As 1996 drew to a close, MetalForming magazine completed its 30th year of publication. Accordingly, we surveyed a number of industry experts to determine the current state of the metalforming industry, to pinpoint developments that are likely to take place in the near-term and to discover specific problem areas that will require long-term solutions if the industry is to survive and prosper.

Subject areas were selected based on an educated guess that these would be the primary segments over the next three to five years. Subject areas included in this segment of the article are: controls, government regulations such as EPA and OSHA, equipment, international, process technology, quality systems, software, tooling and training.

Controls

Kenneth R. Heindrichs, vice president - marketing, Link Systems, Nashville, TN, reports: "When it comes to press controls, the most significant advances have been in combining of clutch/brake controls, automation controls, die protection, tonnage monitoring with signature analysis, etc., into one operator terminal/modular rack combination. Information can be displayed on a liquid crystal screen. Numerous press-related data such as press speed, crankshaft angle and system diagnostics lead to quicker die setup, increased productivity and better part quality.

"Modular designs for these newer controls allow for future expansion of plug-in modules for networking and counterbalance adjustments, as well as automatic shut-height adjustments."

Ten-year old Alison Willuweit charges GM's new EV1 electric car using the Magne Charge inductive charging technology. The EV1 features a 137-hp AC induction motor. The motor is computer controlled, weighs only 150 lb. and can accelerate the car from 0 to 60 mph in less than nine seconds. The EV1 is one example of the type of technology changes that could have a major impact on the metalforming industry.

Richard T. Wilhelm, president, Helm Instrument Company, Inc., Maumee, OH, points out that, for their intended application, current controls are adequate because most, if not all, comply with the applicable OSHA, ANSI and CSA requirements. "However," he says, "the recent migration toward PLC-based (programmable logic controller) controls rapidly is changing the intended application of controls. With their open-end architecture, programming flexibility and networking capability, PLCs offer virtually unlimited monitoring and control options. This new generation of controls will improve overall machine efficiency without compromising safety. Die life will be extended and quality measures improved because the controls are compatible with the latest die protection sensors, such as position, force and vision. When networked, these controls will provide data management necessary for continuous improvement."

Bill Jones, manufacturing engineering manager, Orchid International, Advanced Manufacturing, Mt. Juliet, TN, feels that controls in use at Orchid's Mt. Juliet plant are more than adequate for their needs on a power press. "By using one press control package (Data Instrument SmartPac)," Jones explains, "we are able to integrate several functions at the press, such as feed control, die protection, tonnage monitoring, brake monitoring, programmable limit switches and safety devices. The application of these controls improves our efficiency, shows areas for improvement, improves die life and reduces die maintenance.

"The most significant recent advance is the ability to do pressroom reporting by interfacing the press controls with a PC-based software package to collect critical data from the pressroom in real time. In-die part inspection is an area that could be better integrated with the press controls," Jones concludes.

Bob Jenkins, vice president, Automation & Robotics Business Development, Orchid International, Corporate-Brentwood, TN, notes that today's controls are adequate for their intended applications. "The more frequent use of programmable limit switches, variable speed press drives (including vector drive) and PLC-based press and auxiliary equipment controls have improved the integration of automation equipment," he says. "These devices also can play an important role in determining the requirement and return on investment for equipment installed."