Progressive Stamping Tool Concerns For the Metal Stamping Industry
In any metal stamping tool operation, trial and error is a time-consuming, difficult and costly way to find the source of a problem. Also, analysis and adjustments when done at the beginning of the process usually save time and money to a greater degree than if it is done at the end of the process. To prevent problems from occurring after the dies have been built and operations have begun, progressive stamping tool and die engineers, designers, operators, and production managers now are being provided with new tools to help them make changes on the “easy side of the press.”
The cause of errors can be difficult to diagnose. Certain errors cannot be detected by the naked human eye or might be even dangerous if you have to take a closer look. It might need cameras which is safe, and that can capture images in closer proximity. Too, many problems occur because material is out of spec, or because of the work material’s metallurgy.
In metal stamping, every stroke of the progressive stamping tool exerts tremendous pressure on the metal being formed. And over time, this could lead to unpredictable problems, unless sensors are in place. Parts can be deformed or metal can feed improperly, might not eject correctly, and the die or part could be damaged. In turn, this may result in parts being wasted, increase material waste, damage the tooling, delay production, and increase the overall costs. To help catch any problems before they occur, press tool manufacturers are turning to new metal stamping sensor technology, rather than the typical mechanical monitoring techniques.
Metal stamping sensors are the in-thing of metal stamping industry.
In order to identify defects and quality issues as quickly as possible, metal stamping industries have used many techniques to monitor production. On the other hand, mechanical technology has its limits. As an example, micro-switches and electric pilots used on progressive stamping tool can detect the location of the metal strip inside the stamping tooling and identify misfeeds, but they do not stop the metal stamping tools before making the hit, which can result in damage to the stamping tooling, the part, and the press.
Die crashes, High reject rates, high levels of scrap, cosmetic defects on parts are indications, and so on, are indicators that it is time for a manufacturer to replace out-of-date mechanical monitors with metal stamping sensor technology. These issues with the progressive stamping tool runs affect the metal stamper and also the client is negatively affected by the expense of rebuilding or repairing a metal stamping tool or line interruptions.
By detecting problems in production before they occur, the electronic sensor technology addresses these long-standing issues. Additionally, the press will not run if the sensor itself is not working properly. The benefits of press tamping tool sensors are improved overall quality (zero defects), reduced sorting cost, improved on-time deliveries, and improved focus on the root cause, reduced tool maintenance costs, reduced set-up time and downtime.
How do electronic in-die sensors work?
Given the complexity of metal stamping, in-die sensors must be customized and programmed for each progressive stamping tool and each process. A metal stamping industry that is concerned with quality should have customized electronic sensors. The sensors are used in combination with progressive stamping tool controls, which can automatically shut down the system before a die crashes and stop the presses when something goes wrong.
Testing progressive stamping tool sensors to ensure accuracy
With the quality of the part and the integrity of both the sensors and the stamping tool at stake, progressive stamping tool sensors must be tested periodically to ensure that they are reliable and to check their continued operation. Before installation to evaluate each sensor’s consistency and accuracy, and its ability to withstand the frequent shock of progressive stamping tool operations without damage, the metal stamper will test all sensors. The sensor should be tested at different points of the production process. This includes testing during press runs to troubleshoot any issues and to identify the cause of the problem.
Sensor technology is enabling metal stampers to produce extremely intricate parts without a malfunction. And sensors are capable of measuring critical angles and features on each and every part that goes through the press. Therefore, while putting a stop to die crashes and minimizing downtime, metal stampers are able to ensure part quality.
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