Page 23 - MetalForming January 2011

conveyor allows us to manage the end of the line with only two operators rather than four.”
Lastly, Thomas showed us a pair of Aida four-press tandem lines in the plant, which stamp exhaust-system components, recently upgraded with new robotic transfer systems. The lines initially were set up with a robot between each press; presses would run intermittently, stopping to await trans- fer movement. The new robotic trans- fer setup on each tandem line employs a common feed bar that runs the length of the line. In addition to dramatically reducing each line’s footprint (since Newman was able to locate the press- es closer together), the presses now run continuously—during each trans- fer cycle, the feed bar tends to all four presses.
Thomas explains that the produc- tivity gain—line speed has increased by as much as 8 strokes/min.—was criti- cal to meet new exhaust-stamping pro- duction requirements. The new model
Common feed bar
One of Newman’s two four-press tandem lines, which stamp exhaust-system compo- nents, illustrates a new robotic transfer system that employs a common feed bar run- ning the length of the line. In addition to dramatically reducing each line’s footprint, line speed has increased by as much as 8 strokes/min.
exhaust systems take all laser-welded components, Thomas explains, which required Newman to completely redesign its stamping procedure.
“Laser welding the exhaust-system stampings (rather than arc welding) requires much tighter tolerances on part dimensions,” he says, noting that tolerances are now +0 and –0.2 mm,
compared to ±0.5 mm before. “Meeting the tighter tolerances required not only an entirely different approach to die design and build, but also forced us away from two-out stamping to a more controllable and repeatable one-out process.”
Hence the desire to increase line speed via the new robotic transfer system. MF
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