High speed handling enhances transfer press

CNC linked to rotary encoders enable a high capacity transfer press feed to be halted in 605ms in the event of a mis-feed or tooling problem and can be operated in manual transfer mode.

To maintain a leading position in any manufacturing sector is tough enough these days.

But to do so when supplying precision presswork to the automotive industry calls for something special; the ability to consistently produce top quality components faster and more cost-effectively than your competitors.

It is a lot easier said than done.

But, by harnessing the capabilities of state-of-the-art manufacturing plant, APS in Birmingham has established an enviable track record of success as a world leader in metal forming technology.

So, when the company came to invest in a new 6000kN transfer press to meet demands for heavy duty automotive pressings, it is no surprise that the company should also specify a PressTrans work handling system from Gudel to maximise the full potential of its new machine.

Based in the Hockley area of Birmingham, UK, APS Metal Pressings (formally, A P Smith and Son Metal Pressings) has grown consistently over the past 35 years to become one of the country's foremost specialists in precision presswork, welded assembly and flow forming techniques.

The company's success has been achieved through harnessing its in-house tool design and manufacturing skills with high capability production plant, in order to meet the needs of customers like Ford, Delphi Automotive, NSK Steering Systems, GKN Sintered Metals and Nissan Showa Europe.

APS is also a past winner of the innovation category in the Accelerate Supplier of the Year awards and is constantly looking to streamline its processes.

As part of this drive, the company recently identified the need for a high speed, 6000kN (600 tonf) press to extend its capabilities into larger, more heavy-duty components.

"The new press was justified primarily on its ability to handle structural, as well as deep drawn suspension parts, for the Land Rover T5 series vehicles," says APS technical manager, Ralph Arnold.

"With up to four of these safety-critical units on every vehicle, we not only needed equipment that could meet Land Rover's stringent quality standards, but also maintain high production rates." * Evaluation - a thorough evaluation of the market led APS to consider several alternative press suppliers.

However, the company already operated a variety of AIDA production machines on site and, on the basis of past experience, Ralph and his colleagues quickly moved towards an AIDA NST 600 as their preferred option.

With principal customers in the automotive sector, key factors in their purchasing decision were speed, versatility and the ability to achieve fast change-overs.

"The order quantities we were contracted to produce also meant that efficient, high speed parts loading and transfer would be an important consideration," adds Arnold.

The specified transfer system needed to be capable of handling a wide variety of components from 1mm to 6mm thick, as well as accommodating everything from 6 to 16 station tooling with pitches up to 750mm.

Furthermore, it would have to be fitted with a compatible control system to the press in order to be quickly programmed for relatively short runs.

"Given our requirements, AIDA recommended a high speed PressTrans system from Gudel to complement the NST 600's capabilities," Arnold continues.

"And after seeing an installation in action for ourselves, we were happy to proceed on this basis." * World's Fastest - the specified PressTrans system is not only one of the most accurate on the market today - reflecting Gudel's pedigree as a manufacturer of high precision positioning and automation equipment - but also one of the world's fastest.

Its capacity of 100kg at up to 50 strokes per minute is well in excess of the maximum 28 strokes per minute the press can achieve.

The PressTrans system also features CNC controls linked to rotary encoders, which enable the equipment to be halted in 605 milliseconds in the event of a mis-feed or tooling problem.

In addition, the whole installation can be operated in manual transfer mode using light guarding, if required.

"PressTrans is an extremely flexible system, and the ideal choice as an original equipment option on many presses," says Gudel UK's joint Managing Director, John Niven.

"However, customers can gain virtually the same benefits from our 'GullWing' system too, which is suitable for retrofitting to existing machines, particularly those with smaller windows." On commissioning, Gudel allocated an on-site technician to provide comprehensive training for the customer's operators.

"We initially experienced a minor teething problem with the equipment," notes Arnold.

"But that was quickly resolved and the system has been extremely reliable in action ever since".

"This, backed by the local support from Gudel UK's headquarters in Coventry means that we have received all the 'hand-holding' we have ever needed." During the past few months, the new press and loader have more than proved their worth; currently meeting requirements for three principal components that are scheduled at up to 440,000 units per year.

"The installation dovetails perfectly with our other capabilities," says Arnold.

"Its accuracy, speed and flexibility help to provide us with the competitive edge needed to win major automotive supply contracts, not just against competitors in the UK, but from around the world as well." * About Gudel UK - Gudel UK provides a comprehensive range of automation systems integration services based on the company's high precision work handling solutions for components weighing from a few grams to several tonnes.

Systems are typically used for high volume metal working, assembly or manufacturing applications - in particular within the automotive, logistics, warehousing, pharmaceuticals machine tool, aerospace, defence, electronics and process sectors.

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