Improve the transfer capacity of the stamping process
Will future stamping machines be more flexible, efficient and faster than today? Is there better automation? In the face of these problems, even the stamping factory does not dare to give a positive answer. At least they dare not say this, they can keep up with the rapid changes in the OEM car production plant strategy. Similarly, there is no uniform standard on the issue of the proportion of external stampings. But one thing is very clear, that is, high power and fast pace are the general development trend. Therefore, future stamping equipment should have higher production efficiency and more flexible use. In order to adapt to this trend, there are already interesting solutions.
Müller Weingarten has developed three stamping parts transfer processes called Crossbar: workpiece swing transfer systems for small suction cup presses; workpiece linear transfer systems for small press lines; for standard press lines and Single machine workpiece cross transfer system.
According to Müller Weingarten, the use of these three workpiece transfer systems allows the lateral swing arm or workpiece transfer that can only be used on large press machines to be used in all types of press machines.
The traditional workpiece transport and transportation classification, that is, the workpiece transportation in the automobile manufacturing industry and the workpiece transportation technology used by the component suppliers, the boundary between them becomes more blurred, and various transmission technologies tend to be more "unified." In addition, Müller Weingarten's successful lateral swing arm workpiece transfer device can be added to the existing equipment in the technical transformation, which provides a mutual exchange between the supplier and the OEM automobile production plant and the use of a common stamping die. Convenience.
Müller Weingarten's SynTec technology solution meets an important requirement in the market. Today, the division of labor between OEM car manufacturers and auto parts suppliers has been very clear, especially in the production process of stamping parts, in fact, a tacit understanding has been formed. In addition to the proliferation of products to suppliers, OEM automotive manufacturers also consider how to coordinate the production of automotive stamped parts based on changes in market demand. By coordinating production with suppliers, it is possible to increase production capacity, reduce production costs, and improve market adaptability of automobile manufacturers.
Müller Weingarten summarized the advantages of Crossbar workpiece transfer technology. When configuring a new small suction cup type workpiece transfer press machine, the swing arm type workpiece transfer system reduces the investment cost of a single product by 20% compared with the conventional suction cup type punching machine; the swing arm is modified in the existing press line. After the workpiece transfer system, it will reduce the cost of a single piece of investment by 15%. In the calculation of the investment cost of such a single product, only the investment cost is considered, and the benefits brought about by the product diffusion and coordination between the supplier and the automobile production plant are not considered. Another competitor of stamping production technology, Schuler, used ComPact stampings to counter Müller Weingarten's SynTec technology solution.
This type of stamping equipment has been successfully sold 8 sets since its launch in 2002, including Ford's Saarlouis production plant. The workpiece transport mechanism in the press line does not transfer the stamped workpiece at a uniform speed and uniform beat. Instead, it can be individually programmed and adjusted one by one. Therefore, the working cycle of the entire press line is not limited by the longest stamping die.
According to Schuler, in the future, a workpiece transfer device with a larger range of motion than the existing Crossbar transfer mechanism will be produced, so that the workpiece can be taken directly from the stamping die, omitting the original vertical transfer tool. At the same time, it can also be rotated around 3 axes to simultaneously transport two workpieces to the next processing station.
Despite the high flexibility and high power of the Schuler ComPact-Crossbar stamping machine, according to Schuler, this new stamping machine costs 10-15% less than the traditional Crossbar stamping equipment because it More cost-effective electronic control systems have been used to reduce mechanical transmission control components.
In order to meet the needs of the transformation of the press machine user equipment, Schuler prepared a new generation of stamped workpiece transfer mechanism of the Crossbar-Feeder type. It increases the production capacity of existing press lines, reaches 13 workpieces per minute, and combines the flexibility of the robot with the highly efficient Feeder technology. Like the transport robot, the stamping line can be omitted from the intermediate storage station and the second stamping unit.
These new stamped workpiece transfer units have also been improved to improve the front section stamping preparation of the press line. For example, the UK's Automatic Feed Company (AFC) hopes that the stamped sheet will be well-organized and neatly discharged during preparation. To this end, AFC replaced the old-fashioned robots and suspended transport units with new robots from Strothmann LLC, which greatly increased the discharge rate of stamped sheets and discharged the cut sheets at the speed of modern shears.
The entire system can be equipped with two sets of mutually coordinated vertical transfer mechanisms on a vertical stand. When a conveyor mechanism removes the iron plate from the conveyor belt, the other conveyor mechanism is discharging and finishing the sheet. The conveyor can achieve the task of discharging 40 iron plates per minute.
At the cleaning station in front of the press line, Strothmann also fully exploited the potential of stamping equipment. Not long ago, they developed a robot specifically for sheet cleaning. The cleaning robot was not integrated into the press line, but was operated in accordance with Strothmann's “Stand alone†approach. This type of robot makes the press line more flexible and more productive.
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