|Machine Size and Press Load: we build presses ranging from low-force, interference-fit assembly systems, to presses capable of generating over 100 tons of load.|
|Tooling Flexibility: our presses are always designed with future flexible manufacturing in mind. A single press, for example, is capable of assembling multiple components (during a single machine cycle if necessary) using interchangeable tooling. Press rams may be oriented in any direction (horizontal or vertical).|
|Hardware Flexibility: the type of hardware used (cylinders, valves, controls hardware, etc) can be specified by the customer.|
|Press Power Sources: apart from traditional hydraulic systems, we also develop and manufacture pneumatic-based systems, air-over-oil presses, and servo-based electric presses.|
|Integration: we can provide a stand-alone, offline press, or we can integrate a machine into an existing process, including process tracking and data collection.|
|System Upgrades: to save cost, we are capable of retrofitting existing, out-of-date machines with new controls and press hardware, preserving the value of the original machine's frame. Or, we can provide one of our standard frames as the base for a new press system.|
|Data Collection and Analysis: press-fit assembly of components is often overlooked as a potential source of data. Important information about the quality of an assembly (such as the amount of interference between components) can be measured: this information can improve downstream first time through and may even detect potential failures in the field.|
|EXAMPLE: Hydraulic Bearing Press|
|The OP30 Hydraulic Bearing Press is a simple example of the types of presses we build. The machine applies a hydraulic load of up to 10 tons to assemble a bearing onto a pinion. Force and distance are continuously monitored to assure that the components are assembled correctly.|
|Machine Type||production assembly machine|
|Controls Package||Siemens PLC|
|Cycle Time||15 seconds|
|Dimensional Repeatability||+/- 0.2mm|
|Notes||A hydraulic ram is mounted to the top tooling (top green section). The bearing and pinion are pressed against the lower anvil (bottom green section). Machine can accommodate multiple pinion and bearing sizes.|
|IN DEPTH: Dynamic Analysis of Force and Distance|
industrial presses use rugged, reliable PLC's for control. The PLC
monitors force and distance in real time, and is capable of
differentiating between a successful press and an invalid press (such
as a slip-fit component). In addition, a record of all press
data can be downloaded from the PLC into Excel using a simple tool
(included with the press). This data can be used to produce an analysis
of the press procedure. |
The chart below demonstrates one successful press and two invalid presses.
The successful press operation (in blue) shows the ram (approaching from the right) sense an increase in force as the bearing and pinion are fitted together (starting at about 97mm). This increase in force continues until the two components are bottomed out, after which force spikes (at about 70mm).
The first failed press operation (in red) uses a slip-fit bearing (in which there is no interference between the bearing and pinion). There is no significant force sensed until bottom-out is reached. The PLC is capable of sensing when a moderate amount of force is expected, and because this moderate amount of force is not seen when expected, the assembly operation is rejected.
Finally, the last failed press operation (in green) illustrates a 'double' press: a bearing has already been installed on the pinion, and another bearing is placed on the pinion. The ram bottoms out almost immediately due to the increased component stack height, and as an emergency measure the PLC automatically shuts off hydraulic power (gross failure).
|Click to download an Excel sheet example