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Automated adapter production for water systems
The task at GF JRG
A production plant manufactures adapters for the sanitary sector, which connect multilayer composite pipes with fittings, sleeves, or valves. They consist of a plastic body with O-rings for sealing and a precision-manufactured threaded connection that is screwed in. This creates a reliable connection for water systems. Until now, this process was carried out pneumatically. GF JRG has now switched to a special machine from Soldati AG, achieving improvements in energy efficiency, maintenance requirements, and process precision.
Special machine construction by Soldati AG
The system was developed and built by Soldati AG, an experienced Swiss special machine manufacturer. The focus was on a compact, flexible, and sustainable solution for the production of large quantities.
Engineering & implementation of the servo press by Parkem
A Parkem flexiPRESS servo press solution with 2.5 kN pressing force is used for the pressing process. Parkem carried out a feasibility analysis with in-house tests during the project phase. In particular, the force-displacement curves of various components were measured and the pressing process was optimized according to the following criteria:
- Fast approach to target forces without force overshoot
- Achievement of high cycle rates
- Ensuring precise evaluation despite variable starting positions
In addition, the entire Profinet mapping between the higher-level Siemens control system and the servo press was defined and implemented by Parkem.
Based on the proven ecoPRESS servo press, we used the flexiPRESS for this project. With its greater installation versatility and flexibility, it offers exactly the features that were required for the special specifications and unusual installation conditions.
The flexiPRESS is equipped with an HMI control panel, which can be used to teach new adapters and save their process parameters during setup. The higher-level Siemens control system retrieves these parameters via Profinet and starts the respective process. The pressing operations are executed and evaluated in the flexiPRESS control system, while the current status is reported back to the Siemens control system via Profinet.
A central element is the integrated recipe management: The envelope curve of a new adapter piece can be created automatically using the teach function, adjusted manually if necessary, and then saved as a recipe. This allows the appropriate parameters to be called up at any time.
Envelope curve monitoring ensures that each press-in process along the press-in path remains within the defined minimum and maximum values – a decisive contribution to process reliability and consistent quality.
In addition to defining and parameterizing the servo press, Parkem also took care of commissioning and training on site. This ensured that the system could be used reliably right away.
The result
Parkem's flexiPRESS servo press has contributed significantly to the realization of a compact and efficient special-purpose machine with high quality and process reliability. Previously, GF JRG relied on a pneumatic solution. With the electric servo press, GF JRG now benefits from greater energy efficiency, sustainability, and significantly reduced operating and maintenance costs. In addition, adjustments to the function or cycle can be made at any time.
Soldati's collaboration with GF JRG and Parkem in this project impressively demonstrates how expertise and partnership-based cooperation lead to sustainable success.