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TASK
Major HVAC (air conditioning) supplier located in Texas U.S.A. manufactures 4 different part sizes of air conditioner tops within a 1500 Ton 6100 x 2400 transfer press.
SOLUTION
Coil steel is processed into the first cutoff and draw die where the formed part is separated from the strip. A set of integrated fingers preset to accommodate 1000 mm pitch are used for all four different sizes of parts. This set of fingers are attached to a fully programmable 3 Axis Transfer System that will transfer parts thru each station and deposit the finished parts onto a nest located within the exit window of the press. These parts are then removed from the window utilizing a common magnetic end effector (spider) that is attached to a 4 axis part stacker that deposits them onto a common part pallet.
SCOPE OF SUPPLY
GÜDEL's fully programmable 3 axis servo transfer system, model gullWing GW-342 which provides travels up to 1500 mm in the pitch direction, 610 mm clamp and 300 mm of lift. GÜDEL also utilized the mechanics of its BDS-1 Blank Destacker and created a fully programmable Part Stacker system. This system utilizes the overhead gantry of the BDS-1 Destacker and 2 custom carts that accept pallets which will handle 4 different finished tops ranging from a 16 inch diameter part thru 33 inch diameter. After a cart is full, the system automatically switches from the full cart to the empty one allowing for continuous operation. The full cart is then moved to an out position allowing removal of the full pallet via fork truck and is then replaced with an empty one.
GÜDEL was also the supplier of the finger tooling that included programming and start up integration for all 4 different diameter of parts.
The complete system operates at a maximum speed of 22 S.P.M.
RESULT
With the pitch from the previous transfer being fixed at 1000 mm for all parts a freely programmable servo transfer allowed for the difference in part diameters to be compensated within the clamp and lift stroke of the system. This allowed successful startup of all (4) different diameter of parts utilizing (1) common finger rail.
With replacement of the original mechanical transfer the GÜDEL transfer system, up time, quick die changeability and increase of part production allowed for major reduction of press capacity of approx. 60 %.
The GÜDEL stacker system also was capable of reducing the quantity of press operators and material handlers from six to one.
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