br kunststoff gb sq
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for fiber-reinforced thermoplastic and thermosetting plastics
Hydra ul i c press sy stems an d
direct process
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Expertise and innovative potential
an unbeatable combination
When it comes to planning and imple-
menting presses or complete produc-
tion lines, expertise and experience
are in just as much demand as capital
resources and innovative technologies.
This is why customers from all over the
world place their trust in us.
The processing technologies we have
developed, in particular the direct pro-
cess for thermoplastic and thermo-
setting composite fiber materials,
combine the highest levels of efficiency
with a significant cost-saving potential
and wide-reaching flexibility in the
choice of materials.
Our specialists are committed to
achieving your targets in their everyday
work. In doing so, they benefit from
the synergy effects from our various
divisions, subsidiaries and research
institutes.
Our developments are motivated by
the demand for ecological production
processes to deal with our valuable
resources efficiently and sparingly. The
future of lightweight design shapes our
products just as much as the require-
ment for highest availability, efficient
use of energy and an attractive price/
performance ratio.
Research and development
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As a leading technological company,
we regard the challenge facing us as
being to develop new, economical
processes.
The more that 1000 presses and lines
that we have delivered, as well as the
innovation prizes awarded toDieffenbacher, are the results of many
years of development work and stra-
tegic cooperation with the renowned
research institute, Fraunhofer ICT.
The objective of our efforts is to push
ahead with the development of effi-
cient solutions using optimized pro-
cedures for processing fiber-reinforced
plastics in the direct process.
Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
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Control Technology
Service
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Technological leadership
K-TV Award innovation award International award of the JEC Paris Technology Center
System Expertise
Innovative potential
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System Expertise
During the 135-year history of the
company, our creative ideas, consistent
ongoing development work and the
courage to be innovative have turned
us into one of the globally leading
manufacturers of hydraulic press
systems and lines for SMC, GMT and
LFT technology.
Our range of products and services
includes both process technology
for manufacturing fiber-reinforced
components including reworking and
direct technologies, as well as complete
system solutions with automation.
For example, we can offer you future-
oriented technologies and compre-
hensive services for manufacturing
moldings made from composite fiber
materials and for forming thermo-pla-
stics and thermosetting plastics
all from a single source.
Dieffenbachers renowned quality is
guaranteed by experienced designers
and software developers, the most
modern production methods in our
plants at Eppingen (Germany), Brno
(Czech Republic) as well as Shanghai
(China) and Windsor (Canada) with
continuous quality control based on
DIN EN ISO 9001 and VDA 6.4.
Success through tradition
Assembly cellLFT-D loadingNeedle gripper
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Water jet cutting machine
Visualization of a machine layout
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Mould change cart Robot-based vision system
Range of products and services
Proven press technology
Standardized press series are
available for GMT, LFT, SMC and
HP-RTM processing with application-
oriented hydraulic drives and
process controllers.
Complete solutions by automating
the press environment
Standardized systems adapted to the
material in question, such as
conveying, weighing and trans-
porting raw materials and pressed
parts supplement the production
system.
Our successful plant construction
business is based on having an expert,
imaginative engineering team, our
decades of experience in plant
construction as well as with system
components of defined types that
have successfully proven themselves in
production.
Our leading market position is under-
lined by the large number of automa-
ted press environments. Our engineers
plan processes and the production
sequence adapted to your particular
requirements.
Made-to-measure system solutions
1. Preform supply 2. Preform feed 3. Preform fabrication 4. Weighing cell 5. Loading robot with gripper system 6. Gripper change station
7. Hydraulic press 8. Press mould 9. Unloading robot 10. Cleaning robot 11. Cooling station 12. Reworking 13. Gate-out belt 14. Safety fence
Automated mould change systemsand clamping systems increase the
efficiency of machines.
Individual reworking of the finished
product
Machining systems for drilling,
milling, water jet cutting, punching
and deburring allow finished pro-
ducts to be produced.Gluing lines
for connecting components round
off the portfolio.
Fully tailored project planning and
consulting service
Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
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16
18
Control Technology
Service
10
System Expertise
Innovative potential
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Precision through proven technology
Dieffenbacher supplies presses in a
standard version or as a high-precision
press with an active, servo-controlled
parallel motion system. The press
design fulfills all the requirements for
fiber-reinforced plastics.
High structural rigidity, guides accom-
modating thermal expansion as well
as control technology adapted to the
flow process meet the quality demands
of our customers. Quality controls
and verifications on the components
produced are provided via process data
acquisition and archiving.
An appropriate press system is avail-
able for every application, depending
on the requirements in terms of parts
geometry, specified tolerance values
and demands regarding surface quality
(class A). A tried-and-tested design
principle as well as the use of standard
components that have proven them-
selves in practice and a high-perfor-
ming, globally active service network
are guarantors of high reliability.
Dieffenbacher presses and fully auto-
mated press lines are used by leading
processors of fiber-reinforced plastics.
Features
Controlled speed profile for the
forming process to adapt to the
flow rate of the preform or
compound.
Controlled roller guides of the ram
for precise and low-wear closing of
moulds.
Controlled opening of the mould to
reduce wear on the component.
Process-oriented PC-based controller
for exact adaptation of the pro-
cessing parameters to the flow
properties of the materials being
processed.
Ecological production processes to
support efficient
Press technology
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Energy-saving COMPRESS PLUS COMPRESS ECO compact series
With the COMPRESS ECO, Dieffenbacher is offering an
attractive alternative which optimally meets the require-
ments for an economical forming press for all components.
Compact
The ECO series is supplied with press forces from 4,000
to 25,000 kN, in a standard version. The modular system
meets the requirement for flexibility in terms of
expansion.
Economical
The COMPRESS ECO offers an attractive price/perfor-
mance ratio in response to the immense cost pressure to
which our customers are exposed.
Modular
The ECO series can be delivered as a standard press with
press force from 10,000 kN onwards with a controlled
closing unit and an actively controlled parallel motion
system for the ram.
The COMPRESS PLUS generation of presses is
Dieffenbachers response to market changes
to ensure and expand customers competitiveness.
Energy
Our response to constantly increasing energy prices is
to cut energy requirements by 50 % and more compared
to other press systems, based on our new COMPRESS
PLUS closing concept.
Quality
Our response to uncompromising quality requirements
comes in the form of the precision of the COMPRESS PLUS
for top quality components.
Series
The COMPRESS PLUS is supplied for the range of press
forces from 18,000 to 50,000 kN.
Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
12
16
18
Control Technology
Service
10
System Expertise
Innovative potential
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SMC Duroline
Modern machine concept for
SMC technology
SMC is an excellent material for manu-
facturing automotive components with
first-class surface quality.
Additional and major requirements
exist in electronics, the construction
and rail vehicle industry as well as
replacements for steel and aluminum
as structural components.
Dieffenbacher supplies modern press
technologies as well as fully automated
systems including reworking for SMC.
The core of the Duroline is the high-
speed, high-precision press with active
parallel motion control. The system is
rounded off by machine components
for providing the preform such as
cutting and package forming systems
as well as automation for loading and
removal. Optionally, the machine can
be expanded with a cooling station,
conveyor belts and protective equip-
ment.
The overarching production line con-
trol ensures that entire lines can be
operated without problems, as well as
providing complete process monitoring
as well as quality assurance.
Fully automated line for ensuring
reproducible parts quality
Almost unmanned production with
low emissions
Reducing reworking and scrap
High-precision component manu-
facture, potentially for lightweight
design
Low tooling costs for small and
medium batch sizes
Sheet Moulding Compound
Truck bumper system
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SMC Directline: direct process for SMC
The advanced D-SMC direct process
opens up new possibilities for using
thermosetting plastic composite mate-
rials in lightweight construction for the
automotive industry.
The technology of direct compound-
ing bypasses the cost-intensive steps
of banding, storing and logistical
handling that used to be required for
SMC semifinished parts. The precisely
reproducible process and direct further
processing of the preform guarantee
constant quality levels.
In the direct process for SMC, the
SMC preform is manufactured directly
before it is processed in the forming
press. In a compounder, resin, fillers
and glass fibers are formed into a flat
material according to an individual
recipe. This material can be processed
like conventional SMC semifinished
parts. An integrated SMC cutting
machine creates pressing packs that
can be supplied to the press mould
automatically.
Consistent Class-A quality
at a high level
Continuous process with a high
degree of automation
Line control from compound to
finished component
Individual series sizes and wide
range of applications
Complete control, visualization and
documentation of all process
parameters
Energy and cost savings in the
storage and transport process steps
Individual recipes optimized to
particular components, with a high
glass-fiber content
Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
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16
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Control Technology
Service
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System Expertise
Innovative potential
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SMC DirectlineSheet Moulding Compound
Resin blender
Sidefeeder forfilling material
Premix
Extruder
Glass Rovings
Cutting unit
Sheet
Compounder
Cutting unit
Scale
Loading
Hydraulic press
Unloading
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HP-RTM
High-performance components
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High Pressure Resin Transfer Moulding
High-performance composite fiber-
reinforced plastics are becoming ever
more important. The high dynamic
strength values achieved mean that the
high-pressure resin transfer molding
process (HP-RTM for short) will take on
a key role in structural components and
also in the skin panel area.
Dieffenbacher has succeeded in de-
veloping a high-performance,
completely automated HP-RTM pro-
duction line. Successful cooperative
ventures mean that turnkey systems
and machines can be supplied any-
where in the world for the high-
pressure resin injection process, and
all from a single source.
The production system is divided into
three automated system units:
Preform manufacture
Press and injection unit
Reworking unit
These can be operated independently
or in a complete line.
1. Cutting2. Laminating3. Stock in/out4. Preforming5. Net Shaping
6. Transfer Container
7. Water Jet8. Milling9. Washing
10. Parts Stock11. Surface Treatment12. Inspection/Bonding
Preforming
Finishing
RTM
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1. LWRT oven2. Handling robot3. Discharging and loading4. Plant control panel5. Press
LWRT
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Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
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16
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Control Technology
Service
System Expertise
Innovative potential
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Applications:
Underbody covers with
large surface area
Engine covers
Wheel arch linings
Interior door trims
Low Weight Reinforced Thermoplast
Materials for noise insulation and
lightweight construction
The LWRT material is ideally suited to
improving thermal insulation and
acoustic absorption properties in the
vehicle. The newly developed produc-
tion process allows light components
and components with a large surface
area to be manufactured. For this
purpose, a fabric mat made from glass
fibers and plastic fibers such as poly-
propylene or polyester is used as the
preform.
Heating in the forced-air oven incre-
ases the volume of the LWRT material,
thereby producing the typical insulating
properties. Once the heated preform
has been removed, it is formed within
a hydraulic press under low pressure.
During the pressing procedure in the
heat-controlled mould, the material
takes on its final geometric shape, but
is only partially compacted.
The component is removed from the
press mould and then transported to a
blanking press. A robot places the
finished parts on a conveyor system
for further processing.
Straightforward process technology
and complete automation of the
overall system ensure reliable compo-
nent quality.
Underbody shield
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LFT Directline
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A material and process technology isbreaking through in the market
Dieffenbacher LFT-D technology is
characterized in particular by its
enormous efficiency combined with the
ability to adapt the materials flexibly to
the demands of the components, for
example in structural and semi-
structural components in the
automotive industry.
A hydraulic high-precision press then
presses a plastic compound into the
finished component in the extrusion
process. The compound consists of glass,
synthetic or natural fibers and plastics
such as PP, PA or PET. As an option,
recycled materials can also be mixed in,
in the form of granulate or chips.
Dashboard carrier Spare wheel well
Long Fiber Thermoplast Directmoulding
High efficiency by direct manufacture
of the preform
Individual adaptation of the
compound to component properties
Greater productivity
by short cycle times
In-line processing of recycled materials
Turnkey production cell with
overarching line control and
integrated quality assurance
Structured surfaces on visible
components
Underbody components
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Dieffenbacher 2-machineLFT-D mixing extruder
Pick-up belt Supply conveyor
Cutting unit
PC line control
PC line control
Servohydraulic control system
Cutting unit
Profiled LFT-D strand
Adjustable LFT-D slot dieDieffenbacher 2-machineLFT-D mixing extruder
The adjustable plasticized material
outfeed nozzle makes it possible to
create different thicknesses within a
plasticized material strand. This allows
material concentrations to be achieved
according to requirements at the
necessary points. Minimized flow paths
reduce the distortion in components.
The double-belt feed system offers high
levels of flexibility for plasticized
materials. For one thing, the materials
can be sorted in advance so that a
loading gripper system offering
minimum costs can be used for more
complicated placement patterns. For
another, two presses can be loaded by
one extruder system, in which case the
plasticized materials can be allocated
to the subsequent press moulds.
Profiled plasticized materialmanufacture
Loading with double-beltconfiguration
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Optimized for fiber reinforcement
LFT-D-Technology
The dual machine technology devel-
oped by Dieffenbacher guarantees
optimum compounding and ensures
that the reinforcement fibres are
contained gently. This procedure,
combined with a process-controlled
hydraulic press, is essential for re-
taining the majority of the fibers in the
component. Depending on the require-
ments, it is possible to set the required
fiber length which is generally longer
than 20 mm. The proportion of fibers
with lengths between 20 and 50 mm
is more than 75 %. High levels of
flexibility are chiefly reflected in the
ability to use various matrices and
reinforcement fibers individually, the
infinitely variable fiber content setting
as well as combining LFT-D with local
reinforcements.
Rear of vehicleTunnel for motor carSpare wheel cover
Plastics for the best material properties
Filler-reinforcedplastics
Impact strength
Strength/stiffness
Non-reinforced plastics Elastomers
TailoredLFTs
Short fiber-reinforced
thermoplasticsLong fiber-reinforced
plastics
High standard of material properties
by retaining long fibers
Fiber content can be set
Long fibers > 20 50 mm
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The possibility of integrating functions in
parallel to weight reductions mean that
LFT components increasingly represent
an alternative to steel and aluminum
concepts. Furthermore, single-substance
solutions create economical recycling
options.
The tailored LFT-D process combined
with the LFT-D material places local
reinforcing materials in the component
wherever there are increased require-
ments in terms of rigidity or toughness.
This means the material can be adapted
to the required mechanical properties by
using fabrics, sections or UD fibers. As a
result, plastic components meet the
requirements in terms of crash proper-
ties.
Tailored and advanced LFT-D for struc-
tural parts and components with visible
surfaces
Rear doorVehicle frame Front-end assembly carrier
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Schematic view of a LFT-DIRECTLINE Source: Weber
EF equipment
PP-granulat& additives
Glas-Rovings
LFT-D plasticizedmaterial
E-LFT component
EF profiles
EF SEMIFINISHED PART
HYDRAULIC PRESS
LFT-D PLANT
EF LFT
Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
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18
Control Technology
Service
10
System Expertise
Innovative potential
4
6
8
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High strength properties and high
energy absorption capability
Weight reduction by substitution of
steel and aluminum components
Single-stage local pressing of
endless fiber and fabric inlays
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Control Technology
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CNC-based intelligence Features
Nowadays, exacting requirements are
placed on production machines in terms
of accuracy, reproducibility and ease of
operation. These requirements by our
customers set the standard for our pro-
duction systems.
The control systems and controller
strategies developed by Dieffenbacher
ensure trouble-free production
sequences with high levels of service-
ability and reproducible component
quality at the same time as excellent
convenience for operation and servicing.
Press control via industry PC with
fieldbus and MS Windows user
interface
Digital absolute position sensing
systems
Fault diagnostic system
Database for tool management
PLC integrated in the PC controller
Production plant controller
Process monitoring and production
data acquisition (PDA)
Data analysis system
Online connection for
tele-engineering service
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Fault diagnostic system Nominal value curve input for speed profile Data analysis system
Press visualization
Nominal data input
Actual value display
PDA
Data analysis system
Fieldbus I/O modules
Beckhoff
Digital position sensing system / valves
Ram
Ejector
Ramtiltage monitoring
Core pull functions
Locking
Fieldbus models
Beckhoff
Bus I/O modules
Pilz PSS 3006
Safety controller
Ram
Ejector
Connection to other
machine components
Core pull functions
Connection to:
Extruder, metering units,
servo dies, robot, etc.
Fieldbus coupler
Industry PC with Windows XP
Press control
Beckhoff TwinCAT
Sequence controller
Core pull function control
via matrix
Press closed-loop control
Active ram parallelism control
Press force and speed control
Fieldbus
Dieffenbacher controller with industry PC and fieldbus system
Press technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
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18
Control Technology
Service
10
System Expertise
Innovative potential
4
6
8
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Expert services worldwide
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We are well aware that delivering the
machine is not the end of the job.
For this reason, we have put together
an attractive package of services for
you in order to ensure excellent
machine serviceability. We want you to
be happy with all aspects of our work!
If you need our assistance, we are
ready to help you with a well trained
and expert service team in Europe,
North America and Asia.
Spare parts service
Spare parts warehouses designed
for customers requirements permit
rapid delivery. We support you in
defining your spare parts as well as
the necessary retrofits.
Maintenance and servicing
On request, we can take over all the
maintenance work on your presses
and machines on your behalf, even
for machines we did not build.
Our experts will be happy to provide
you with individual advice about the
scope of maintenance.
Tele Engineering Online service
With our online service, we can
offer you local, independent and,
above all, rapid assistance at any
time when it comes to questions
about process parameters and
eliminating faults. On request,
this is also possible round the clock.
Repair
If one of your machines does need
a repair, our highly qualified service
technicians can soon be at your side.
Customized consulting,quick service worldwide
Worldwide spare parts warehouses guaranteerapid availability
Our service -Committed and professional
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Retrofit-solutions
Machine modernizations are
another key competence. The
use of new controllers, electrical
subassemblies and hydraulic com-
ponents increases the serviceabilityand safety of machines and permits
process data acquisition systems
as well as automation systems to
be incorporated. We analyze your
presses and lines, even if we did not
build them, and offer you moderni-
zation concepts tailor-made to your
requirements.
Press Technology
SMC Technology
LFT-D Technology
HP-RTM/LWRT-Technology
12
16Control Technology
Service
10
System Expertise
Innovative potential
4
6
8
2
Training
We offer practically oriented in-
struction courses directly on your
machines or in our training center.
Other training courses serve to pro-
vide information about the typicalmodules in the machine. In addition,
we offer targeted product or
machine training courses right
through to the communication of
process expertise.
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COMPANY LOCATIONS
www.dieffenbacher.com 99-998
1-00-93-00
09/10
MRTIENS ROBOTEC GMBHZum Haug 1076646 Bruchsal, GermanyTel. +49 (0)7251-9573-0Fax +49 (0) 7251-9573-25E-mail: [email protected]
KARLE + JUNG GMBHWerkzeug- und MaschinenbauHeinrich-Hertz-Strae 376470 tigheim, GermanyTel. +49 (0) 7222 40655-0Fax +49 (0) 7222 40655-51E-mail: [email protected]
DIEFFENBACHER CZ S.R.O.
Hydraulick lisyRipsk 15, 62700 Brno,Czech. RepublicTel. +420 5 4842 3111Fax +420 5 4821 7087E-mail: [email protected]
000 DIEFFENBACHER1. MPZ imeni KazakovaKutuzovsky Prospekt 36121170 Moscow, RussiaTel. +7 495 690 71 51Fax +7 495 690 71 52E-mail: [email protected]
DIEFFENBACHER PANELBOARD OY
Wipaktie 115560 Nastola, FinlandTel. +358 10 572 9000Fax +358 10 572 9001E-mail: [email protected]
SUNDS MDF TECHNOLOGIES ABUniversitetsalln 3285171 Sundsvall, SwedenTel. +46 60 524 200Fax +46 60 524 299E-mail: [email protected]
DIEFFENBACHER GMBHMaschinen- und AnlagenbauHeilbronner Strae 2075031 Eppingen, GermanyVisitor address Forming Division:Jakob-Dieffenbacher Strae 4Tel. +49 (0) 7262 65-0Fax Wood-based Panel Division+49 (0) 7262 65-377Fax Forming Division+49 (0) 7262 65-297E-mail: [email protected]
Dieffenbacher GMBHMaschinen- und AnlagenbauBetriebssttte PfungstadtWerner von Siemens Strae 2
64319 Pfungstadt, GermanyTel. +49 (6157) 803-0Fax +49 (6157) 803-109E-mail: [email protected]
B.MAIERZERKLEINERUNGSTECHNIK GMBHBrockhagener Strae 1633649 Bielefeld, GermanyTel. +49 (0) 521 4471-0Fax +49 (0) 521 4471-200E-mail: [email protected]
SCHENKMANN-PIEL-ENGINEERING GMBHBrgerbuschweg 151381 Leverkusen, Germany
Tel. +49 (0) 2171 3996-0Fax +49 (0) 2171 3996-99E-mail: [email protected]
DIEFFENBACHERMASCHINENFABRIK GMBH*Gewerbestrae 2975059 Zaisenhausen, GermanyTel. +49 (0) 7258 609-0Fax +49 (0) 7258 8751E-mail: info@dieffenbacher-zaisenhausen.dewww.dieffenbacher-zaisenhausen.de
DIEFFENBACHERSYSTEM-AUTOMATION GMBHHeilbronner Strae 2075031 Eppingen, Germany
Tel. +49 (0) 7262 6550-00Fax +49 (0) 7262 6550-11E-mail:[email protected]
DIEFFENBACHER NORTH AMERICA, INC.9495 Twin Oaks DriveWindsor, Ontario N8N 5B8, CanadaTel. +1 519 979 6937Fax +1 519 979 6803E-mail: [email protected]
DIEFFENBACHER, INC.3100 Cumberland Blvd.Cumberland Center II Suite 1470Atlanta, GA 30339, USATel. +1 770 226 6394Fax +1 770 226 6397E-mail: [email protected]
DIEFFENBACHER BRAZIL
Av. Benedito Castilho de Andrade, 609 sala107
CEP (zip code) 13.212-070,Jundia So Paulo - BrazilTel. +55 11 4523 1298Fax +55 11 4523 1298E-mail: [email protected]
DIEFFENBACHER INDIA PVT. LTD.Unit 105, First Floor, Prestige Towers99, Residency Road,Bangalore-560 025, IndiaTel. +91 80 4151 0060Fax +91 80 4151 0062E-mail: [email protected]
DIEFFENBACHER ASIA PACIFIC SDN. BHD.Unit #11-02 11th FloorMenara Multi-Purpose, Capital SquareNo. 8 Jalan Munshi Abdullah50100 Kuala Lumpur, MalaysiaTel. +60 3 7490 0183Fax +60 3 7490 0184E-mail: [email protected]
DIEFFENBACHER MACHINERYSERVICES (BEIJING) CO., LTD.Scitech Tower, Unit 1305 13th Floor22, Jianguomen Wai Dajie100004 Beijing, P.R.CTel. +86 10 6522 0935Fax +86 10 6522 0936E-mail: [email protected]
www.dieffenbacher.cn
DIEFFENBACHER MACHINERY(CHANGZHOU) CO., LTD.No 18 environmental protection 1st roadThe National Environment Industrial ParkXin Bei District, Changzhou,Jiangsu 213034, P.R.C.Tel. +86 519 586 6378Fax +86 519 586 6377E-mail: [email protected]
SHANGHAI WOOD-BASEDPANEL MACHINERY (SWPM) CO., LTD.No. 299 Hejing Road, Anting,Shanghai 201805, P.R.C.Tel. + 86 21 595 77480Fax + 86 21 595 72 568E-mail: [email protected]
www.shbanji.com
DIEFFENBACHER AUSTRALASIA PTY LTD.9 Widford StreetHawthorn EastVictoria, 3123, AustraliaTel. +61 3 9813 2916Fax +61 3 9813 1195E-mail: [email protected]
* Allianz