Page 33 - MetalForming January 2015

the firm employs at its 600-ton press. “That 600-ton press line also has a feed line with an oversized motor,” adds Bennett, “yet we’ve had some overheating issues there. So we made sure this new line has the right gear ratio and motor capacity (20-hp motor with AC variable-frequency drive) to handle heavy-gauge high-strength
work.”
AT&D already has seen benefits
from the servo-press line that have enhanced its competitiveness in the market. For example, Bennett cites a job where the press performs multi- ple hits in one die station at the bottom of the stroke, with just a 1-mm rise in the ram between hits.
“In this case we’re effectively warm- forming the part,” he says, “which allows us to eliminate preform die sta- tions. That operation is supported by the seamless and flawless integration of the feed-line controls with the press controls. In the end, we eliminate a die station so that the die is smaller, less complex and less expensive, improving our competitiveness.”
Bennett also points out the laser- based loop control feature provided with the feed line, with synchronized payout at feed rate. And, he expresses appreciation for the Dallas Profile Select feed programming function that automatically matches the speed of the feed advance to the available feed window and press-speed requirement, which can be tricky when synchroniz- ing with the action of the servo press.
“This technology allows us to min- imize movement in the loop, so that it remains consistent,” Bennett adds. “We feel this helps in consistently delivering straight, flat material to the press.”
Having Operators’ Backs
Also noted when we took a look at the new coil line was a pair of Hyper- therm plasma-arc-cutting (PAC) machines docked to the line, to allow operators to trim the leading edges of coils as needed.
“This relatively minor investment means that the press operator need not take the time to leave the press to
locate a cutting machine and move it over to the press so he can trim the coils,” says Bennett. He notes that ATD plans to eventually add PAC equip- ment to all of its press lines.
“We’re listening to what the opera- tors are telling us,” Bennett continues, “addressing their needs and letting them know that we’re committed to making their jobs easier and making them more productive and efficient.
C5091
It’s all about productivity.”
Bennett describes the firm’s pro-
duction schedules as becoming “more erratic day by day, requiring more fre- quent setups. If we’re not prepared to do that in an efficient manner, we’d be costing ourselves money. Customers won’t pay for setups, only for press run time. Everything else is added costs we must absorb, so we’re working to reduce those.” MF

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MetalForming/January 2015 31