Fully automatic press systems

WICKERT supplies fully automated press systems for calibrating and hot bonding friction discs – with maximum precision in temperature control in the tool and exact geometric tolerances. This accuracy not only has a positive effect on the bonding of the friction layers to the steel carrier, but above all improves the thickness variance of the entire friction lining.

Essential grooves for oil guidance, as required for oil cooling in wet multi-plate clutches, can be embossed directly in the process with sufficient power reserve. This eliminates the need for time-consuming post-processing or segmented application of the friction pads.

Another advantage is the consistent traceability of all production and process data. These are seamlessly transferred to the customer's higher-level MES systems via modern OPC UA interfaces – fully integrated into the WICKERT control system.

Upstream processes such as thermal straightening or sinusoidal wave forming of the carrier discs are also covered by WICKERT technology. The systems also include heat treatment furnaces and ergonomically designed assembly and disassembly stations with fully automatic locking and opening units for carrier lamella stacks.

The use of sinusoidal friction discs also helps to reduce drag torques in the clutch – and in many cases enables a more compact design of the entire disc pack.

Using a modular system, we can offer presses with the appropriate pressing surface and pressing force for all conceivable friction lining sizes.

The presses themselves can be operated manually or with the appropriate automation concept in nested bonding with multiple cavities to achieve the desired output quantity.

A single-plunger system in the multi-cavity design of the presses guarantees an individual stroke per tool, thereby achieving the greatest possible precision in the tool, which, with a high component output of the system, also results in only a very small thickness variance per lamella. The drive concept of the presses is a benchmark in the application, because in addition to outstanding performance in terms of speed when opening and closing as well as pressure build-up and release, the energy requirement during the bonding time is reduced to a minimum, which means energy-optimized production. The same applies to the design of the servo-driven automation.

In addition, our systems can be integrated directly or decoupled into the upstream and downstream production processes, such as a connection to the automatic test cell after hot bonding or before bonding in an inline chain.

To this end, we have the right automation solutions with transfer and handling systems or cycle time-decoupled component magazines Preheating

To this end, our product portfolio includes suitable automation solutions with transfer handling systems or cycle time-independent component magazines, preheating stations for the friction discs to be bonded, press loading and unloading systems, and suitable conveyor systems.

In terms of availability, care is always taken to ensure that the gripper systems are setup-free or that automatic tool clamping guarantees the shortest possible setup time.

Preheating stations also allow preheated tools to be replaced. This reduces the heating time in the press and thus contributes significantly to increasing plant availability.