Page 24 - MetalForming July 2015

Die Protection
Place proximity sensors, so that the possibility of sensor damage is minimized should material or a tool locate out of position.
sensor will stop the machine only when a real problem is present. ‘Plug it in’ should be the only task for the setup per- son. A properly bench-tested sensor should be installed so that it will never have to be moved or adjusted. While an adjustment might come in handy initially, adjustability becomes a liability once the sensor runs correctly.
Moving sensors from die to die. New sensor users may try to save money by purchasing a part-ejection sensor with the intention of moving it to various dies as needed. In the end, this practice does not save money, and often leads to nuisance stops and damaged tooling. Select specific sensors for spe- cific dies and leave them in place. You’ll avoid the expense of additional sensor-related setup time and the pitfalls of adjustability. Also, sensors moved from die to die tend to be compromise choices that can be shoehorned into many applications, rather than providing an ideal solution tai- lored to meet the exact needs of each application. And, sup- pose that the sensor you need is already in use on another die. Do you run without protection?
Requiring too much precision. Though desirable, a high level of precision is not always needed when installing sen- sors in the die. For example, with a bit of bench testing one could easily install a proximity sensor in the die to detect a strip misfeed of as little as 0.0005 in. But this almost guar- antees ongoing nuisance stops because such a level of pre- cision is unobtainable in most production environments. If you determine that the pilots can align the strip when it is misfed by ±0.010 in., then install sensors so that they won’t signal a stop unless the strip misfeeds by more than 0.010 in. This provides the setup person and equipment enough wig- gle room to keep the process running while still protecting the die from misfeed damage. MF
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