PRESS BUILDER SHOWS STAMPERS HOW TO MAINTAIN A MODERN MANUFACTURING ENVIRONMENT PRESS BUILDER SHOWS STAMPERS HOW TO MAINTAIN A MODERN MANUFACTURING ENVIRONMENT SPECIAL EMPHASIS: Presses, Press Feeders, Conveyors, Coil HandlingALSO:

• Servo Feed Retrofit Provides Savings, Added Life and Capabilities to Your Old Equipment• Significant Improvement with Engraved Marking Dies vs. EDM Types• Meet the New Bionic Dave

SPECIAL EMPHASIS: Presses, Press Feeders, Conveyors, Coil HandlingALSO:

• Servo Feed Retrofit Provides Savings, Added Life and Capabilities to Your Old Equipment• Significant Improvement with Engraved Marking Dies vs. EDM Types• Meet the New Bionic Dave

American Tool, Die & Stamping News42400 Grand River, Suite 103

Novi, MI 48375-2572Change Service Requested

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PAIDRoyal Oak, MIPermit No. 430

January/February 2009Volume 37, No. 1

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AIDA’s mechanical presses, 30 to 4000 tons, total turnkey packagesand its AMS program with the capability to upgrade or refurbish allaspects of mechanical stamping press equipment helps stampersmaintain a modern manufacturing environment.

rville and Wilbur Wright, two self-taught engi-neers who made bicycles for a living, invented

the airplane and changed the way people looked atthe world. The two brothers could have continuedbuilding bicycles, but they shared an extraordinarycuriosity and creativity that drove them to find an-swers and solve problems. In the current economicclimate, stampers can take a lesson from the Wrightbrothers and put creativity to work in the pressroomand the boardroom. Stampers who choose to be ex-traordinary will likely find paths to success that moreconventional approaches might miss.

New OpportunitiesIndustries such as renewable energy and fuel cell

development offer potential for growing new partsbusiness. Stampers must constantly be on the look-out for opportunities and areas outside their tradi-tional markets. To be prepared to branch out, it isalso essential that stampers maintain a modern man-ufacturing environment. To this end, AIDA’s AfterMarket Support (AMS) program offers stampers theability to upgrade or refurbish mechanical stampingpress equipment and includes:

• Electrical Press System Support • Mechanical Press System Support • Logistics Support • Press Automation Systems Support • Used Press Support

AIDA AMS has design and manufacturing capa-bilities that allow stampers to modify existingstamping press equipment to increase runningspeeds, available work energy and other perform-ance characteristics. AIDA AMS can also install an-cillary press equipment to reduce changeover timesand improve press room efficiency.

Complete press refurbishment is available for oldmetal stamping equipment that no longer meets cur-rent manufacturing standards. Press refurbishmentprovides the opportunity to increase product quality,reduce tool wear and enhance production efficiencies.

Replacing obsolete or inefficient motor drives withnew technology can significantly reduce downtimeand energy consumption costs. For stampers that ex-perience regular electrical press control system errorsor have incurred costly downtime waiting for servicetechs, AIDA AMS can also provide remote technicaltroubleshooting through installation of modem/ether-net connectivity.

Evaluating OptionsWhile there are a number of things to consider

when upgrading or refurbishing a press, if the basicpress specifications still meet current part require-ments, these options can be positive alternatives. Atier-one automotive stamper with AIDA presses,some of which have been in operation for more than15 years, chose to upgrade its equipment as a costeffective solution to reduce downtime and mainte-

Press Builder Shows Stampers How to Maintain a Modern Manufacturing Environment as They Consider New Markets

O

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nance costs, achieving higher speeds and improvingefficiency. The presses produce automotive compo-nents from materials that include galvaneal steel, coldroll and high strength steels.

In 2004, AIDA upgraded three mechanical TMXtransfer presses with complete servo-transfer anddestack feeder packages for the supplier. A total trans-fer system solution, AIDA’s TMX, 300 to 4000 metrictons, combines fast speeds, quick-die changing and anon-stop blank feed system to meet the demands oflean manufacturing.

A servo transfer mechanism, easier to maintain,gives a transfer press the ability to change the motionprofile for the transfer pitch, the transfer bar clampmotion and the lift motion. The servo transfer can de-liver increased production speeds and greater effi-ciency because all three profiles can be adjusted andretimed for each part or each job to achieve optimaloperating speed. In addition, once job programs havebeen written, they can be stored in job memory elim-inating the need to constantly reprogram the press. Asynchronized transfer drive can provide uninterruptedproduction by eliminating frequent machine stop-pages.

“The ability to partner with a press supplier likeAIDA gives us access to a manufacturer that can workwith us on improvements other companies can’tmake,” a spokesman for the stamper said. “BecauseAIDA built both the mechanical transfer and the servotransfer, they understand the design and technologybehind the equipment. That’s a big advantage.”

Best SolutionsRunning just in-time production, the stamper de-

cided to further enhance efficiency by upgrading an-other AIDA TMX with new servo drives and motors.“In addition to upgrades AIDA-America’s analystsand engineers can support us when we have a newconcept that requires custom work,” the spokesmansaid. “Their design and manufacturing capabilitiesmake it possible for us to receive total turnkey pack-ages tailored to our individual requirements.”

The stamper was able to carve out additional effi-ciences by standardizing its press controls in 2007.“Our newer AIDA presses had Q Series MitsubishiPLC controls,” the spokesman explained. “Parts hadbecome obsolete for an older control (a differentbrand) on our AIDA PMX progressive die press. Wewanted to be proactive and address parts availabilitybefore it became a problem. In addition, we didn’t

want to have to stock a lot of different spare parts.AIDA’s engineering department designed the controlusing a Mitsubishi PLC platform and standardized theother press controls.”

AIDA’s PMX, 300 to 1000 metric tons, designed forprogressive die applications, helps eliminate slide tip-ping caused by off-center loading. The PMX alsohelps customers extend tool life, reduce ownershipcosts and improve production efficiency while its ad-vanced link motion minimizes secondary forming andassembly operations.

Complex TaskUpgrading press controls is a complex task, taking

three to four months preparation. The data pro-grammed into the old controls must be properly con-

AIDA engineers and analysts are able to evaluate and design themost cost effective solutions for upgrading or refurbishing a press.

AIDA technicians can provide electrical press system support fromcontrol systems to motor drives, operator interface units to amodem to allow remote technical troubleshooting.

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verted into the new controls. According to thespokesman, AIDA technicians worked seamlesslywith Mitsubishi to make the conversions. The actualupgrades, which took about one week per machine,were done during shutdown periods. AIDA techni-cians were also present when production was restartedto make sure everything was operating properly. Thestamping supplier is also working with AIDA on acomplete servo control system replacement for itslargest TMX transfer system.

In July 2009, AIDA will implement a custom solu-tion for the stamper’s second PMX press to help meetchanging material requirements for high strength steel.In addition to AIDA’s AMS program, the press builderis able to help stampers diversify and remain flexibleby providing a broad range of mechanical stampingpresses and total turnkey packages.

Experience and HelpBecause of lean operating practices, most compa-

nies don’t employ an experienced staff that can prop-erly specify equipment. Whether parts requirementsdictate a capital equipment purchase or a mechanical

upgrade, AIDA is able to perform the necessary leg-work by evaluating production requirements and rec-ommending the most efficient solution. In addition tothe right press, this evaluation should answer ques-tions pertaining to automation, quick die change, part-to-part changeover and any other features that may berequired. Whether a company is looking to purchasenew equipment or modernize existing presses, a sup-plier with a broad line of equipment and an applica-tions team able to analyze current and future jobrequirements, can help define the choice that will de-liver the necessary efficiencies while helping to raiseprofit margins.

For more information about AIDA contact:

AIDA-America Corp.7660 Center Point 70 Blvd.Dayton, Ohio 45424-6380Phone: 937-237-2382Fax: 937-237-1995Email: comments@aida-america.comWebsite: www.aida-global.com

When it comes to logistics, AIDA has the in-house knowledge to plan a move from its initial stages to scheduling, rigging, erectingand on-site installation at a customer’s facility.

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