11.3.2025 / 5-minute read

Automatisierte Stahlplatten-Wendemaschine | 180° Flip-Lösung für Stanzlinien

Übersicht

This case study explores how an Automated 180° Plate Turnover Machine (also known as a Steel Plate Turner) resolved critical bottlenecks in a high-volume stamping line.

By automating the flipping of large, delicate sheet stacks, the solution dramatically reduced surface scratches, slashed labor costs, and increased overall line throughput by over 20%, delivering a full ROI in under 18 months.

Grundlegende Parameter

Modell	B21-FZ03T	B21-FZ05T	B21-FZ10T	B21-FZ15T
Kapazität	3 Tons	5 Tons	10 Tons	15 Tonnen
Motorleistung	1.5 kW	2.2 kW	2.2 kW	3.0 kW
Drehgeschwindigkeit	30s ±10%	30s ±10%	40s ±10%	40s ±10%
Tabelle Größe	800–2500mm (Customized according to workpiece size)	800–2500mm (Customized according to workpiece size)	800–2500mm (Customized according to workpiece size)	800–2500mm (Customized according to workpiece size)
Antriebsmethode	Mechanical drive or hydraulic drive	Mechanical drive or hydraulic drive	Mechanical drive or hydraulic drive	Mechanical drive or hydraulic drive
Table Shape	① A-flat/B-flat surface ② A-flat/B “V” saddle surface ③ Customized surface	① A-flat/B-flat surface ② A-flat/B “V” saddle surface ③ Customized surface	Customized surface	Customized surface
Betriebsart	① Pendant control ② Wireless remote control ③ Control cabinet buttons	① Pendant control ② Wireless remote control ③ Control cabinet buttons	Control cabinet buttons	Control cabinet buttons
Eigengewicht	1.5T	2.0T	2.5T	3.0T
Abbiegewinkel	90° / 180° / 360°	90° / 180° / 360°	90° / 180° / 360°	90° / 180° / 360°
Stromversorgung	380V three-phase four-wire 50Hz	380V three-phase four-wire 50Hz	380V three-phase four-wire 50Hz	380V three-phase four-wire 50Hz

Herausforderungen

Product Damage: Manual handling with cranes and slings inevitably caused surface scratches and scuffs, leading to high rejection rates and costly rework.
Labor-Intensive & Unsafe: The process required multiple operators for a physically demanding and hazardous task, posing a significant safety risk.
Production Bottleneck: The slow, inconsistent flipping cycle created a major pacing issue, limiting the output of the entire automated stamping cell.
Incompatible with Automation: The manual station could not integrate with the plant’s MES, creating a data black hole.

Unsere Lösung

Automatic Loading & Positioning:
- The upstream conveyor transfers the sheet stack into the turnover machine’s open infeed section.
Secure Hydraulic Clamping Sequence:
- Upper/Lower Cylinders actuate to drive clamping plates, securely pressing the stack from the top and bottom.
- A subsequent rear cylinder drives a backstop plate forward, completing a three-point fixation process that firmly holds the stack without distortion.
Precision 180° Rotation:
- Eine AC motor coupled with a high-torque reduction gearbox drives the entire clamping assembly through a smooth, controlled 180° rotation.
- The robust mechanical design ensures perfect alignment and eliminates any risk of sheet slippage.
Automatic Unloading:
- After the flip, the clamping cylinders retract, releasing the stack.
- The now-flipped stack is automatically transferred onto the downstream conveyor, ready for the next operation.
Seamless PLC Integration:
- The machine’s PLC synchronizes perfectly with the main production line controller, ensuring a continuous, uninterrupted material flow and providing real-time status updates to the MES.