Die Change

Solutions

Our History…. At Atlas, our entire 46 year history has been centered around the goal of optimizing the movement of sheet metal and dies during stamping processes—in short, solving pressroom production problems and taking advantage of automation opportunities to help our customers excel. Atlas is a full service facility with the tools, talent and experience to provide objective based engineering studies that examine alternatives and find the most productive and cost effective mixture of manual and automated operations, specifically tailored to suit each individual customer and their requirements. Atlas has complete in-house capability for total system responsibility, mechanical and controls design, fabrication, machining, assembly, test and installation. We then back our equipment with a full one year warranty and support our customers with 24-7-365 emergency service. You can trust Atlas with your die handling needs...after all, we have more installations around the world then all of our competitors combined.

Atlas designs and builds the most comprehensive range of accelerated die change solutions in the industry. Systems utilizing powered die carts and integrated die racks are used in applications ranging from a single press or multiple independ-ent presses, to sister tandem lines. With these systems, handling of dies becomes highly predictable, manageable and very fast. Die change is reduced from hours to minutes. Scheduling for reduced inventory becomes practical...Just-in-Time becomes possible. Stock piles disappear and response time quickens. You no longer need to live with potential compromises to product quality due to the down time required to pull dies for checking.

The World’s Best Die Change Automation

Atlas Die Change Systems give you complete con-trol of the changeover process for: • Faster Response to changing production schedules or sudden demands, since dies can be changed over in mere minutes • Reduced Inventory Reduce batch size costs effectively, minimize

work-in-progress and meet Just-In-Time requirements • Greater Press Uptime and Utilization Reducing die change from hours to minutes can

add hours of stamping productivity per day without added presses • Quality Control Dies can be pulled and checked quickly without

destroying your production schedule. Controlled handling means less chance for damage to the dies

Reasons to Establish a Die Change Program

Many of the steps within a die change are larger time wasters than you might realize. Some of the largest culprits are organizing tools and people, removing of the old die and locating the new die within the press. With Atlas Die Change Systems, we strongly recommend three basic areas of consideration to best utilize time and personnel: 1. Dies mounted to subplates for commonality 2. Rolling rather than skidding 3. Pre-staging of the in-coming dies

The Principles of Atlas Die Change

Fundamental to Atlas die change systems is a common interface between the die, the press and the die change equipment. The use of subplates provides a common surface for all of your existing dies, allowing them to roll into and out of the press. A subplate is normally the same size as the bed of the press and approximately 2 1/2” thick. Most subplates have a pattern of tapped holes to mount a number of different dies. Die locator pins mounted on the left to right centerline of the subplates are used to locate the various dies accurately on the plate. The subplate is designed to be bolted or clamped in position on the press bolster. The common surface is also the key to fast, consistent die clamping. The consistent location achieved by pre-staging dies on subplates is maintained through the use of a keyway or side guides, which guide the die subplate into the press. The common height provided by the sub-plate makes either powered or manual clamping easier.

Subplates

Rolling a die out of the press reduces frictional forces so that the die is moved smoothly and efficiently. To accomplish this rolling feature, Atlas recommends the use of hydraulic lifters (Lif-T-Rols or Max-Rols). These lifters raise the die off of the press bolster and place it on wheels. This reduces the force required to move the die to approximately 1% of its total weight. When Atlas designs die change equipment employing the rolling concept we use a 10 times safety factor and figure on 10% of the weight to be moved. In contrast, when the skidding technique is used, the equipment must be designed for 70% of the weight. These higher forces mean heavier equipment with higher potential failure. Atlas die lifters are designed to fit in T-slots or milled pockets in a press bolster and will raise the die’s subplate just enough to allow it to roll off the bolster with only minimal effort.

Rolling Dies

Lif-T-Rols

Max-Rols

The third ingredient of an Atlas die change system is the pre-staging of dies on Atlas Die Racks. Without this feature quick die change would be impossible. When the in-coming die is pre-staged, all of the positioning work of the next die on the subplate is accomplished prior to going into the press and more importantly, while the press is in operation. Pre-staging removes the crane or other forms of die moving equipment from the die change process, thus greatly reducing the time required to change dies. Shown left, subplate mounted dies are pre-staged on Atlas Die Racks fully prepared for the next die change at a major appliance manufacturer.

Pre-Staging

Die Change Configurations

Die T-Table Atlas Die T-Tables are based on our die cart technology and our racks combined. The long rack portion contains a conveyance device and is divided by a center die table section complete with a push/pull module. Atlas T-Tables provide a very cost effective die change capability in situations where floor space and/or economic constraints prohibit the use of die carts.

Die Exchange is as follows: 1.) The incoming die is delivered to Station 1 and conveyed to station 3 for pre-staging and/or waiting for changeover. 2.) The out-going die is pulled to Station 2 3.) The conveyor indexes both dies to the left to move the outgoing die to Station 1 for pick up and moves the incoming die to Station 2, and then into the press

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2

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Die Tables

Atlas die tables utilize a combination of push/pull modules and powered conveyors to automatically unload and load dies to and from a press. They are often mated with elevating die carts for automatic die storage and retrieval. Die tables provide complete, cost effective die change capability in situations where floor space and/or economic constraints prohibit the use of die carts. Adjustable height tables can service two adjacent presses of varying heights. The table itself is moved by fork truck or crane.

Die Tables & T-Tables

Die Carts

Atlas Die Carts have become the industry benchmark with over 1000 installations around the world. Self-powered and controlled either by pendant or remotely, Atlas carts move on floor rails at speeds up to 30 feet per minute, transporting dies of almost any size to and from presses and die racks. Precision ballscrew driven push/pull modules engage die subplates on either end, indexing one or more dies on or off the cart and into or out of the press. For safety and long life, carts are built to handle much more weight than your highest load requirements. Die racks become a “close to the press” staging area. Equipped with rollers, they are ruggedly built like Atlas die carts. In many configurations, added racks extend the usefulness of each cart, maximizing the benefit of your investment.

Single Cart with Two Racks

An Atlas die cart with two racks in the perfect way to increase the versatility and output rates of a stand alone press. Dies are exchanged in minutes allowing for rapid changes in production and increasing JIT capabilities. The next in-coming die is pre-staged on one rack while the press is in operation. When die exchange is required, the die cart moves into position in front of the press, pulls the old die from the press and places it onto the empty die rack. The cart then moves into position in front of the rack holding the incoming die and pulls it onto the cart. The cart moves back into position and pushes the new die into the press, then returns to the home position. The die is clamped into position and production begins.

Single Cart with Two Racks

Dual Position Cart (single press)

The Atlas dual station (position) die cart eliminates the requirement for racks that would typically be used for pre-staging of the incoming die. In this scenario, the pre-staging is done on one position of the cart while the press is in operation. The benefit of this configuration is that the area surrounding the press is left clear. Die exchange would occur as follows: • The die cart moves in front of the press • The die cart pulls “old die out of the press • The die cart is advanced to the second die

position • The “new” die is loaded onto the press • The die cart is moved to the home position • The crane removes the old die and pre-stages

the next die to be run Racks may be used in conjunction with the dual station die cart if additional pre-staging of dies is desired.

Dual Position Cart (single press)

One Die Cart with Three Racks (two presses) One Atlas die cart used in conjunction with three die racks to service two presses has two benefits. First, the dies may be fully prepared to enter the press by pre-staging the in-coming dies on the racks while the press is in operation, thereby increasing production time. Secondly, the cost to implement a die change system is dramatically reduced by sharing the automation between the presses. Die exchange is as follows: 1.) New dies are pre-staged on the racks beside each press (one rack will be empty) 2.) The die cart pulls the first old die onto the cart 3.) The old die is deposited on the open rack 4.) The die cart picks up the pre-staged new die 5.) The die cart pushes new the die into the press 6.) The die cart removes the old die in the adjacent press 7.) The die cart deposits the old die on the empty rack and picks up the new die 8.) The cart then moves into position in front of the receiving press and pushes the new die into position Once the dies are clamped into position, press operation may start and the old dies may be exchanged with the next set of in-coming dies.

Die Carts with Racks

Dual Position Die Carts

Atlas Technologies dual position die cart utilizes one cart with a double push/pull module and four racks (2 pre-staged with the in coming dies and 2 empty) to service two presses. This method of die change is accomplished in approxi-mately 12 minutes due to the die exchange process, yet greatly reduces the costs to automate. Die exchange is accomplished as follows: 1.) The cart moves in position and pulls the old die from the press 2.) The cart travels to the empty racks and unloads the old dies 3.) The cart then moves to the pre-staged racks and picks up both incoming dies 4.) The cart moves to the press and pushes the new dies into position. 5.) The cart moves back to the clear position

Dual Position Die Carts

Die Change Configurations - Domino (single line) Domino die change consists of utilizing one additional cart to the number of presses in the line. All but the last cart would be pre-staged with the incoming die while the presses are in operation. The carts would then move into position (to include the empty cart). The push/pull module would then latch onto the subplate of the old die and push it out of the press, onto the next cart while pulling the new die into the press. The carts then travel back to the home position. The new dies are clamped into position and the old dies are removed from the carts while the presses are in operation. Die change may occur in either upstream or downstream directions.

Domino Lines

Die Change Configurations - Domino (sister lines)

Sister line domino die change is identical to single line domino die change except two lines of presses share the carts used by one line in the first example (7 carts service 12 presses). The presses must share common alignment with each other to implement this configuration. Die racks may be utilized beside the presses to assist in the pre-staging efforts to ensure the carts are continuously available for die exchange.

Domino Sister Lines

Transfer Press Die Change

Atlas transfer press die change utilizes two die carts, one cart on either side of the press. One cart is pre-staged with the in-coming die and another cart is empty. The use of two carts allows pre-staging of the in-coming die and simultaneous exchange with the old die. Die exchange is accomplished as follows: 1.) The empty cart travels into position in front of the press via pendant controls 2.) Once in position, pins are lowered into floor bushings to positively locate the cart and lock it into position 3.) The die lifting devices are actuated to raise the die off of the bolster 4.) The push/pull module then pulls the old die onto the cart 5.) As the old die exits, the pre-staged die on the opposing cart is pushed into place

Automatic Storage & Retrieval Systems

Atlas automatic storage and retrieval systems (AS/RS) are a high speed, proven, fully programmable method of efficiently storing and handling dies, parts, coils and other items weighing up to 50 tons. Our customers gain valuable floor space by utilizing vertical, otherwise unused space. The average lead time to complete retrieval is less than 5 minutes, which eliminates the time associated with personnel searching for lost items. A touch screen user interface is used to facilitate ease of part storage. Automatic operation allows items to be presented at a common location at the prescribed time. The Atlas AS/RS can span from one crane bay or building to another, eliminating the need for die trucks. The controlled handling of items, reduces the potential of costly damage to dies, coils and parts. Our AS/RS systems are available in wire rope or ballscrew lift designs and feature lift and carry capability.

Automatic Storage & Retrieval Systems

Die Transfer Carts

Atlas Transfer Carts have been used in hundreds of installations for fast, smooth and safe movement of materials and/or product through manufacturing facilities. Based on our world renowned die cart technology, Atlas transfer carts provide consistently controlled movement of oversized and heavy loads. Transfer carts increase production by eliminating lost time waiting for material or dies to be delivered to the appropriate location. They also eliminate the need for overhead cranes and fork trucks to move heavy loads through manufacturing areas, thereby greatly improving plant safety and ergonomics and potential damage to dies or material. Atlas Transfer Carts are capable of carrying loads from 10,000 to 180,000 pounds and have available options such as accurate shot pin floor locators, self loading/unloading, automatic operation and safety features such as horns, lights, E-stop, bumpers and lasers.

Die Transfer Carts

Why Atlas? All automation companies talk a good game. At Atlas we back it up… with results. We understand that excellent technical skills aren’t the goal, they’re the price of entry. We will design, build and integrate a solution that will achieve your goals. Our engineering documents will be accurate and complete. Our designs will function as promised. Our manufacturing will be precise and durable. Your project will be spearheaded by a contract manager that is intimately familiar with your industry. Our finished product will exceed your expectations. Every customer. Every project. PERIOD.

Contact Information

3100 Copper Avenue Fenton, MI 48430 USA Phone: +1 810.629.6663 Fax: +1 810.629.8145 www.atlastechnologies.com www.pressroomautomation.com