John Walas, manager, product and solutions group, Komatsu, points to how automation, specifically cobots, allow stampers to perform some processes in a stamping press that cannot be done with human operators. Case in point: perforating a solid tubular part while holding it in proper position as work is performed.  

“Stampers can form features on parts that we never thought were possible, such as going from a blank die to a spline part in a stamping press rather than in a machining center,” Walas says. At its FABTECH booth, Komatsu demonstrated how the use of cobots tending presses allows for the greater use of servo technology. “Not only do cobots keep operators out of the hazardous areas, they can work with the parts in the presses to make things that we couldn’t do before,” Walas says. He points to a tubular spline in which a servo press’ ability to slow at bottom dead center prevents what he calls “mushrooming,” or deformation, and allows for forming features such as perforations. 

“We’ve been talking for years about how servo technology has changed the stamping industry,” Walas says. “We’re making parts that we never thought were possible, such as perforating already-formed tubing. Once the tube is clamped into the press, the cobot rotates it around for perforating and punching. Then the operator can unload it and load another one.”

Previously, a full automation cell was required to perform that operation. “Now, metal formers can use a system that’s easy to program and set up, and which will interact easily with the press,” Walas says. “Automation is taking us into the future of manufacturing.” 

Stuart Cordrey, vice president of sales, Colt Automation, says that stampers have been asking the company to automate more of the feed-line components and processes, including coil threading. Feed-line processes include loading of the coil from the car into the correct location on the uncoiler and centering it; feeder and straightener material guiding; straightener entry guiding, pinch-roll adjustment and roll adjustment; threading-table adjustment and pass-line height adjustment on the feeder. “We’ve noticed recent trends specifically around automating the feed line for increased efficiency—without taking our eyes off of safety,” Cordrey says. “What was a very manual process is becoming more and more automated. Today we can do complete auto threading—a popular customer request. 

“With the use of a programmed, permission-based recipe built into a job number, we can automate all of those adjustments,” he continues. “A variety of sensors and encoders take over the intelligence of the feed line. Instead of manually adjusting coil centering, guiding and the straightener roll, the operator can just enter a job number or recipe to automate those processes on the feed line. The leading edge of the coil goes right through the feed line to the press entrance, and then the operator simply can put the feed line into auto mode. This reduces coil changeover time and eliminates the manual adjustments on the feed line.” 

Tim Wilson, engineering/operations manager at Greenerd Press and Machine, says that metal formers are adding more sensors and more capabilities to their automation systems to enhance their ability to troubleshoot pressroom problems. 

“A lot of that need occurs when our customers have senior maintenance personnel retiring or have a single-point individual who is the only one who knows how to maintain the equipment,” Wilson says. “By adding more sensors, more feedback and more diagnostics to the equipment, we can alert operators to problem trends such as tool wear. By having hundreds of fault signals to pinpoint problem areas in the press rather than dozens or a generic error code, we’re finding that this greatly helps find the source of a problem.” 

Jim Finnerty, product manager, Wintriss Controls, says that the company’s new automation-development efforts—its WPC Apex press control and Shadow 10 safety light curtain—focus on safety. The Apex bridges the gap between a basic clutch/brake control and a full-blown SmartPac Pro integration. The Apex clutch/brake control incorporates automation-friendly features such as programmable-limit inputs, setup memory, and a large, color touchscreen interface while also being OSHA/ANSI-compliant.

Designed specifically for metal-stamping applications, the Shadow 10 safety light curtain ensures worker safety without hurting productivity. As many as four light-curtain heads can connect to one control box to provide front and back guarding with pass-through protection. Red LEDs indicate which beams are blocked and aid in alignment. The receiver displays a fault code when a light curtain triggers lockout, allowing stampers to identify the lockout reason and affected light curtain.

And, its unique three-beam floating blanking allows air-ejected parts to pass through the light curtain without initiating a nuisance stop.  Its self-learning feature allows the user to quickly program fixed blanked areas.

Adam Nordmeyer, sales manager, Bihler America, relays that the company’s automation efforts have centered on moving fourslide presses forward using servo technology. “We’ve integrated servo technology into all of our mechanical multi-slide machines, including the traditional mechanical fourslide,” Nordmeyer says. “The advantages are speed, quick tool changes and efficiency. Servo technology offers the metal former the ability to have incredibly quick changeovers on our 4 Slide-NC, and it also provides the ability to really dial in machine movements to increase speed. Users experience a dramatic increase in efficiency on the machine and the process.” The company can adapt most mechanical fourslide tooling for use on its 4 Slide-NC machine as well.

Stefan Knudsen, sales manager, AP&T, cites the labor shortage, safety concerns and a need for flexibility as drivers for pressroom automation. “The labor market has become increasingly competitive,” he says. “It is difficult for companies to find workers to load and unload the presses. Automation takes that risk out of the equation.”

Safety always is a concern, he adds, more than profit. “It’s not always the speed of the automation that matters; some of the parts are too heavy to be operated manually,” Knudson offers. “Having light curtains and guarding in an automated setting makes it much safer for operators to operate the presses than having workers load the press directly.” 

Finally, stampers have a lot of old equipment in their factories, and they are ready to replace or rebuild, according to Knudsen. “Automation always is part of that discussion,” he says. MF

See also: Greenerd Press & Machine Co., Wintriss Controls Group LLC, AP&T North America Inc., Bihler of America, Inc., HMS Products Co.

Technologies: Coil and Sheet Handling, Pressroom Automation, Sensing/Electronics/IOT

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