Bottleneck - signpost of the improvement.

With the multitude of organizational and operational possibilities offered to the press plant manager and system installer, the effects of a problem are met - usually with a high additional investment in effort and / or money. It does not always have to be this way.

In terms of stroke rate and process optimization, the setter has a large number of parameters, not only due to the highly flexible forming machines, but also due to the increasingly complex die automation and additional in-die motions.

 

This requires a holistic view of the production process, from the coil/blank supply, the forming of the components, the transfer and tool movements to the parts removal.

 

In a current example, the transfer of a transfer part in the deposit station always resulted in incorrect deposition / part detection errors and thus downtime. A complicating factor for the setters was the fact that the transferred part was flipped once by 180 ° within the transfer feed movement.

The Bottleneck was thus - as my experience confirmed again and again – known by the setter personnel, but optimization efforts had no success, rather brought deterioration. In such a situation, there are several options for adjustment and improvement:

  • slowing down the lowering movement of the transfer (reduce acceleration)
  • slow down the feed motion of the transfer, thus reducing the horizontal vibrations
  • check the picking position and mounting of the grippers
  • start flip-over motion earlier enabling the reduction of the rotation speed through a throttle of the rotation unit
  • extend the centering pins in the tool to prevent parts from jumping out
  • check cam settings for opening / closing the pneumatic grippers

 In summary, it can therefore be said that changes to machine settings - "changing transfer cams", die modifications and maintenance - "setting grippers", as well as tooling / gripper modifications would have been relevant measures.

 

Experience and an interdisciplinary approach to optimizing the output helps to minimize this complexity and the associated time expenditure (loss of availability).

 

In the example above, varying the stroke rate set for production, made it clear that the problem must have a dynamic, motion-dependent cause. It also became clear here that vibrations are not the cause of incorrect deposition of the metal component. The solution to the problem - the correct setting of the gripping time by means of a dynamic correction, using the appropriate adjustment parameter on the HMI.

Result:

8% more output with 70% higher tool availability on a conventional 3-axis transfer forming press. Fortunately, I was called in to this problem. A great success for both sides!

Have I piqued your interest? Would you also like to increase your output and thus reduce costs?

 

I would be happy to make you an offer of a service to increase the output at your place or for a workshop to instruct your staff in it. I am looking forward to hearing from you.

For immediate results - optimized setup as a service

Service: Process optimization for 3-axis transfer and progdie dies

Tasks:

  • Analysis of the actual situation together with your set-up / operating personnel
  • Develop a strategy for optimization based on the machine’s capabilities and features
  • Improvement and optimization of press & transfer parameters
  • Trial run and documentation

Machine types:

  • Servo- und conv. driven presses operated with 3-Axis transfer systems (NC) or in progdie mode.

Location:

  • At your machine

Duration

  • depending on die concept, app. 4-6 h / die

OR

Long term approach - increasing personnel's know-how

Workshop: Stroke Rate Optimization for 3-Axis Transfer And Progdie Production

1. Day:

  • Theory & basics of transfer- & press set-up

Subsequent days:

  • Analysis of the actual situation together with your set-up / operating personnel
  • Develop a strategy for optimization based on the machine’s capabilities and features
  • Improvement and optimization of press & transfer parameters
  • Trial run and documentation

Target group:

Setter, skilled operators, process engineers, supervisors, where required - die designers

 

Machine types:

  • Servo- und conv. driven presses operated with 3-Axis transfer systems (NC) or in progdie mode.

Location:

  • At your machine

Duration

  • Basic session: 3-4 days
  • Advanced session: 3 days (app. 4-6 weeks after basic session)

Language & Documents:

German / English or by arrangement with interpreter


Don’t hesitate to get in touch with me for a request or to discuss your specific situation at any time via the contact form.