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The scope of the article is to describe the automated production of a thlxoformed steel part. The production plant was set up within a prototype initiative at the Institute of Metal Forming in cooperation with the Institute of Automatic Control of RWTH Aachen University and Industrial partners. Preliminary experiments showed that the quality of the formed parts varied to a great extent due to changing production conditions since the handling of the billet was carried out manually. To eliminate the possible disturbances introduced by the manual handling of the billet, an automation concept has been elaborated in order to guarantee a defined production environment. An industrial robot (KUKA) fulfils the handling tasks like the feeding of the induction coil with the feedstock material and the placing of the heated billet into the hydraulic press. The removal of the formed part from the press Is realised by a simple mechanical device in order to be able to use only one gripper. The design of the gripper ensures a minimal heat loss during handling. The induction coil, the gripper system and the cavity are flooded with inert gas in order to prevent scaling. The sequence control for the production of a part is realised on the controller of the robot which provides sufficient PLC functionality and can be easily equipped with the required I/O components to trigger the different automation components.

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