Page 30 - MetalForming January 2010

George Keremedjiev has been writing this column for more than 20 years. He regularly consults with metalforming companies worldwide and provides metal- formers with training on the appli- cation and implementation of sen- sors for die protection. For more information on his seminars and consultancies, contact:
Tecknow Education Services, Inc. P.O. Box 6448
Bozeman, MT 59771
phone: 406/587-4751
fax: 406/587-9620
www.mfgadvice.com E-mail: gk@mfgadvice.com
No, it is not a typo. This column will showcase a spectacular QDC process that fully and totally achieves true QDC with one-finger control. This sys- tem was designed, developed and imple- mented at Marwood Metal Fabrication in Tillsonburg, Ontario, and is one of its superb sensor-based technologies that will be presented in this column. To place the one-finger QDC process with- in context, it is important to first under- stand the foundation upon which it was built. Namely, a superb corporate- wide and mistake-proofed manufac- turing system. Driven into a sharp focus by Chris Wood, the company president, its manufacturing culture is never sat- isfied with the status
slug detection. It now runs well at 70 strokes/min. and there is no operator standing in front of the press with their hand hovering over the E-stop button.
In Fig. 1, taken shortly before the T-89 die was retrofitted with electron- ic sensors, a micro switch short-feed detection mechanism is visible at the top. The die was thoroughly analyzed and marked up as needed during brain- storming sessions between the sensor department and the toolmakers.
Thorough sensor monitoring was implemented for short feed detection, part ejection (two sensors mounted within the dual track exit ramp as seen in Fig. 2) and slug detection with strip-
METALFORMING ELECTRONICS GEORGE KEREMEDJIEV
One-Finger Quick Die Change (QDC)
quo.
The following
comments are based, in part on remarks made by Jake Fehr, sensor applications specialist at Marwood Metal Fabrication. “Fully sensored dies lead to many great and wonderful things such as presses run- ning much closer to their maximum speeds,” says Fehr. For example, one of Mar- wood’s dies, known as T-89, a two-out die that used to run at 30 strokes/min. with an operator at full alert watching the formed metal cups exiting the die, is now fully sen- sored including the feed, part out and
Fig. 1—Die T-89 Before
This CD-ROM presents dozens of George’s columns as well as papers and exclusive new presentations covering all aspects of die protection and part-quality inspection, starting and maintaining sensor programs, the role of controls in in-die sensing, and the benefits of a sound sensor program. Order it online at www.metalformingmagazine.com.
28 METALFORMING / JANUARY 2010
www.metalformingmagazine.com
Fig. 2—Die T-89 After