Page 16 - MetalForming December 2016

2016 Awards of Excellence
manufactures
mechanical and CNC vertslides to produce
a variety of metal and wire formed parts from simple stampings to complicated assemblies using a multitude of options such as tapping, welding, and automated assembly. Represented in North America by Gibraltar Corp.
To more efficiently streamline packaging of high-volume parts, Tella Tool & Manufacturing developed a carousel that automati- cally orients, stacks and counts parts as they exit the press.
With its automated
solution, the com-
pany can deliver
accurate part stacks
while increasing press
speed by 48 percent and
freeing two operators for
other work as only one is needed for this operation.
metal-stamping, fabrication and CNC machining business servicing, among others, the automotive, aerospace, defense and consumer-goods markets.
The original process for stacking, weighing, packing and performing in-process inspection during the stamping process required three operators. With the press running at 37 strokes/min., parts, busbars, often became tangled and twisted sliding down the exit chute, leading to press stoppages and downtime. The busbars were then required to be manually weight-counted to ensure that 120 parts/bundle were properly orientated and wrapped with interleaf paper. Finally, three bundles were placed together into a carton ready for shipment. Also, bent parts from the stacking process caused issues with automated pick-and-place equipment at the customer.
The Tella Tool & Mfg. cross-functional team brainstormed many ideas that finally led to the development of a machine called the Auto Stacker, an automated piece of equipment that orients, stacks and counts parts as they exit the press and travel down the conveyor. The Auto Stacker, designed and fabricated inhouse, includes 12 magazines situated evenly around a precision indexing carousel with cartridges engineered to wrap bundles with paper interleaf. PLCs and electronic sensors control automated indexing of magazines, timing of the servo motor and the number of parts needed per bundle.
This new process enables one operator to complete the entire stamping and packaging operation, while effectively performing in-process inspection—without having to stop the press. It completely eliminates the need to manually stack, weigh and count parts coming off of the press.
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