CROSSBEAM SYSTEMS

Overview

CROSSBEAM SYSTEMS produces fully automated production lines for cross-members made of aluminum extruded profiles — from the bar stock to the finished component. The key parts of the system are a forming and stretch-bending system, machining systems, and an in-line inspection station, and possible extensions such as a heating station, embossing stations, or assembly stations (e.g., for setting rivets, welding applications, or applying adhesive) can be integrated. Raw profiles are fed either in finished length or cut to length in the system; a handling system unstacks profiles in layers, separates them, and indexes them through the production line. Depending on the alloy or tempering state (T4, T6), the profile can be heated before forming, and the forming process can be performed by hydraulic press or servo-driven stretch-bending machine. Additional operations such as embossing or punching can be performed, followed by mechanical machining operations (milling, drilling, and deburring), assembly operations (rivet setting, mounting/welding/gluing of add-on parts), in-line quality inspection of bending contour, length and drilled-hole position/presence, and automatic labeling and placement of OK components in transport containers or output racks. Machine data: Cycle times: 18 6 30 s/piece, depending on design. Component length (mm): 800 to 2,000. Component cross-section (mm): approx. 40x40 to 200x100. Electronic controller: Siemens Simatic S7-1500. Features include a fully automated process chain for low personnel costs, servo-controlled feed and positioning axes for precise production, innovative handling concepts for indexing and repositioning, tool technology tuned to individual operations, short resetting times on type change via quick-change systems, and a manufacturing concept tailored individually to meet customer requirements. Manufacture of complex bumper bars and other cross-members from aluminum extruded profiles in short cycle times (18 6 30 s/piece, depending on design). Provision of a complete, in-line process flow from bar stock to finished component including feeding/cutting, optional pre-heating for alloys or tempering states (T4, T6), forming by hydraulic press or servo-driven stretch-bending, secondary operations (embossing, punching, milling, drilling, deburring), assembly steps (rivet setting, mounting/welding/gluing of add-on parts), in-line inspection of bending contour/length/hole position and presence, labeling, and automatic stacking or placement into transport containers or output racks.