s most advanced production line for manufacturing press-hardened automotive components. By collaborating, we not only solve technological challenges and gain valuable experiences, we also manage to meet high expectations.”

So how does the end result compare to earlier AP&T press-hardening lines? First and foremost, the new lines are considerably more energy-efficient, much due to the fact that the servo-hydraulic press consumes up to 70% less energy than conventional hydraulic presses. The latest generation of multi-layer furnaces, consuming 40% less energy than its predecessors, also delivers an important contribution. In addition, the new lines make it possible to shorten manufacturing cycle times of certain products by up to 20%, freeing up time for more production.
For further information www.aptgroup.com

Rhodes Interform, part of Group Rhodes, continues its success in mechanical and hydraulic press manufacture and refurbishment with another major project win in the aerospace industry. The contract, recently completed successfully, is phase one of two for the refit of a 1989 vintage 3000 Ton ‘Chester Hydraulics’ SPF press, at BAE Systems, Samlesbury. The press is a critical piece of equipment that manufactures major parts for the Typhoon (Eurofighter) aircraft.

Rhodes Interform’s technical director Peter Anderton says: “This is a specialist repair to the ‘hotbox’ ensuring the stringent temperature accuracies required during the manufacturing process are maintained. We won the contract based on our vast expertise in the manufacture, design and repair of SPF presses in the aerospace sector. The lockdown was obviously a difficult time for the industry, but over the past few months we’ve won a number of contracts for both new machinery and equipment refurbishment. We’re very optimistic for the continued recovery of the UK aerospace sector.”

Rhodes Interform’s machine refurbishments offer customers a cost-effective solution to improve equipment life and increase productivity. The company provides a complete one-stop refurbishment service, from arranging transport to the company’s maintenance facility in Wakefield, through to retrofitting new components and re-commissioning on site.

Parent company Group Rhodes, based in West Yorkshire, boasts a 200 year metal-forming history and has also been manufacturing presses to form composite materials from as early as the 1930s. The company has won Queen’s Awards for both Innovation and International Trade in recent years, particularly for its work in the aerospace sector.
For further information www.grouprhodes.co.uk

A £1m investment in a new press line is helping one of the UK’s leading sheet metalwork specialists diversify into larger projects and higher volumes. BPL Engineering Group (BPL) has strengthened its strategic partnership with Worcester Presses by installing a 600-tonne Yeh Chiun hydraulic press, one of the largest it has ever commissioned.

The decision, which follows the success of a 300-tonne H-frame press purchased four years ago, gives the Kings Norton-based firm access to a machine that offers an increased bed size (2500 x 1500 mm), crucial for going after stampings destined for the automotive, aerospace, rail and other sectors.

Worcester Presses has also installed remote monitoring in addition to its maintenance and service package.

“Our expertise lies in supplying stampings and assemblies to OEMs like Jaguar Land Rover, Lotus and Aston Martin, ranging from prototype projects to production volumes,” explains Matt Adams, operations director at BPL. “This complete service has seen sales increase rapidly past £6m and our latest collaboration with Worcester Presses gives us additional capacity and a larger world-class press to take on different types of work. The machine, which was installed as part of a three-month factory reconfiguration project, allows us to target larger stampings in various material grades, including aluminium, mild steel, structural steel, stainless steel, brass and copper.”

Russell Hartill, managing director of Worcester Presses, was delighted with the faith BPL has put in its capabilities: “The 600-tonne Yeh Chiun is some press, delivering massive power, superb accuracy and repeatable quality, which is ideal for the type of work at BPL.”

For further information
www.worcesterpresses.co.uk

It is possible to manoeuvre dies quickly and safely on and off the table of power presses using a wide range of carrying consoles from Roemheld. Now, the maximum forming die weight that can be handled has increased by more than half from 32 to 50 tonnes with the introduction of a new console featuring an electrically actuated chain drive and support feet.

Roemheld’s latest console is intended for shortening set-up times when changing over batch runs in press shops where components are formed from large metal sheet, such as in the automotive supply chain. The equipment is either dedicated to one press and fixed in position, or supplied as a mobile unit on wheels that allows easy transportation between different presses. Special customised solutions are also available, including for handling even heavier loads.

Once at the machine, the carrying console’s integrated docking system, which is equipped with a hydraulic lifting column and foot lever for easy adjustment, ensures that it attaches firmly in position at the press before placing a die on to it by forklift or crane. An integrated chain drive moves the die at up to 2 m/min to its final position in the press via integrated roller and ball bars, positioning it with millimetre precision.

The equipment is available in different versions suitable for almost any type of press. It may be factory-fitted in the case of a new installation or retrofitted to existing presses. Of particular note, the compact design makes it suitable for use when the press bed is low or where space is limited. By integrating sensors and stops, it is possible to integrate the console into a partially or fully automated process, either via the power press control or a separate, optional control system.

For further information
www.roemheld.co.uk

Aalborg-based Mekoprint Mechanics has ordered a new press line from AP&T. The new line, the company’s third from AP&T, will not only increase production capacity, but also enable the manufacturing of large metal components.

“Following a period of great fluctuation in demand for our products, we’re now seeing a strong recovery from many customers,” says Karsten Møller, technology and product manager at Mekoprint Mechanics. “To increase capacity and strengthen our competitiveness, we’re making a substantial investment in new buildings and machines, of which, the new AP&T production line is an important part.”

Mekoprint Mechanics manufactures cabinets, chassis parts, front panels and other metal components for a large number of companies in different industries. For installation in the autumn, the new line includes a press with 500 ton of press force, a 1900 x 1600 mm press table and a SpeedFeeder for unloading. The order also includes two years of complete service and maintenance.

Just over three years ago, the company installed a similar line, which saw the addition of another press in 2019. But AP&T has an even earlier history of delivering equipment to Mekoprint.

“We’ve been collaborating with AP&T for decades and we’re thoroughly confident in their ability to deliver technology that meets our needs for reliability, flexibility and productivity,” says Møller. “Having access to quick, local service is also highly beneficial to us.”

Peter Karlsson, key account and area sales manager at AP&T, adds: “It’s great that Mekoprint is now strongly investing in the future and that we at AP&T are part of their expansion journey.”

For further information
www.aptgroup.com