Page 40 - MetalForming January 2013

Tooling Technology
of-line part bins, eliminating the need for operators to walk 15 or 20 ft. back and forth to attend to the bins and then restart the line. Portable line con- trol also allows relocation of bulky elec- trical panels away from the press, pro- viding clear access for press tending and material handling.
Setup time also has been reduced through various implementations with- in and surrounding the stamping press. Link Systems’ 5100 APC (Automated Press Control) job recipe automatical- ly adjusts shut height and counterbal- ance, and controls timing for any in-die processes. The APC’s programmable limit switches control the sequence for material feed, lubrication and air thrust for part ejection. Also, all die-protection inputs are stored as part of the job recipe to monitor critical processes in the tool, eliminating die crashes and catching quality issues quickly, accord- ing to Wenzel.
The control also automatically starts and stops part-out and scrap-system conveyors, with sensors to ensure that all of these subsystems are functioning, and to halt operation should errors should arise. Control diagnostics pro- vide plain-English prompts for opera- tors. Besides directly controlling and monitoring these events and subsys- tems, the control also sends a com- mand to the coil-feed-line control, call- ing up the proper coil-line recipe.
Press Built to Reduce Setup Time
The press itself offers features that assist in setup-time reduction. For exam- ple, its roller gibbing system brings the tooling halves together precisely. And, because they run without oil, they elim- inate contamination from gib oils coating parts and creating quality problems downstream in the paint department.
Simple in-press solutions also decrease setup time. One example: An extendable CoilBridge conveyor (from Bennett Tool & Die Co., Nashville, TN) stores inside of the press columns dur- ing die changes, then stretches out to support strip making its way from the feeder to smaller progressive dies.
Tooling in Miller’s new press is held via state-of-the-art magnetic clamping technology.
38 MetalForming/January 2013
www.metalformingmagazine.com
“A long stretch of sagging material would not feed easily,” notes Wenzel. “The support removes that sag and rep- resents a simple method to ease feeding without the use of tools. Otherwise, operators would have to employ boards or other items to prop the material.”
Quick Tooling Changeout
A key component of rapid setup, die change also is addressed in the new line. Without shopfloor space for a ded- icated die shuttle, Miller uses forklifts to transport tooling. Bolster extensions enable die loading without potential damage to the press, as the lift never enters the die area. “Upon die delivery from a staging area, die lifters rise in the press bolster and the operator pushes even heavy tools smoothly and easily into the press,” explains Wenzel. “He moves the tool against integrated die- locating pins, which enable proper positioning in the press.
“Accurate positioning of the tool is a big part of rapid die exchange,” Wenzel continues. “The die must be placed in the correct location the first time and align with the feed line. If not perfect- ly aligned, technicians can spend hours struggling to achieve proper setup and begin production.”
Another feature, magnetic clamping, allows automatic clamping and unclamping of the dies in 8 to 10 sec.— much quicker, notes Wenzel, than hav- ing to walk around the press to clamp and unclamp manually. The c lamping mechanisms also operate via the main press-line control.
Part-Out, Scrap Conveyors Aid Quick-Setup, Productivity Effort
A part-out conveyor, supplied by QC Industries, Batavia, OH, and incor- porating magnets to grip and quickly eject parts, offers quick adjustment to further reduce setup time. As described in an article appearing in the June 2012 issue of MetalForming, the conveyor’s slide system (designed by Norb Kloss- ner of Tooling Innovations, New Ulm, MN, to meet TCR’s requirements) allows an operator, without tools, to quickly slide the conveyor in to reach smaller-sized dies, and an air motor provides for vertical adjustment. The conveyor slides out of the way during die change, and performs double-duty by also acting as a safety guard. Whether extended or retracted, the conveyor prevents human access into the point of operation while the press runs. Therefore, no adjustable guarding is needed. And, a scrap-handling con- veyor (via a shuffle-drive conveyor sys- tem from Mayfran International, Cleve- land, OH) includes scrap trays that slide into the press during setup. Scrap is carried up and out to a remote scrap bin.
“Personnel can change out scrap bins during production without stop- ping the press,” says Wenzel. “The underground conveyor pauses as a remote bin is rolled out and another deposited in its place. This not only keeps the press running as much as possible, it also reduces setup time.”
MF