Advanced power press line changes tools quickly

Swedish stampings supplier has invested in an advanced flexible power press line having an automatic tool change system with automatic tool clamping to cut tool changeover times.

An automated three-press line from AP and T, which is asid to 'handle anything', has been installed at a Swedish stampings (pressed sheet metal components) subcontractor in Sweden.

Esska Metall was running out of capacity on an existing line for deep drawing of automotive sheet metal components, supplying the automotive industry and its subcontractors.

Esska presses components such as hubcaps, heat shields, side skirts and various types of brackets for Scania's heavy vehicles.

Demand was growing from ventilation and pump industries for components.

Esska sought a high degree of flexibility, while delivery reliability was paramount.

The company said it was vital to be able to quickly changeover production while maintaining a high degree of availability in the facility.

* Additional capacity - Esska drew up expansion plans in 2005.

President of Esska Metalls, Lennart Morin, explained: "The automated press line with three hydraulic presses that we purchased from AP and T in 2001 is now fully booked with assignments in three shifts.

There was no reserve capacity and we quite simply needed more".

Esska again brought in AP and T to devise a high production capacity production system, but which had to have great flexibility for automated manufacture of a large number of yet unspecified different sheet metal components.

AP and T's key account manager for Esska Metall, Gote Allansson, said: "We received the order in the spring of 2007 and delivered in the early part of 2008.

Now, production is in full swing".

* Robotic press line - three AP and T 6300 kN ZM presses with third cylinder function and cushion function are served by a blank feeder picks the blanks from a pallet.

One of four SpeedFeeder press robots puts the blank in the press tool.

There are two 4-axis SpeedFeeders located between the presses.

A SpeedFeeder can even rotate the components.

The two others are 3-axis.

A mobile turning device can turn over the components between the presses.

Allansson said: "This type of production solution is more advanced and requires greater investment than a press line built for a specific component.

But, the great flexibility makes it possible to quickly see a return on the investment".

* Minimal changeover times - the tool change (die change) system with automatic tool clamping has cut changeover times maximally.

Morin was enthusiastic about this feature, he said: "Now, we can convert production from one component to another in half the time compared to the three hours needed in the old press line".

He added: "This streamlines things considerably since one component is normally produced for one or two shifts before conversion.

The entire press line is monitored via three operator panels with LOGOS - an operator interface developed by AP and T".

AP and T also has responsibility for the entire press line installation, including training operators for effective use of the equipment.

* Service agreement - in order to achieve a high level of press line availability, Esska Metall has also taken out a service agreement with AP and T.

Morin reported: "We have delivery reliability of 99 percent due to the high level of availability offered by the press system.

For this reason, we work exclusively with planned preventive maintenance and if anything else should arise, AP and T technicians are on site in no time".

* Huge investment for a subcontractor - this is a big investment for Esska Metall.

In addition to the press line, the company had expanded its premises to expand production.

Morin said that the company has a good partnership with its clients.

Esska is often involved from an early stage, including the designing of components.

He added: "We make our investments without knowing exactly what products will be produced, but with our contacts in the automotive industry, we know relatively well what demands are placed on us".

Morin concluded: "And with the new flexibility of the new AP and T press line, Esska Metall is ready for the next products - whatever they may be.".

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