Page 25 - MetalForming-Jan-2018-issue

Improved Line Integration
“Better integration increases productivity.”
With those words, Hui details how integration has improved and what it means for metalformers.
“An operator may have to enter job information on numer- ous consoles, perhaps separately for the press, a transfer system and the feeder,” he explains. “Back and forth, back and forth. That wastes time. By working with press manu- facturers, feed-equipment providers such as Colt Automation have been able to integrate feed controls into job storage on the press control. Punching in a job or part number auto- matically sets all feed parameters, including pass-line height, progression speed, acceleration, loop settings, etc.”
The use of electronic-cam motion profiles to replace mechanical cams represent another advancement in line integration.
“Now, the feeder actually cams to the press, similar to a mechanical cam but without mechanical linkages,” says Hui. “Speed and acceleration follow the press. This makes a lot of sense when attached to a servo press, which allows the feeder to run at 350 strokes/min. or whatever speed at which the press is running.”
This allows feed equipment to properly synch to the unique speed variations of servo presses. With high-speed communication (Siemens Profinet RT, for example) the press can share its master axis with the feeder and/or transfer line, ensuring synchronicity all the way through the press line.
“So everything is cammed to the press, with every other line component following the press as a slave,” Hui explains.
Eased Coil Changeover
Job-recipe-driven feed lines offer the advantage of auto- matic coil loading.
“Before, centering a coil to a line meant a lot of walking back and forth for the operator,” says Hui. “No more. Now, the coil automatically positions to the center line, and retain- ing arms or coil keepers, guides, and rolls automatically adjust to the proper position. Automatic positioning and coil tapering save a lot of time. And, during threading, once the stock passes the straightener, the balance of the threading process can be accomplished through the feeder console. Also, a feeder pendant can jog the straightener. No excess travel by the operator is necessary. Equipment providers such as Colt Automation have been trying to minimize coil- change time and setup times between jobs, and we’ve done that.”
Highway Miles
Think about buying or selling a used a car. A big selling point is ‘highway miles.’ Why? A car with more highway than city miles has not been subjected to as many starts and stops, which is consistent with driving in the city. That means less wear and tear on the frame and mechanical components. The same holds true for feed lines.
Continuous-payout feed lines can interface with an analog
A press line starts with the uncoiler. For tougher, thicker materi- als, a motor may be installed to assist with uncoiling. Powered uncoilers deliver synchronization with other press-line compo- nents, thus providing material feed at proper speeds without undue stress on feed-line components.
loop sensor, and, as provided by Colt Automation, for exam- ple, control a straightener and/or an uncoiler to run at a constant speed equal to the throughput speed of the feeder, even with a shallow loop.
“Cruising the highway, and using the gas and brake, can cause a lot of problems with your vehicle, and the same is true for your press-line equipment,” Hui offers. “Many lines run that way, with a fast slowdown or startup. But straight- eners in continuous-payout feed lines run at constant speeds, matching the feeder throughput speed. You don’t have the pulling and struggling the coil and its inertia. Instead, motion is smooth, which means no downtime to replace the shaft or gears. Feed lines can last much longer due to continuous payout.”
Some feed lines offer simulation functions that can test the line apart from press operation to help ensure smooth material travel.
IoT for Feed Lines
In this day and age, no press-line discussion would be complete without mentioning the Internet of Things, or IoT. Smart technology extends to feed lines.
“Feed-equipment providers such as Colt Automation are incorporating artificial intelligence and IoT into feed lines,” Hui explains. “For example, metalformers with our equip- ment can use an iPhone or Android smartphone as a jogging pendant. Users can jog an uncoiler, a straightener, a feeder and multiple machines from one device. And, just like smart- phones, users can gain machine-control access via facial recognition or fingerprints. In addition, we can even build a customized voice-command library for users who prefer to communicate machines commands in that manner.”MF
www.metalformingmagazine.com
MetalForming/January 2018 23