Die Change Systems

7/31/2019 Die Change Systems

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Die ChangeSolutions


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Our History.At Atlas, our entire 46 year history has been

centered around the goal of optimizing the

movement of sheet metal and dies duringstamping processesin short, solving

pressroom production problems and taking

advantage of automation opportunities tohelp our customers excel.

Atlas is a full service facility with the tools,

talent and experience to provide objectivebased

engineering studies that examine

alternatives and find the most productive

and cost effective mixture of manual andautomated 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 thenback 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.


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Atlas designs and builds the mostcomprehensive range of accelerated die

change solutions in the industry. Systemsutilizing powered die carts and integrated dieracks are used in applications ranging from asingle press or multiple independent presses,to sister tandem lines.

With these systems, handling of dies

becomes highly predictable, manageableand very fast. Die change is reduced fromhours to minutes. Scheduling for reducedinventory becomes practical...Just-in-Timebecomes possible. Stock piles disappear andresponse time quickens. You no longer needto live with potential

compromises to product quality due to thedown time required to pull dies for checking.

The Worlds Best Die Change Automation


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Many of the steps within a die change

are a larger waste of time than youmight realize. Some of the largestculprits are organizing tools andpeople, removal of the old die andlocating the new die within the press.With Atlas Die Change Systems, westrongly recommend three basicareas of consideration to best utilizetime and personnel:

1. Dies mounted to subplates forcommonality

2. Rolling rather than skidding

3. Pre-staging of the in-coming dies

The Principles of Atlas Die Change


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SubplatesFundamental to Atlas die change systems is acommon interface between the die, the press and

the die change equipment. The use of subplatesprovides a common surface for all of your existingdies, allowing them to roll into and out of the press.

A subplate is normally the same size as the bed ofthe press and approximately 2 1/2 thick. Mostsubplates have a pattern of tapped holes tomount a number of different dies. Die locator pins

mounted on the left to right centerline of thesubplates are used to locate the various diesaccurately on the plate. The subplate is designedto be bolted or clamped in position on the pressbolster.

The common surface is also the key to fast,

consistent die clamping. The consistent locationachieved by pre-staging dies on subplates ismaintained through the use of a keyway or sideguides, which guide the die subplate into thepress. The common height provided by thesubplate makes either powered or manualclamping easier.


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Rolling a die out of the press reduces frictionalforces so that the die is moved smoothly andefficiently. To accomplish this rolling feature, Atlasrecommends the use of hydraulic lifters (Lif-T-Rols orMax-Rols). Theselifters raise the die off of the press bolster andplace it on wheels. This reduces the force requiredto move the die to approximately 1% of its totalweight.

When Atlas designs die change equipmentemploying the rolling concept we use a 10 timessafety factor and figure on 10% of the weight to bemoved. Incontrast, when the skidding technique is used, theequipment must be designed for 70% of theweight. These higher forces mean heavierequipment with higher potential failure.

Atlas die lifters are designed to fit in T-slots or milledpockets in a press bolster and will raise the diessubplate just enough to allow it to roll off thebolster with only minimal effort.

Rolling Dies


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Die Change Configurations


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2

3

Die T-TableAtlas Die T-Tables are based on our die cart technology and our racks combined. The long rackportion contains a conveyance device and is divided by a center die table sectioncomplete 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 diecarts.

Die Exchange is as follows:

1.) The incoming die is deliveredto station 1 and conveyed tostation 3 for pre-staging and/or

waiting for changeover.

2.) The out-going die is pulled tostation 2

3.) The conveyor indexes bothdies to the left to move the

outgoing die to station 1 forpick up and moves theincoming die to station 2, andthen into the press


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Die Tables

Atlas die tables utilize a combination of push/pull modules and powered conveyors toautomatically unload and load dies to and from a press. They are often mated withelevating die carts for automatic die storage and retrieval. Die tables provide complete,

cost effective die change capability in situations where floor space and/or economicconstraints prohibit the use of die carts. Adjustable height tables can service two adjacentpresses of varying heights. The table itself is moved by fork truck or crane.


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Die Tables & T-Tables


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Die CartsAtlas 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 pressstaging 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.


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Single Cart with Two Racks

An Atlas die cart with two racks is the perfect way to increase the versatility and output rates of astand alone press. Dies are exchanged in minutes allowing for rapid changes in production andincreasing 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, pullsthe old die from the press and places it onto the empty die rack. The cart then moves into positionin front of the rack holding the incoming die and pulls it onto the cart. The cart moves back intoposition and pushes the new die into the press, then returns to the home position. The die isclamped into position and production begins.


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Single Cart with Two Racks


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Dual Position Cart (single press)The Atlas dual station (position) die cart eliminatesthe requirement for racks that would typically beused for pre-staging of the incoming die. In thisscenario, the pre-staging is done on one positionof the cart while the press is in operation. Thebenefit of this configuration is that the areasurrounding the press is left clear.

Die exchange would occur as follows:

The die cart moves in front of the pressThe die cart pulls old die out of the press

The die cart is advanced to the second dieposition

The new die is loaded into the press

The die cart is moved to the home positionThe crane removes the old die and pre-stagesthe next die to be run

Racks may be used in conjunction with the dualstation die cart if additional pre-staging of dies isdesired.


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Dual Position Cart(single press)


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One Die Cart with Three Racks (two presses)One Atlas die cart used in conjunction with three die racks to service two presses has tow 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 inoperation, thereby increasing production time. Secondly, the cost to implement a die change system isdramatically reduced by sharing the automation between the presses.

Die exchange is as follows:1. New dies are pre-staged on the racks beside

each pres (one rack will be empty)2. The die cart pulls the first old die onto the cart3. The old die is deposited on the open rack4. The die cart picks up the pre-staged new die5. The die cart pushes the new die into the press6. The die cart removes the old die in the

adjacent press7. The die cart deposits the old die on the empty

rack and picks up the new die8. The cart then moves into position in front of the

receiving press and pushes the new die into

position9. Once the dies are clamped into position, press

operation may start and the old dies may beexchanged with the next set of in-coming dies.


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Die Carts with Racks


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Atlas Technologies dual position die cart utilizes onecart with a double push/pull module and four racks (2

pre-staged with the in coming dies and 2 empty) toservice two presses. This method of die change isaccomplished in approximately 12 minutes due to thedie exchange process, yet greatly reduces the costs toautomate.

Die exchange is accomplished as follows:1.) The cart moves into position and pulls the old diefrom

the press2.) The cart travels to the empty racks and unloadsthe old

dies3.) The cart then moves to the pre-staged racks andpicks

up both incoming dies4.) The cart moves to the press and pushes the newdies into

position.5.) The cart moves back to the clear position

Dual Position Die Carts


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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 modulewould then latch onto the subplate of the old die and push it out of the press, onto the next cartwhile pulling the new die into the press. The carts then travel back to the home position. Thenew dies are clamped into position and the old dies are removed from the carts while thepresses are in operation. Die change may occur in either upstream or downstream directions.

Die Change Configurations - Domino (single line)


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Domino Lines


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Sister line domino die change is identical to single line domino die change except two lines ofpresses 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 beutilized beside the presses to assist in the pre-staging efforts to ensure the carts are continuouslyavailable for die exchange.

Die Change Configurations - Domino (sister lines)


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Domino Sister Lines


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Atlas transfer press die change utilizes two diecarts, one cart on either side of the press. Onecart is pre-staged with the in-coming die andanother cart is empty. The use of two cartsallows pre-staging of the in-coming die andsimultaneous exchange with the old die.

Die exchange is accomplished as follows:

1.) The empty cart travels into position in frontof the press via pendant controls

2.) Once in position, pins are lowered into floorbushings to positively locate the cart andlock it into position

3.) The die lifting devices are actuated to raisethe die off of the bolster

4.) The push/pull module then pulls the old dieonto the cart

5.) As the old die exits, the pre-staged die onthe opposing cart is pushed into place

Transfer Press Die Change


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Atlas automatic storage and retrieval systems(AS/RS) are a high speed, proven, fullyprogrammable method of efficiently storingand handling dies, parts, coils and other itemsweighing up to 50 tons. Our customers gainvaluable floor space by utilizing vertical,otherwise unused space. The average leadtime to complete retrieval is less than 5 minutes,

which eliminates the time associated withpersonnel searching for lost items. A touchscreen user interface is used to facilitate ease ofpart storage.

Automatic operation allows items to bepresented at a common location at theprescribed time. The Atlas AS/RS can span from

one crane bay or building to another,eliminating the need for die trucks. Thecontrolled handling of items, reduces thepotential of costly damage to dies, coils andparts. Our AS/RS systems are available in wirerope or ballscrew lift designs and feature lift andcarry capability.

Automatic Storage & Retrieval Systems


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Automatic Storage & Retrieval Systems


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Atlas Transfer Carts have been used in hundreds ofinstallations for fast, smooth and safe

movement of materials and/or product throughmanufacturing facilities. Based on our worldrenowned die cart technology, Atlas transfer cartsprovide consistently controlled movement of oversizedand heavy loads.

Transfer carts increase production by eliminating losttime waiting for material or dies to bedelivered to the appropriate location. They alsoeliminate the need for overhead cranes and fork trucksto move heavy loads throughmanufacturing areas, thereby greatly improving plantsafety and ergonomics and potential damage to diesor material.

Atlas Transfer Carts are capable of carrying loads from10,000 to 180,000 pounds and haveavailable options such as accurate shot pin floorlocators, self loading/unloading, automaticoperation and safety features such as horns, lights, E-stop, bumpers and lasers.

Die Transfer Carts


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Die Transfer Carts


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Why Atlas?All automation companies talk a good game. At Atlas we back it up with results.

We understand that excellent technical skills arent the goal, theyre 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 yourindustry.

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


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Documents

Die Change Systems