“Old girl” Gets a New Lease on Life


After a complete electrical and mechanical modernization, a 50 year-old press at Meleghy Automotive is as good as new again

The experts from Schuler repaired the crown and installed new motors and drive parts.

The 1,500-ton press at Meleghy Automotive wasn’t so young anymore: The “old girl”, as the machine is affectionately referred to by the automotive supplier’s workers in Bernsbach, was built in 1968. The aging machine’s days appeared to be numbered, as last year saw teeth break off of the pinion shaft and cracks were also found in the crown and press uprights. Despite these signs of wear, Meleghy Automotive wasn’t so eager to put its trusty system out to pasture – and instead opted for a complete modernization.

“When a machine like this one is removed from everyday production operations, the additional costs quickly pile up,” says CEO Dr. Thomas Werle. This made an on-schedule completion of the extensive overhaul project even more important for Werle: “That’s why we decided to go with the original manufacturer for modernization.” As the producer of the Müller Weingarten machine, Schuler offers the necessary expertise.

The teams from Meleghy Automotive and Schuler worked extremely well together in modernizing the 1,500-ton press.

The team in charge of maintenance at Meleghy Automotive actively supported the preparation, supervision and overhaul work. In late April 2017, the experts from Schuler completed welding work on the crown and proceeded to install the new drive parts. They also replaced motors, control cabinets, wiring, and the straightener cassettes and feed rollers on the coil system.

As part of the electrical upgrades, new control cabinets were installed.

In the process, Schuler merged and updated various outdated controllers as well as the entire worker safety precautions on the machine. To ensure that system operation would be intuitive, Schuler revamped the entire visualization system. This makes both the equipping process and fault diagnostics much simpler for production employees. Since September 2017, the “old girl” has been restored to its former splendor. “A new machine also would have required a new foundation and a die modification,” notes Dr. Werle. “That’s why the decision in favor of a complete overhaul was the right one, especially since the press is basically in great shape. With the proper care, it will give us many more years of solid service.”

 

About the Schuler Group – www.schulergroup.com

Schuler is the technology and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and lightweight automobile construction. Its customers include automobile manufacturers and automotive suppliers, as well as companies from the forging, household appliance, packaging, energy and electronics industries. Schuler is a leader in coin minting presses and implements system solutions for the aerospace, rail transport and large-dimension pipe manufacturing sectors. In the 2016 fiscal year, Schuler generated sales of 1.174 billion euros. After acquiring toolmaker AWEBA and a majority stake in Chinese press manufacturer Yadon, Schuler has a presence in 40 countries with roughly 6,600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

About Meleghy Automotive – www.meleghyautomotive.de

Meleghy Automotive is a partner and supplier for the international automotive industry with a focus on producing structural components and complete body assemblies. With seven production plants and roughly 1,050 employees in three countries, the company offers extensive expertise in the areas of metal forming, joining technology, plastics technology and surface technology. It is part of Meleghy International – a medium-sized, owner-managed and internationally positioned group of companies. The group sees itself as a wide-ranging and comprehensive full-service supplier in the automotive industry. With over 100 years of history, it combines tradition and innovation. The group’s other divisions include Meleghy Engineering (engineering services) and Meleghy Innovations (research and development).