With the Compact High Speed Servo Tandem Line, AIDA Engineering has developed a flexible, more-compact system that meets the demands of tomorrow’s jobs.
The right automated press setup meets not only the requirements for today’s stamping jobs, but allows for flexibility to meet the demands of tomorrow’s jobs.
Transfer operations have been widely used in automated systems, however, since all forming processes are performed in one press, the transfer press must necessarily be large. Such Large size brings a number of concerns:
For stampers, remaining competitive requires them to make the right technology choices, to not only meet current job demands but also to have the infrastructure in place to support customers’ future requirements. Stampers can support ongoing growth and productivity by considering these primary elements when choosing new pressroom equipment:
On a more fundamental level, press equipment must be reliable and well maintained.
In recent years, a flexible alternative automated transfer press system called ‘Compact High Speed Servo Tandem Line’ has begun attracting attention because it can compensate the conventional transfer press systems. The system was achieved by using a general-purpose servo press at each stage and linking these presses using high-speed transfer robots—enabling a newly designed platform for dedicated robot lines.
So, how does a compact high-speed servo tandem line achieve the ability to match the size of a large press? By arranging the small servo presses in tandem for each process, it is possible to optimize different processes at a time. In transfer processing, there are various forming processes such as drawing, bending, trimming, punching, and coining, to name a few; but in the compact servo tandem line, each process can be set independently and optimum slide motion can be achieved.
Equipped with a predictive function that avoids interference between the timing of the press slide and robot transfer motions, it enables synchronization of the entire line without slowing the line speed, thereby achieving productivity that is even equivalent to that of a large transfer press.
Compared to the conventional transfer press, which performs multi-step process operations with one slide, it is possible to bring out the features of the servo press to an even greater extent. When used in a compact servo tandem line, automation can deliver improved productivity as parts move from press to press.
With the configuration, there was an issue that the timing of process and material transportation is different in each process. Therefore, AIDA installed a transfer device independently in each press, and set up a mechanism to transfer according to each slide operation non-processing timing. This determines the optimum line speed based on the slide motion set for each press and the transportable time calculated from SPM, for the speed of the entire line.
In other words, by adjusting the non-processing area time of each press so that it can be applied to one cycle of the entire system, it is possible to synchronise the entire line without lowering the line speed compared to the past. The system also has the flexibility to add multiple presses later to change the line configuration.
Servo System Versatility
To further improve flexibility and uptime, servo technology stampers can produce a range of parts from materials such as aluminium and magnesium alloys, and high-strength steels and titanium alloys, while achieving higher speeds and working energy, and improved control and precision.
Pre-programmed motion curves and the ability to design programs unique to the job at hand, along with the ability to change from producing one part to the next quickly, also add to the system’s versatility. Operating in continuous mode can deliver even higher productivity rates.
Advantages
1. Enhanced frame rigidity
Using a press frame that is symmetrical front-to-back delivers uniform front-to-back elongation and improves dynamic accuracy.
– AIDA is working towards even better durability by taking measures to reduce stress concentrations.
2. Isolating electrical components to extend service life
Electrical components are located in separate cabinets to isolate them from stamping vibration. This extends the service life of electrical components.
3. High-speed transfer robots NCAH-III (S)
AIDA has effectively increased the productivity of a conventional compact tandem line, thanks to high-speed transfer robots and high-precision synchronised controls.
As the entire line can be synchronised without sacrificing speed while still avoiding interference between the timing of the press slide and robot transfer motions, it achieves an equivalent, or even better, productivity than a dedicated transfer press.
In addition to that, a separate press slide for each stage of the forming process not only reduces the effects of off-center loading, but also enables the choice of optimal forming motion for each stage of the process. This contributes significantly to uniform product accuracy.
4. Reduction of factory equipment cost
Utilising compact presses in tandem will also change the conventional factory equipment design. Unlike larger transfer presses, the physical size of a compact servo tandem line system is relatively small. The height of the building, which was decided according to the machine height of the large press, can be kept low. The compact servo tandem line can be placed without preparing a pit for installing the press, making it possible to considerably reduce the equipment cost in the factory.
Since large buildings and deep pits are not required, factory capital investments, such as the capacities of cranes and the power of air conditioning, and equipment power, are significantly reduced too. Such system does not require any large accessory equipment, making press-layout changes a breeze.
This is a major advantage for companies that are expanding, as it significantly reduced the amount of capital investment.
5. Space-saving design
When combined with a NCAH-III (S) transfer robot system, the installation footprint of a line composed of six 2,000 kN presses is 40 percent smaller than a conventional transfer press.
6. Synchronised operation servo motion
Thanks to dedicated press slide for each process stage, forming is possible with optimal motion for each stage.
Stampers that install flexible equipment and incorporate a system-wide approach to make automation part of their operations have an opportunity to remain competitive with lower-cost labour markets.
For a more economical alternative, Mechanical Compact Tandem line is available too. For more info, please log on to www.aida.com.sg.
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The global jigs, fixtures, and dies manufacturing market reached a value of nearly $56.8 billion in 2018, having grown at a compound annual growth rate (CAGR) of 8.6% from 2014, and is expected to grow at a CAGR of 9.3% to nearly $88.8 billion by 2023, according to a new report by The Business Research Company.
Previously, the main drivers of the market were the rise of manufacturing activity in emerging markets and increased spending on construction projects, while the main restraints were fluctuating raw material prices. Going forward, the main market drivers will be the growth in the automobile industry, technological advances and growth in consumer markets.
One of the key drivers of the dies, jigs and other tools market is the increased spending on construction projects. The market benefitted from the rise in metal consumption by the construction industry globally. Buildings with metal structures have become a standard choice for the construction of commercial and industrial facilities. For instance, around 40 million tons of steel were used in the construction industry in the United States in 2018. According to the Metal Building Manufacturers Association (MBMA), 34% of its members’ sales are generated from commercial buildings. This rise in metal consumption increased the demand for tools used for welding positioners, jigs and cutting dies.
Major trends influencing the dies, jigs and fixtures market include automation, and additive manufacturing and 3D printing. Automation tools and robotic solutions are being used by tool manufacturers to reduce downtime and increase productivity. Automatic tools include the use of computerized control systems for operating manufacturing equipment. Major automatic tools include smart camera systems, intelligent control systems, shop floor monitoring systems, 3D vision technology and robotic material handling systems. Robots allow faster assembling of complex components as compared to traditional manufacturing techniques. Robots also automate milling, trimming, drilling, cutting and forming processes, thereby reducing the production time. Automation further enables machine manufacturing companies to significantly increase production volumes with automation technologies, thereby decreasing production costs and increasing profit margins.
Meanwhile, tool manufacturers are also increasingly deploying additive manufacturing technologies to offer customized designs to customers. Additive manufacturing refers to the application of 3D printing to create functional components including prototypes, tooling and end-use production parts. Additive manufacturing aids in cost-effective production of small batches of intricate parts and complex part designs. It provides a high degree of design freedom, optimization and integration of functional features, and product customization.
Opportunities and Threats
The dies, jigs and other tools market size will gain the most in China. Meanwhile, the top opportunities in the global market will arise in the stamping and other tools segment, which will gain $22.7 billion of global annual sales by 2022. In fact, the stamping and other tools segment was also the largest sector in the global dies, jigs and fixtures market, with more than 67% of the market share, worth around $38 billion, in 2018. This higher share was due to extensive use of equipment to give shape to metals by electronics, automotive, metal manufacturing and plastic manufacturing companies, and the higher prices of these products compared with the prices of dies, and jigs and fixtures. Going forward, the stamping and other tools segment will continue to grow the fastest, growing at a CAGR of 9.7% between 2018 and 2023. The other segments of the market—dies, and jigs and fixtures—will grow at 9.2% and 8.3%, respectively, during the period.
The main threat, meanwhile, will be trade protectionism. Trade barriers are expected to have a negative impact on the market as many countries are placing trade restrictions, especially on imports, to boost local production. For instance, Brexit is likely to lead to more trade restrictions between the UK and other countries in Europe. The US is also implementing several trade restrictions, especially with China, to boost its local production. For instance, the US imposed 25% tariff on steel and 10% tariff on aluminium, in 2018. Steel and aluminium are extensively used in manufacturing of these tools. These trade restrictions are likely to limit the growth of demand going forward due to higher prices.
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The global metal stamping market 2019-2023 is expected to post a CAGR of nearly five percent during the forecast period, according to a report by Technavio.
Precision metal stamping is generally used to produce large volumes of metal products. The automated process reduces labour and enables the production of precise parts with tight tolerances at high accuracy. Precision metal stamping can also be automated to include secondary operations in both die and press. This process is also suitable for several customized applications. Hence, the increasing demand for precision metal parts from end-user industries has increased the adoption of precision metal stamping. This is one of the key drivers that will fuel the growth of the global metal stamping market during the forecast period.
The advent of 3D printing and additive fabrication is expected to positively impact the growth of the global metal stamping market. Additive fabrication can produce complex shapes and reduce the wastage of raw materials. This process can manufacture different parts and reduces the need for other tools. The additive fabrication can also be integrated with existing manufacturing processes to reduce time and production costs.
APAC led the market in 2018, followed by Europe, North America, South America, and MEA respectively. The dominance of APAC can be attributed to the growth of the automotive manufacturing industry and the expanding consumer base.
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According to Research And Markets, the global metal stamping market is projected to grow at a CAGR of 3.9 percent from 2018 to reach USD 289.2 billion by 2023. Contributing factors for this growth include rising urbanisation and industrialisation, growth of the automotive industry, increasing demands from the aerospace and aviation industry and a rise in technological advancements. To add to this trend, the increased adoption of sheet metal across manufacturing industries and the blooming of metal stamping facilities has further supported the metal stamping market. However, the emergence of plastics and composite materials have also hindered market growth.
Blanking processes currently hold a huge market share and this can be attributed to the popularity of the technique among the automotive, aerospace and aviation and consumer electronics sector as this is a process that can mass produce precise and superior quality metal work pieces in large volumes at low costs. Similarly, the application of metal stamping in the automotive industry is highly popular, especially in China and India as both countries are experiencing rapid technological advancements and possess a large number of automotive metal stamping companies.
Growth of the market in Asia Pacific is expected to continue as the region held the largest share of the global metal stamping market in 2017, followed by Europe and North America. This can be attributed to factors such as the displacement of manufacturing from the west to the east, rising regional industrialisation,increased investment inflows and industrial growth across numerous sectors.
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SME covers how stamping presses transform sheet metal into functional products.
