EFFECTUVE AUTOMATION OF FORGING PRESSES

In the last few months, I have seen a few requests from US forgers for automation of their existing presses.?Needless to say, most of those presses are 60-70 years old, they also lacking a number of important features needed to implement full automation.

I decided to put all aspects of the problem together in order for a better understanding.?If anybody is interested, we can provide a complete turnkey automation solutions.?Please contact me at [email protected]

I.???????????????Requirements to equipment and process for automation.

1.????Forging technology and die design that allows an easy access to forged parts on all stages for picking up and transfer.

2.????Different plant layout with the space allowance for:

-???????robots;

-???????automatic die lubrication;

-???????line operator panel;

-???????control cool conveyer;

-???????quick die change.

3.????Shut height adjustment built into ram.

If shut height adjustment is built into the press table it will cause a constant resetting of robots’ positions due to changing table height.

4.????Appropriate die space.

It is needed for a few reasons:

-???????enough room for robots’ access;

-???????large side windows allow for placing robots on press’ sides;

-???????possibility to incorporate additional guidance in the bolster thus decreasing a number of re-settings.

5.????Automatic die lubrication.

It will keep an operation completely automatic without any manual labor.?The best place to put automatic die lubrication is on the back of the press.

6.????Hydraulic lower ejector with option of dwell time in the top position.

It gives a robot the time to pick the part up from the ejector.

7.????Presence of quick die change system.

8.????High level electronic integration with a common operator panel for the whole line.

?Since the main target of automation today is to introduce man less operation every requirement has to be in place.?Any partial solution can only worsen the situation.

?II.????????????Personnel qualification.

?Please keep in mind that running an automated forging line requires a presence of qualified personnel with the knowledge of mechanical, electrical, robotic, hydraulic, etc.

From our experience a training of automation specialist will take 6-9 months for a person with a previous experience and mechanical background.

Therefore, we see the situation where a lot of workers with basic mechanical skills will be replaced just with a few service engineers with a very high qualification.

On the top of it you still will need a few qualified die setters.