Service for bright bar processing lines

Spare Parts

SMS group offers solutions to minimize unplanned downtime and maintain the performance of critical components in production assemblies. They provide wear part packages, including grinding spindles, dressing mechanisms, and safety covers, which ensure the longevity of these components. Additionally, SMS group recommends stocking spare parts and pre-assembled exchange packages to enable an immediate response in case of wear or breakdown, thereby preventing unexpected production downtimes.

Repairs

An example for the expertise of SMS group is a comprehensive modernization of the WDHV 360 machine. It includes replacing all major components with new parts to restore their original or like-new condition. Updates involve a completely new control system, hardware, and software, along with new main motors and the latest rotary encoders. The machine now meets UL standards and incorporates Siemens S7-TIA technology. Improvements include modernizing the extraction carriage hydraulics to the latest standards, enhancing functionality, and overhauling the extraction carriage cylinders at an SMS workshop. Customized solutions will be integrated, as well as monitoring systems for cooling and raw diameter. The outcome is that the machine functions and delivers performance as if it were new, serving as a prime example of successful refurbishment.

Maintenance

The maintenance team installs and commissions parts within a specified timeframe, ensuring quick recovery and preventive maintenance. Additionally, complete replacement assemblies for entry guides are available. These are pre-assembled and ready for installation, enabling quick recovery of the peeler's performance and minimizing production interruptions. The replacement of guide columns, tailored to the type of peeling machine, is another key maintenance measure. These columns are pre-assembled and ready to use, ensuring immediate response to wear or breakdown and maintaining the reliability of the peeling line.

Modernizations & Upgrades

Infeed unit synchronization systems
SMS group offers several modernization solutions for peeling lines to enhance their performance and efficiency. These include the installation of infeed unit synchronization systems, which are pre-assembled and checked for quality, ready to use. This modernization helps recover the performance of the peeler and prevents unexpected production downtime. Additionally, complete replacement assemblies for entry guides are available, ensuring immediate response in case of wear or breakdown, thus maintaining the performance of the peeling machine. Furthermore, SMS group provides replacement of guide columns, which are pre-assembled and ready to use, helping to prevent unexpected downtime and recover machine performance. Safety and sound-proof covers are also offered to enhance operational safety and reduce noise during peeling operations. These modernization solutions are designed to optimize the functionality and reliability of peeling lines, ensuring they operate efficiently and with minimal downtime.

Spare parts

Roll Contours and Straightening Rolls
The manufacturing and reconditioning of rolls for straightening machines fall under the categories of modernization and repairs. These services aim to enhance the performance of existing equipment and restore worn components to their original functionality, ensuring optimal operation and extending the lifespan of the machinery. 

Training
SMS group provides comprehensive training sessions designed to impart knowledge on straightening techniques. These sessions include practical applications and guidance on setting machine parameters to optimize performance. Additionally, SMS group offers roll contour-specific pinch limit angle tables, which are instrumental in enhancing straightening outcomes. These tables help reduce surface markings on materials and ensure smoother operation of the straightening machines.

Modernizations & Upgrades

New Straightening Machine Generation (SPM)
The SPM straightening machines offer a range of modernizations designed to enhance performance and efficiency. These upgrades include the implementation of hydraulic diameter adjustment, which allows for precise control of straightening forces and gap regulation, improving the overall straightening results. The machines feature a plate construction design that enhances rigidity and accessibility to actuators, reducing oil leakage and improving maintenance. Additionally, the adaptive adjustment of entry and exit troughs ensures quick setup and fine-tuning, contributing to a smoother operation. These modernizations aim to extend the lifespan of components, reduce wear, and improve the quality of the straightened material.

Hydraulic diameter adjustment in straightening machines 
Hydraulic diameter adjustment in straightening machines is a patented technology offered by SMS group that enhances the straightening process by providing a constant straightening force through precise roll gap and force regulation. This system eliminates the need for mechanical drives to transmit straightening force, resulting in a simpler, wear-free construction. The hydraulic adjustment allows for easy retrofitting into existing WRP machines, improving the straightening results without requiring maintenance of mechanical components. Additionally, the hydraulic system facilitates a complete, ready-to-install solution that can be directly exchanged, ensuring improved straightening outcomes and operational efficiency.

Maintenance

Regular maintenance is crucial for extending the lifespan of grinding machines and minimizing unplanned downtimes. This involves routine inspections, proactive planning, and timely replacement of wear parts. The service contracts offered ensure guaranteed personnel deployments for repairs and equipment checks, contributing to the overall sustainability and operational efficiency of the machines.

Modernizations & Upgrade

Centerless through-feed grinding
Centerless through-feed grinding is a machining process that offers significant advantages over traditional grinding methods. It eliminates the need for clamping or centering the workpiece, allowing for the efficient processing of bar material and thick-walled tubes. This method supports workpieces across the entire width of the grinding wheel, enabling the grinding of very small diameters with higher roundness accuracy. The process is highly automated, resulting in higher speeds and productivity with minimal idle times, making it an efficient and precise grinding method. The RSM 60 modernization project focuses on upgrading and overhauling grinding machines to improve their performance and reliability. This initiative includes refurbishing ten RSM 60 units at the Mönchengladbach service workshop from 2023 to 2027, with plans to reactivate two additional machines. Key improvements involve removing hydraulic components for easier maintenance and integrating pre-assembled modules with Siemens motors. These upgrades have been successfully implemented in several machines, with a complete overhaul scheduled for 2025-2026. 

HMI Visualization and PLC Siemens S7-TIA
The Siemens S7-TIA PLC (Totally Integrated Automation Portal) is a state-of-the-art control system integrated into grinding machines to enhance their functionality and efficiency. It provides advanced automation capabilities, including precise control, improved visualization, and seamless integration of hardware and software components. By modernizing grinding machines with Siemens S7-TIA, operators benefit from reduced downtime, optimized processes, and enhanced reliability, ensuring the machines perform at their best.

Modernizations & Upgrades

ProConTube
A prime example of our innovative thinking is the ProConTube system, which substantially reduces copper tube eccentricity. Wherever it is installed – as part of a complete new production line or in an existing copper tube manufacturing process – you benefit substantially. That’s because every decrease in copper tube eccentricity translates into high material savings and improved cost effectiveness. ProConTube is an independent machine unit positioned directly upstream of the drawing unit.
ProConTube is based on special sensor technology integrated into the die. This continuously calculates the wall thickness distribution over the circumference of the tube as it passes through the machine. The control system immediately processes the data, then a mechanical unit upstream of the copper tube drawing unit regulates the entry of the material into the die. Plus, there is an ultra-dynamic hydraulic system that ensures fast, precise swivel motions.

Electrohydraulic Jaw Control
This service involves replacing maintenance-intensive plungers with a mechanical control block, specifically designed for copper tube production. For sensitive dimensions in copper tube manufacturing, the timing can be individually adjusted on the HMI. This adjustment significantly reduces maintenance needs and improves production efficiency in copper tube facilities.

Critical major spare parts
We recommend having ready-to-install assemblies for the core equipment in copper tube manufacturing. Typical examples include a complete main shaft with pre-assembled and aligned cams specifically designed for copper tube production. Another example is a fully assembled spare drawing carriage tailored for copper processing. Quick repairs significantly reduce unexpected production downtime in copper tube lines. SMS group can provide comprehensive lists for all copper tube production lines, detailing recommended parts and assemblies.