ULTRALIGHT TRANSFERS TECHNICAL PRESENTATION

Transcription

1 ULTRALIGHT TRANSFERS TECHNICAL PRESENTATION

2 The Company Since its creation in 1979, Misati has designed and manufactured high-quality pneumatic fastening elements, also known as pincers & pneumatic clamps. It currently has 25 employees in its headquarters in Barcelona and a wide worldwide sales network. Misati is well-known for its premium quality products, its capacity for innovation & research and its eagerness to offer simple, cheap & long-lasting solutions with its standard products to its customers. Pág. 2

3 Technology Misati has its own Research & Development Department, which designs and develops all Misati s fastening and structural elements used to automate transfer presses. All Misati s technology is patented. Misati also offers engineering services to its customers, either advising them on the use of its minipincers (application engineering), revising their projects or developing projects of transfers for them. Pág. 3

4 Production Process Misati s production process is fully automated with the newest CNC machining centres, which enable us to manufacture minipincers and structural elements with the maximum dimensional accuracy at the minimum cost. Pág. 4

5 Distribution Network Misati has a worldwide sales network that gives support and personalized attention (sales engineers) to customers in Europe, America and Asia. Find a Misati s expert in your area at Pág. 5

6 Some of our Customers Pág. 6

7 ULTRALIGHT TRANSFERS Page 7

8 Ultralight Transfers Misati has many years of experience automating multi-die transfer presses. Page 8

9 Ultralight Transfers Such experience has allowed us to get a close look at the real needs of the users of our transfers: more strokes per minute, more security when transferring sheets and lower costs. This is why Misati has developed a new range of Ultralight Transfers, which give the following advantages to the user: Higher production Lower cost Fully reliable Example of an ultralight transfer Page 9

10 1. Higher Production Servo presses that are being automated with Misati s ultralight transfers can reach more than 30 strokes per minute. Page 10

11 1. Higher Production To get 30 parts per minute, it is not enough to have the latest servo presses or the simplest sheet to stamp. An excess weight affects negatively the production of sheets. Imagen tomada de Page 11

12 1. Higher Production As there is less moving mass, the transfer moves faster and gets more strokes per minute. For that reason, our new range of ultralight mountings & brackets manufactured in technopolymer contributes to reduce the total weight of the transfer, thus becoming more productive. Page 12

13 1. Higher Production What is technopolymer? The technopolymer we use is a glass-fibre reinforced polyamide perfect for parts subjected to severe forces, such as mountings and brackets. Mechanical properties Good elasticity under fatigue and creep Impact resistance High stiffness, toughness and compactness Good performance: static & dynamic loads and vibrations Improved dimensional stability High tensile strength. Lower wear Repeated production Environmental friendly Recycable Pollution-free It consumes less energy during production than steel or aluminium Page 13

14 1. Higher Production Physical properties Density = 1,56 kg/dm3 Chemical resistance to solvents, fuels, oils, etc. Electrical insulator Heat resistance (above 120 C) Flame-retardant Good mechanization Economic properties Reduction in costs: injection Cost reduction in the production process: machining, surface finish and treatment Simple maintenance Page 14

15 2. Lower Cost If the increase in the number of stamped parts is accompanied by a reduction in the cost of the transfer, the stamping company will enjoy higher benefits. This is why Misati is concerned about developing higher-quality and cheaper products. Evolution of mountings: They were first made of steel, then aluminium and now technopolymer. Material: Steel Material: Aluminium Material: Technopolymer Page 15

16 2. Lower Cost Misati s ultralight transfers are cheaper for several reasons: We have the most competitive prices in the market. Thanks to the new designs of our products, the transfer can be made up of less elements, which are, moreover, cheaper and standard. Example of some advantages of the new Misati s pneumatic and electrical connections: electrical connections have been simplified by using only one connector. Page 16

17 2. Lower Cost Reduction in production costs. Thanks to the technopolymer elements and the new range of energy-efficient and lighter weight minipincers (ref. TIM2-25 ) the ultralight transfer requires less energy to move. Technopolymer Bracket & Mounting Page 17

18 2. Lower Cost Long working life (20 million cycles or 7 years guarantee) without the need for spare parts. Misati s pincers have a needle bearing mechanish Page 18

19 2. Lower Cost Less hours spent in designing a transfer: as the ultralight transfer is made up of less parts, it takes less time to design it. If you don t have enough time or staff to design a Transfer, Misati s Engineering Department can do it for you: you will save time and money and you can be sure all the elements of the transfer will be correctly applied. Page 19

20 3. More Security As the number of cycles of the transfer increases to get a higher production (more sheets per minute), it is more likely that sheets fall down. If sheets are not well fastened, they will probably slide, causing serious damages to the die, like the one in this picture. Troquel Picture of a real accident Page 20

21 3. More Security Force made by the pincer F P Why do sheets slide? Friction Coefficient μ Inertia Force acts in the opposite direction to the direction of travel of the sheet. Due to the high acceleration (a), the more cycles per minute the transfer can reach, the higher the Inertia Sheet Force of the transfer (F I ) undergone by the sheet. Inertia Force (of the transfer) F I = m a Lower Gripper Finger Retention Force (of the pincer) F R = μ F P For that very reason, high-force pneumatic Displacement of the sheet F R > F I minipincers (F P ), which are able to reliably transfer sheets from one die to another, are required. Page 21

22 3. More Security When a transfer is working up to 30 strokes per minute, it is absolutely necessary to have high-force pneumatic pincers, such as the new TIM , capable of fastening and transferring sheets safely and accurately, even at high accelerations. 180 dan Troquel TIM Pincer Page 22

23 3. More Security However, a high force doesn t mean a large size. The narrower and the shorter the pincer is, the easier it will be to use it in a transfer. With just 130 mm long and from 15 mm width, pincer TIM2-25 is appropriate to access to the narrowest cavities of the die. TIM Pincer 27 mm 130 mm Page 23

24 3. More Security In order to prevent collisions between pincers and sheets, we have developed the new centring shovels, which lead the sheet into the pincer. There are two types of centring shovels, which may be used together: horizontal or vertical. Page 24

25 3. More Security Another factor that improves the security and reliability of the transfer is to have the sheet controlled at all times. - All Misati s pincers are equipped with a sheet detector. - Misati recommends to use a pincer with a sheet thickness control device at the first die of the press to control if one or two blanks are being lifted at a time. TIML2-25-CE-A1-S1 Pincer TLR3-20-CE-S1 Pincer Page 25

26 3. More Security Reliability of a transfer can only be achieved by safely transferring the sheet from the centring pins of one die to the centring pins of the next die. Internal centring pins provide more accuracy and simplicity to the die. Page 26

27 Ultralight Transfers Higher production Lower cost Fully reliable Page 27

28 Customer Service Page 28

29 1. Technical Advice: Handbook of Die Design This Handbook of Die Design for Transfer Presses (free to download on has some practical tips to develop really productive transfers at the minimum possible cost. Content (examples) Handbook of Die Design Design of dies to develop really productive transfers If there isn t enough space in the die for pincers to enter, we will need to use suction pads instead, although the transfer won t make more than 5 or 6 parts per minute. Centring pins, guide columns and other elements may block the entry path of minipincers or the movement of the sheet/ transfer. Page 29

30 1. Technical Advice: Technical Training Course More than a hundred professionals from several countries have attended our Transfer Press Stamping Processes Technology course. List of topics: 1. Transfer handling technology: pincers, shovels & suction pads. 2. Characteristics of pincer handling systems. 3. Requirements for transfer presses dies. 4. Technical study and project of the pincer-holder bar. 5. Factors that help to increase production in a transfer. 6. Assembly and adjustment of a transfer. Download the full syllabus on Page 30

31 1. Technical Advice: R&D Department and Application Engineering How can the sheet be turned? Which gripper finger can better fasten the sheet? Does the planned structure have all the degrees of freedom? Misati s R&D Department will solve any doubts youmay have about your transfer. Page 31

32 2. Technical Study Misati always makes a Technical Study of the transfer. In this Technical Study we determine: - the quantity and types of pincers appropriate to the shape of the sheet - if turning units or linear displacement units are needed and - the structures at each OP Our aim is that your transfer can get the highest possible production. Page 32

33 2. Technical Study The aim of the technical study is that the end user can manufacture as many parts per minute as possible at the minimum cost and without any incidents that may stop the production ofthe press. This is why the Technical Study should be made before designing and building die. If dies are already finished, they cannot be changed and so the resulting transfer may not be optimal or productive at all. Page 33

34 3. 3D Project The 3D Project of the transfer is only made at the customer s request. In this stage, we determine the exact spatial position of pincers and other elements and we make assembly drawings. Page 34

35 3. 3D Project Thanks to this accuracy and previous work, the transfer can be assembled in a few hours with absolute precision. Example of an assemblydrawing Page 35

36 3. 3D Project Another advantage of making the 3D project is the chance of detecting possible collisions. Changing a project may be labourious, but modifying a die or repairing a collision would be much more expensive. This is why Misati makes a simulation of the transfer motion to detect any possible mechanical impacts of the pincers. Page 36

37 4. Assembly, Adjustment & Verification Service Misati s technicians make the mechanical, pneumatic and electrical assembly of the transfer. Then, they make the 3D spatial adjustment of the pincers and check the geometry of the transfer with regard to the stamped sheets. Master Sheets will enable us to adjust the pincer to the right position on the sheet in a few minutes and with no risk of making a mistake. These Master Sheets are marked with the exact position where the gripper fingers of the pincers fasten the metal sheet. Page 37

38 5. Putting the Transfer into Operation Once the transfer is assembled and adjusted, it should be put into operation. However, putting a transfer into operation may be very expensive due to: - Travelling expenses of Misati s workers. - Working hours of these workers. - Number of hours that the press remains stopped. A downtime press is estimated to cost between 450 and 500 /h, so each adjustment can cost up to 6,000 to the stamping company. But, what if there is a way to save these costs? Page 38

39 5. Putting the Transfer into Operation Misati is the only supplier that can deliver assembled Ultralight Transfers. No adjustment is needed, but just a simple start-up that can be made by the stamping company itself, who will save time and money as well as enjoy an excellent product. Page 39

40 5. Putting the Transfer into Operation When purchasing an assembled transfer, Misati delivers to the end user the Handbook for Putting a Transfer into Operation of his specific transfer, which includes among other information: - Verification reports about the geometry of the transfer (the sheet, dies, etc.) - 3D drawings of the technical project - Assembly drawings - Detailed instructions for assembling a transfer or any of its elements (in case of replacement, etc.) Page 40

41 5. Putting the Transfer into Operation If required, Misati s expert technicians - will go to your facilites, - will give technical assistance during the adjustment of your transfer and - will provide technical training to the staff of the stamping company so that they can put a transfer into operation by themselves in the future. Misati s technician Mr. Josep Maiquez putting a transfer into operation. Page 41

42 5. Putting the Transfer into Operation The result is a finished transfer, which will only need a quick adjustment before beginning producing stamped metal parts. Page 42

43 Misati s Service Technical advice Technical studies 3D projects Assembly, adjustment and verification service Putting the transfer into operation Page 43

44 Thank you for your attention. For more information, please visit our website Page 44