Zdas CKW Forming machine 1

ZDAS Open Die Forging Equipment
The production of open die forging equipment is one of the areas where Žd as achieved a great success during the last years and is considered as a top manufacturer of such type of the equipment world wide. This fact was proved by deliveries of open die forging equipment to countries. The integrated forging unit with CKW 1800 t open die forging press, QKK 12 t rail bound manipulator and ingot bogie was put into operation in German company Edelstahl Leuna. The unit is designed to forge bar, shaft, ring, bush, flange and other types of products. The press is provided with both-sided tool
slide, bottom tool magazïne and tool changing system enabling its 
universal technological utilisation. In the upper and bottom swaging
tool body there is a structural steel insert with welded on layer that
significantly extends service life of the swage. The press and manipulator are working as an integrated forging unit where all movements of both machines are interconnected. The complete unit is controlled by one operator from the common control panel. 
0п the top of forging units delivery, the ŽĎAS company realised also
delivery of individual forging manipulators of various sizes. The QKK
35 t rail bound manipulator was supplied to an English customer and
the QKK 8 t manipulator to 1ta1y. One of the manipulators was inśtalled
in the company forge as a part of reconstructíon of the existing 1800
ton open die forging press also manufactured by ŽĎAS, The possibility to realise and verify the latest knowledge of equípment design on deliveries for the own forge is a large competitive advantage of ŽĎAS, that also improves reliability of the equipment at the customers. ŽĎAS does not only supply new machinery, but also takes part in reconstruction and modernisation of the existing presses. Most of these projects are realised in countries,
Example of lntegrated Forgíng Unít Design:

1 CKW 3300/4000 forging press
2 QKK 35 forging manípulator
3 QKK 15 forging manipulator
4 QHZ 40 rotary lífting table
5 upsetting table

New Generatíon of Open Díe Forging Presses
During innovation of the machinery in the ŽĎAS opeп die forge the old push down press 1000 t was replaced with a brand new CKVX 1250 opeп die forging press. This press of a new generation meets all the conditions of the effective production of high quality forgings with a close tolerance range. This is the push down single cylinder open die forging press of the modern two column design. The press is equipped with the longitudinal travel, four position linear bottom tool holder and the upper tool and tool holder
hydraulic clamping device. The press together with the rail bound forging manipulator QKK 8 form a fully integrated and automated forging unìt.

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The original workplace with the older press was enlarged by a modern complex with ŽĎAS baling workplaces. The baling workplaces are interconnected by means of a pneumatically operated dumping chute. Sheet scrap from pressing shops is transported into the dumping chute at the baling press by means of a system of conveyors. The scrap slides from the dumping chute into the dosing and weighing device hopper. The hopper is also pneumatically operated. A dose of the scrap is weighed precisely so that the specified tolerance of the length of bales is maintained. Then, during three independent operations, the scrap is successively compacted into a rectangular parallelepiped-shaped bale and ejected into the bale outlet. The last operation, the pressing device, is equipped with a linear length reader. It can be successfully utilized if the customer requires a specific tolerance for bale length. The string of bales is led through the outlet chute, under the conveyor, and into the conveyor from the other side. Reverse movement of bales is prevented by a reverse fuse placed on the press before the outlet. On the other side of the conveyor is an optical sensor illuminated barrier that prevents the next bale from slipping out in case of an obstruction on the conveyor. Based on the customer’s requirements, the bale outlet was complemented by an emergency switch as an alternative way of bale removal.

The hydraulic drive is placed 1 meter away from the press. The basic part of the hydraulic drive consists of two engine-pump sets and a distribution box. It is equipped with a water cooler. The drive is covered by a noise-resistant casing and four ventilator fans are placed in the ceiling as part of the overpressure filtration and ventilation. The drive cover is unit-built. It consists of a secured steel frame and easily withdrawable damping panels so that each part of the drive is accessible for maintenance and service.

The movable parts of the press are equipped with protection grilles preventing any potential injury to personnel. Entrances into the area behind the protection grilles are safeguarded by indicators built into the door bars. In case of the entrance of unauthorized persons, the entire equipment is automatically stopped.

The cycle time for compacting one bale is up to 31 seconds. The pressing shop operates on 3 shifts. An average of 1,000 bales are compacted per day, with a 200 kg bale resulting in 200 tons per day compacted. At present, the efficiency of the line is 50%. With a sufficient scrap supply, the press is able to process twice the amount of scrap.

Delívery of the CPS 320

 Presses for Automobiie
ŽĎAS has 1ately delivered three complete, fully automatised units
of CPS 320 baling presses to the demanding market of the leading European automotive factory VOLKSWAGEN. Two work-places in VW Wolfsburg and one in VW Hannover are concerned. Brief description of the workplace in Hann e o r v :

Overall view of the line
lnterior of control cabin
Output of finished bales
Computer model of CPS 320 baling press for VW Hannover
Offer of Meta1 scrap Processíng Equípment
amortisation and processing CPB 100, CPB 200 baling presses

metal scrap
metal scrap from pressing shops CPS 160 and CPS 320 baling presses
amortisation and processing metal CPS 630, CPS 1000 and CPS 1250 baling presses scrap, especially for metal scrap CPB 400, CPB 630 and CPB 1000 baling presses
treatment works
light bulky metal scrap CPM 140 - mobile baling press
light bulky metal scrap CNS 630-S shears

CNS 400 K container shears
CNS 320 K container shears
bar scrap CNS 320 KK container shears with hydraulic gripper
heavy bulky scrap CNS 800-CV shear, 1250-CV shear
and 2000-CV shear
cutting - mainly bar material CPNM 400 mobile baling and cutting press
baling and cutting CPN 400 baling and cutting press
of the bulky dimensional scrap
CNS 400 K and CNs 320 K Contaíner shears
These container shears represent quite a new concept of the hydraulic scrap
shear driven with diesel engine. The horizontal movement of the blade sledge holder with the original solution of the scrap transversal compacting without any auxiliary mechanism has been patented. The effect of this solution lies in simplicity of design with the possibility to cut a large bulky scrap, car bodies.
The closed design of the shear with the container connecting elements enables easy transportation of the entire equipment on the trailer. The scrap charging in the shear can be done remotely by the loader operator who is the shear operator at the same time.
Technological process
The ŽĎAS employees realised the second general repair fn compaпy SHADE, Blatná.
The table and síde battens of Müller press were repaired and re-ground. The slide, that
now meets the European standards, was
completely refurbished, the hydraulic drive
was upgraded, hydraulic cylinders and
pumps were replaced as we11 as cooling and
fíltration circuits. The repair included also
new electronic controls with safety features.
ŽĎAS completed another repair of the larger
press of sMG-HPZUX 500 type at the same

machines 
customer already earlier.
The both presses are used for production of
caг body panels for such automobile com-
panies as Volvo, Mitsubíshi, Ford, Audi and
ŠKODA. in the end of 2002 the ŽĎAS s
specialists finished an exactíng reconstruc-
tion of the pressing line in the lndian factory
Ambajhari.

Modernization
of older equípment
Machines

ZDAS for Nuciear Industry
The equipment for the secondary nuclear waste processing - the HDP 2000
press - ensures compacting of the waste in barrels into briquettes. The waste is transported in the barrels directly to the shop whrere the press is located. The equipment that loads the closed barrel into the press working area perforates the air openíng ín the barrel, enlaces the barrel and compacts ít with the slide force. The compacted barrel is moved out of the working area and ít is measured in the despatch area. The entire workíng cycle is automated and carríed out in cycles or in parts of the cycle. The equipment was made as per the documentation of the German company Nukem.
Hígh Pressure Food
Processíng
The ŽĎAS, produced the cYX isostatic press for food processing for purposes of new technological processes in food industry.
it is a completely new technology of non thermal food treatment
г under high isostatic pressure ensuring high utilisation of product
quality. it enables to maintain quality parameters smell, colour,
vitamins, active biological substance practically identical wíth their content in fresh products. This technology of non-standard food processing can be utilised anywhere the customer requires maintaining the natural product quality for a long time while beíng stored either at the room temperature or in the refrigerator only. Utilisatíon of high pressure is supposed also
for shelf life increase of pharmaceutícal or cosmetic specimens.
- for automotive industry

lnvention and production of the car nowadays represents one of the greatest technicai phenomenons. It concerns a very wide process comprisíng hundreds and thotasands of indívidual technical steps and operations. You can meet the ŹĎAS brand name at various world producers during this process.
The basic semí-product for production of automobíle car bodíes ís a coil, eventually a sheet. ŽĎAβ Company produces a number of lines for slitting, cutting-to-length as well as combined dívision of coils for treatment of the sheet being supplied with dífferent surface fínish. Long-time references rank ŽĎAs among the leadíng
European manufacturers of this equipment.
lnitial semi-products for the very stressed components of the automobile aggregates are the dìe forgings beíng forged hot or cold in the die forgès. It concerns mainly the production of crankshafts, pistpn rods or vałves for automobiles.
These components are forged ín the large series in the fully automated lìnes. For a these technoiogies, ŽĎAs delivers the individual crank, screw or hydraulic presses with dífferent automatìon and mechanisation levels as well as the fully automated lines.
Iп the field of pressing of car body parts, the ŽĎAs s products result from the
C long-time cooperation in production of technological units or their parts, but also from repaírs and modernisations of the indívídual mechanical or hydraulíc presses or línes of various producers almost from all over the world. Hıgh-volume productíon of several hundreds of car body parts also requires a large number of press tools. Here the customer can meet the products of the ŽĎAS tool shop again.
During the automobile production much like on termination of its service dife, both the producer and the final user of the car have got worries wíth the metal scrap.
Therefore, ŽĎAs produces a wide range of equipment processíng thís scrap
material in the individual production phases or dísposíng the respectíve worn
product. Cuttings from the car body pressing lines are processed in the balíng presses, metal chips from the machíníng shops are compacted in the bríquettíng and the closed cycle of the automobifë service life ís beíng terminated in the presses for metal scrap balíng ar shearing.
of the supplied equipment
Equípment for the automotíve índustry
Foreígn Countríes
China Forging unit with LVE 250 screw press - forging of valves of internal combustion engines - 2002
lran Forging units with LVE 400 screw press - forging of valves of internal combustion engines - 2000, 2002
Germany/China Press tools for SCHULER - projećt of VW Polo production in Shanghai - 2002
Germany Press tools for GED1A Attendorn - 2002
Germany Fully automated workplaces of CPS 320 baling presses - 3 pieces - metal scrap processing
- for VOLKSWAGEN - 2001
Germany Complete assembly of 3 large hydraulic presses for car bodies for SMG SCHULER - 2001
Germany/Spain Delìvery of 5 lower cross beams, 5 slides and 5 run-out tables for the SCHULER TBS 6450 press
- project of OPEL Zaragoza - 2001
Sweden Mechanical press LKDR 315 B- pressing of car parts - 2000
Poland Hydraulic press CTUA 2500 - pressing of long sheet metal parts for automotive industry - 2003
Germany Mechanical press LKJP 400 - for Sćhöneweiss GmbH - 2005
Czech Republíc
ŠKODA AUTo. M1adá Boleslav - Selection of projects
- Repair of 1 mechanical press PKZV 1250 t heavy line and MECFOND press line 21 - from 2000 to 2003
- Repair of the 1P 2000 injectíon moulding machine foundry - 2002
- Removal of car body presses tool shop - 2002
- Press tools for production of a new car - 2002
- Modernìsation of the PKZV 1250 t press tool shop - 2001
- 2 Fully automated workplaces of the CPS 320 baling presses metal scrap processing - 1999, 2000
- Overhaul of the BL1SS press line 6 - 2000
- Repair of the BL1SS 800 press İine 3 - 1999
- Complete oi1 system of the new pressing shop - turn-key delìvery - from 1999 to 2000
- 12 lower cross beams tables and 24 run-out tables for 2 SCHULER TBS 5900 presses including complete assembly - 1998
- Repair of 6 PKZV 500 t presses line 24 - 1996
- Assembly and maintenance work in the pressing shops - from 1996 to 2005
- Brìquetting line 8 t/hour - 1990
- Repairs and maintenance of the briquettìng line - from 1996 to 2005
- 1 mechanical press DBS 1000 and 5 mechanical presses EBS 800 line 26 - from 1992 to 1993
- Modernisation of the PKZV 1250 mechanical press tool shop - 2004
TRW-DAs Dačíce
- Forging unit with LVE 250 screw press - forging of valves of internal combustion engines - 2002
- Forging unit with LVE 400 screw press - forging of valves of internal combustion engines - 1997
Benteler Chrastava
- 2 Hydraulic presses CYAB 400 - hot pressing of sheet parts for automotive industry - 2002
Ríeter Elítex Choceñ
- Hydraulic press CYA 1800 - pressing of plastic covers for cars - 2001
- Hydraulic press CYA 500 - pressing of car body insulating pads - 1999

Nlagna Cartech České Veleníce
- Repair of 5 presses PKZV 1 800 Erfurt - pressing of sma11 parts for automotive industry - from 2002 to 2003
ŕ Barum Contínental Otrokovíce
о - Overhaul of 1000 t tyre curing press - 2001
- Overhaul of HVL 8520 tyre curing press - 2003
о Autopal H1uk
ŕ - Mechanical crank press LKDR 200 B- pressing of radiator parts - 2001
D
Kovovýroba Hoffman Ostrožská Nová Ves
Q - Overhaul of the HPM 1000 press - pressing of sheet parts for automotive industry - 1999
- Repair of PKZZ 1000 press - 2000
Hayes Lemmerz Autokola Ostrava _
H - Overhaul of VERSON 3000 t press - pressing of wheel disks - from 2000 to 2001
- Overhaul and modernisation of TP 2500 press and mechanísatíon - pressíng of wheel disks - 1998
- Overhaul and modernisation of TP 2500 press and mechanisation - pressíng of wheel disks - 2005

Lι Other projects dísmantling, assembly, removal, etc.
Germany Dismantling of 5 presses PKZZ 315 and PKZV 500 in TOWER ZWICKAU - 1999

Slovak Republic Assembly of these presses in TOWER Malacky - 2002
Z
Slovak Republic Permanent maintenance and repairs of the presses in TOWER Malacky - since 1995
 Czech Republic Dismantling of 6 presses in ŠKODA M1adá Boleslav for Comault 1ta1y - 1999
Czech Republic Disassembly of 5 presses in ŠKODA M1adá Boleslav for RESA Spain - 2000
о- Czech Republic Removal of 6 hydraulic presses SMG 630 and 5 German crank presses 600 t GREBENER
for WAGON Bë1á pod Bezdězem - 2000
D Czech Republic Dismantling of the complete cold pressing technology in the company Neumeyer Nürnberg
Germany, incl. presses SCHULER, E1TEL, KRUP total weight approx. 1100 t . Assembly of the complete technology in the company Neumeyer Oslavany Czech Republic - from