Page 37 - MetalForming January 2011

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The die-change system includes a retractable drawbridge to span the 22-ft. gap between the die cart and press. Telescopic rigid-chain actuators combine with a gear motor to create a push-pull system that powers controlled die movement.
Tooling Technology
handle the newest dies sent to the press—huge two-piece 300-in. 100,000- lb. tools for stamping motor-home frame rails.
What the team settled on is a two- position die cart positioned at the rear of the press and outside of the operat- ing bounds of the existing automated part-palletizing carts, which accept the robot-unloaded stampings. The sys- tem (engineered and manufactured by Serapid Inc., Sterling Heights, MI) moves the dies 22 ft. between the press and die cart via a retractable bridge extension. Serapid engineered the drawbridge concept to bridge the gap between cart and press when it was discovered that the press bay lacked sufficient room behind the press to accommodate tel- escopic bolster extensions.
Serapid’s RollBeam telescopic rigid- chain actuators combine with a gear motor to form a push-pull system to power die movement from the die cart to the press. One die-cart position stages the next die to run while the second die cart accepts the previous die as it leaves the press.
70-Percent Faster, 50-Times More Precise
Die-change time now averages 60
min. from last part to first part, includ- ing disconnecting and reconnecting lubrication lines and changing out shaker-tray scrap conveyors. And, there’s no longer any need to fuss with the blank feeder or reprogram the robots. From the cell control station, a press operator triggers the completely automated die-change cycle: part-pal- letizing carts (on an embedded floor rail) and the robots move out of the way as the drawbridge indexes down into place between the die cart and the press; the old die rolls out and new die rolls in; the drawbridge raises and the line is ready for action.
What about locating accuracy? The slow, controlled movement of rolling the die onto the bolster, rather than bumping it into position as it used to, allows the machined V-groove to more precisely mate to the locator in the bolster. To take full advantage of the precise, controlled push-pull action, West had the die shop machine sharper-angled V grooves in the dies.
“In Serapid’s initial quote,” West says, “they specified die-position repeata- bility of ±1⁄8 in. In reality, we’re seeing sig- nificantly more precise location than that, more like ±0.010 in.” MF
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