What are the latest equipment technology advancements

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Modern stamping presses are capable of producing metal components rapidly and with precision for diverse industries. This manufacturing process is recognized for its versatility, reliability, and affordability, enabling the creation of both simple and intricate items with exceptional uniformity. Stamping is employed in various production scenarios, from large manufacturing plants to small job shops.

To achieve optimal outcomes within the industry, utilizing the finest stamping presses and equipment is essential. FAB Shop Magazine engaged with three stamping companies to delve into advancements in stamping technology and the ongoing evolution within the sector. These companies are leveraging contemporary manufacturing tactics to empower their clients, ensuring they remain competitive both now and in the future.

Stephan Robertson, General Manager and Vice President of Sales and Operations at Simpac America, remarked, "Industry 4.0 is crucial to our growth strategies. We understand the necessity to support our customers in adapting to Industry 4.0, which is increasingly vital due to the diminishing pool of qualified labor. Despite the rising demand for our machinery, we aim to enhance our presence in North America."

Robertson elaborated on the various facets of Industry 4.0: "One of our primary focuses is proper automation of our systems, enabling customers to better monitor machine uptime, serviceability, and construction details. Our goal with Industry 4.0 is to simplify operations for manufacturers, making life less complex."

Bob Southwell, Vice President of Sales at Aida America, echoed these sentiments, underscoring the workforce challenges that the industry faces. "Automation has always been a part of stamping, but we're witnessing a surge in demand for comprehensive turnkey systems, largely due to the labor shortage in heavy industries," he noted.

He continued, "The heightened need for automation spans the entire process—from material loading to line setup and parts sorting. There’s also a growing trend towards automation at the end of the line for collecting and palletizing parts."

Aida America has introduced various Industry 4.0 capabilities, such as its AiCare machine information management system, which provides real-time updates on press operation status and component longevity. Although currently tailored for larger enterprises, Aida is working on making the system modular for smaller contractors.

"The foundation lies in data collection," Southwell stated, "however, the critical aspect is the ability to analyze this data for predictive and preventative maintenance, alongside production optimization."

Seyi's Industry 4.0 Smart Stamping solution is also advancing. It employs a centralized control system via the Internet of Things to gather data regarding press conditions and peripheral devices, which is stored in one comprehensive database. Parameters such as tonnage, die protection, motor status, temperature, lubrication, and power consumption are all monitored.

Visualized statistics summarize all collected data into real-time production metrics, showcasing actual versus target output and estimating remaining time for specific work orders. Additionally, the system uses a color-coding method to indicate varying machine statuses, like ongoing processes, downtime, die changes, or abnormalities.

Emerging Technology Trends

Historically, stamping has evolved gradually, but recent advancements, particularly in servo technology, are becoming increasingly vital in the market. “Manufacturers are increasingly attempting to work with high-strength steel and aluminum, which present significant challenges in formation," Southwell pointed out. "Servo technology has emerged as a key solution to address these challenges by allowing for programmable motion profiles that enhance accuracy."

While hydraulic presses have historically been favored for their superior formability and prolonged dwell time, issues such as power consumption and production efficiency can lead to escalated production costs. Consequently, many users are considering servo presses for enhanced productivity, according to insights from Seyi America.

Robertson indicated that while hydraulic presses remain in use, there are specific processes and products that benefit more from servo or mechanical presses. "It often comes down to production volume requirements, the necessary clamping force, and the types of materials involved," he explained.

Southwell noted the increasing popularity of servo technology at Aida, stating that most of their presses sold are now servo-driven. "Once customers realize the return on investment and quality from a servo press, the value becomes evident," he said.

Additionally, demand for servo technology continues to rise across the automotive, appliance, and other sectors due to remarkable returns regarding productivity and energy efficiency.

Southwell emphasized that it's essential to recognize customer diversity, articulating that needs will vary significantly based on their projects. "A stamper focusing on automotive components will have different requirements than a business producing appliance parts, necessitating tailored press features," he noted.

Understanding this variation is crucial in helping clients find suitable partnerships with knowledgeable experts who can offer the appropriate press models and features. Southwell illustrated this with a recent press development aimed at accommodating a market for medium high-speed presses capable of 200-300 strokes per minute, which took two to three years to bring to fruition.

Technological advancements are continuously reshaping the machinery landscape at an unprecedented pace. Seyi noted their acquisition of over ten patents related to advanced stamping press subsystems or crucial components within five years and has multiple research and development initiatives underway.

Equipment Maintenance Importance

The expansion of services, sales, and technical support in stamping manufacturing is increasingly critical, particularly in recent years. The focus on maintenance and upkeep is paramount for stamping presses, arguably more so than for many other capital equipment types.

Robertson stated, "A stamping press generates revenue only when operational. Most presses function round the clock. Without adequate maintenance, components are susceptible to failure." He explained that the intricate mechanics of stamping presses, which feature numerous moving components, elevate the risk of breakdowns.

He added that the electronic components of stamping presses also suffer from wear and tear. "Generally, parts made from rubber or plastic are particularly prone to wear, necessitating prompt replacements," he added. Components made from materials such as brass may require replacement after several years.

Preventative maintenance plays a pivotal role here. When manufacturers invest in new equipment, performing maintenance inspections every six months to yearly is advisable to assess performance and identify parts requiring replacement.

"By evaluating components that are unexpectedly wearing out, we can perform root cause analyses," Robertson explained. Understanding potential operational misuses by staff can also be instrumental in addressing wear issues.

He noted, "Proper care and expertise in operating the machinery is vital. This should be standard practice across all capital equipment, including press brakes and laser cutters."

Simpac aims to bolster its service capabilities through increased technican staffing and spare parts availability. Innovative technologies also assist in maintenance; for example, Simpac's new XR technology incorporates 3D user views for machine components, significantly benefiting technicians. As Robertson illustrated, "A technician on a night shift, facing a problem, can reference a part on their tablet to generate a work order, allowing day shift coworkers to evaluate it or identify issues." This XR technology also facilitates real-time remote diagnostics.

Aida's Southwell reiterated the importance of regular maintenance due to the sheer number of moving parts and substantial forces exerted within stamping presses. "Leveraging Industry 4.0 technologies can shift focus from emergency repairs to more preventative and predictive maintenance. Detecting potential issues proactively enables timely maintenance interventions." Increasingly, customers are opting for contract preventative maintenance agreements with original equipment manufacturing partners.

Encouraging a Tech-Savvy Workforce

Integrating technology-based tools into stamping operations is essential in this traditionally conservative industry. "The younger workforce will play a pivotal role in driving industry advancements," Robertson noted. "We need to inspire the next generation by showcasing the innovative technologies reshaping manufacturing."

Southwell acknowledged that workforce shortages pose significant challenges throughout manufacturing, but emphasized the potential to engage young talent: "We focus on retaining our labor force and actively promote manufacturing careers to students while collaborating with local technical institutions." The goal is to present modern manufacturing as a dynamic and rewarding career path compared to outdated perceptions.

For more information on stamping press operational efficiency, feel free to contact us.