Page 29 - MetalForming January 2016

en the load on the more sensitive mate- rial, such as aluminum, or on thinner sheet, helping to eliminate marking or waving of the material.”
The feed systems also include seven-roll straighteners (3.5-in. roll dia. on the prog-press line, and 4.2-in. roll dia. on the transfer line); laser- based sensing to track coil OD in real time and automatically adjust roll/ brake pressure as the coil depletes; automatic coil centering; and (on the transfer press) an 8-ft.-deep looping pit to ensure smooth, consistent material feed, “especially critical when stamping Class A parts,” says Long.
Lastly, as yet another example of flexibility at its finest, the feed setup for the progressive-stamping line features a specially engineered end wheel to hold down strip as narrow as 1 in.
With its relatively high-mix low-vol- ume (1500 to 80,000) production plan, quick changeover obviously becomes critical. Long estimates that the press- room spends 12 hr./week in die
changes, and has plans in place to reduce that by half and open up addi- tional capacity. Plans include adding a second rolling bolster to the transfer press, which is equipped with quick- pull quick-change transfer tooling; on the progressive line, an Atlas die- change system moves dies in and out in 7 min.
Automation Outside of the Pressroom
The robot count at QMC is high— 84 robots spread over 12 production cells, performing a wide range of oper- ations including resistance welding, scribing, sealing, press-brake form- ing and riveting.
“Our production cells are more than just about high-volume part produc- tion,” says Long. “They’re finely tuned processing cells engineered with the flexibility required to take on new assemblies with quick programmabil- ity and turnaround.”
We spied, for example, one cell fully
automated with one robot manufac- turing nine variations of an automotive assembly. That workhorse robot carries a complete fixture assembly, compris- ing as many as six different parts, around the cell to its various worksta- tions. Operations performed include resistance welding, sealing, flanging and riveting.
“The surge in automated produc- tion has fostered an entirely new cul- ture here,” Long shares. “The proto- typing culture focuses on process development, providing unique solu- tions, whereas a production-oriented culture is all about scheduling the flow of labor and materials to a planned process. So, as we’ve expanded our pro- duction capabilities, we’ve changed the organizational structure within the company and placed production and prototyping under separate umbrel- las, with separate leadership and man- agement. That will ensure continued growth from both market segments of QMC.” MF
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