1. Automated Transfer Forms of High-Speed Stamping Production Lines
The automated transfer system of a high-speed stamping production line refers to the mechanism and its control system responsible for quickly transferring sheet materials and workpieces between different stations during the stamping process. This system ensures that stamping production strictly follows a preset production rhythm, guaranteeing the continuity of the stamping process. With advancements in equipment technology, automation forms have evolved from the initial shuttle car and robotic arm setup to dual-arm and single-arm automation. As automation technology progresses, the spacing between presses becomes smaller, and the structure of the transfer device becomes more compact, allowing for efficient part transfer in limited space, improving production efficiency, meeting large-scale production demands, and simultaneously reducing the overall length of the production line, saving workshop space, and lowering equipment footprint and installation costs.
The single-arm automated robot, exemplified by the Crossbar, features seven axes of variability, including three rotational axes and four linear axes. During the transfer process, it can flexibly adjust its posture and position to better accommodate workpieces of different shapes and sizes, as well as complex stamping process requirements, enhancing the rhythm of the stamping production line.
Dual-arm automation, due to the cross-bar robotic arm's movement trajectory crossing the entire die installation area, is more prone to interference with the die, which to some extent affects the improvement of the stamping production line rhythm.
2. Key Points of Mold Design
In the mold design process, the positioning of various components is closely related to the position of the end effector suction cup. Except for flat materials, the suction cup position for other workpieces depends on the structure of the parts. Therefore, designers need to pre-set the suction cup position based on past experience and then proceed with mold design. Using different parts as examples, we introduce the key points in the mold design process that affect the improvement of production pace.
2.1 Mold Base Design
Mold base design mainly includes the height and width of the lower mold base's second layer and the partial clearance of the upper mold base's central position. Utilizing the rotation function of the manipulator to reduce its operating height and compress the operating space is a common method for automation curve simulation personnel to optimize curves and enhance pace. When using this method, interference with the lower mold base's second layer or the upper mold base's central position may occur before the manipulator or end effector leaves the mold operating space. Therefore, the following principles can be referenced in the early design stage: ① Minimize the height and width of the lower mold base's second layer as much as possible while meeting the installation of standard parts and mold structure strength; ② While ensuring mold structure strength, the area 250mm to the left and right of the upper mold base's centerline can be partially cleared (not necessary for dual-arm automation).
2.2 Guide Leg Design
Guide leg design mainly includes the selection of the guide leg position and size design. Designers generally tend to design the guide leg on the upper mold base, but when the part depth is relatively deep and the mold size is small, there is a significant risk of interference between the guide leg and the manipulator's operating trajectory, affecting the improvement of production pace. For this situation, the guide leg can be designed on the lower mold base. The following principles can be referenced during design: ① When the part depth exceeds 200mm (empirical data) and the mold length is less than 3800mm, consider designing the guide leg on the lower mold (no mold length limitation for dual-arm automation); ② Minimize the size of the guide leg as much as possible while meeting the guiding requirements.
2.3 Positioning Design
Positioning design primarily involves selecting the position and designing the height of the positioning rod. The positioning in the logistics direction, both front and back, falls within the operating area of the manipulator and end effector, which can easily interfere with them, affecting the improvement of production efficiency. The following principles can be referred to in the design: ① The position of the positioning rod should avoid the operating path of the suction cup as much as possible; ② The height of the positioning rod should be minimized while meeting process requirements; ③ Avoid designing positioning within the 250mm area on either side of the centerline of the mold's logistics direction (this can be disregarded for dual-arm automation).
In special circumstances, attention should also be paid to the positioning design on both sides of the parts logistics direction, such as the upper part of the back cover outer panel or the back cover inner panel. The material flow into both sides during the deep drawing process is relatively large, and when the manipulator carries the workpiece out in the subsequent process, the workpiece is prone to interference with the positioning on both sides. At this time, the positioning should be arranged as much as possible in areas with less material inflow.
2.4 Wedge Design
Wedge design mainly includes the selection of the wedge position and the design of the drive seat. The wedges at the front and back of the logistics direction are located within the operating area of the manipulator and end effector, which can easily interfere with the manipulator or end effector, affecting the improvement of production pace. Usually, after the process is determined, there is little room for adjusting the wedge position, but the following principles can be referred to during the actual design process: ① Try to avoid designing the wedge within 250mm on either side of the centerline of the mold logistics direction (not applicable for dual-arm automation); ② Try to avoid placing the wedge in the path of the suction cup. If it cannot be avoided, minimize the size of the wedge drive seat to leave enough adjustable space for the curve simulation personnel; ③ In special circumstances, a hidden wedge form can be selected.
2.5 Stop Block Design
Stop block design mainly includes the selection of the stop block position and size design. External stop blocks of parts are generally not prone to interference with the manipulator or end effector, but when the stop block is located inside the part, there is a risk of interference. The following principles can be referred to during the actual design process: ① Try to avoid placing the internal stop block in the path of the suction cup; ② Under the premise of meeting usage requirements, minimize the size of the stop block.
3. Other Factors Affecting the Improvement of Stamping Production Line Cycle
The current focus is on studying die structure design to enhance production cycles. However, the cycle of a stamping production line depends on the die of the process with the longest cycle time. During the actual design process, designers should identify bottleneck processes (usually the deep drawing process or those with many cam slides) and optimize the structure based on the aforementioned design points. Nevertheless, there are other factors in the actual production process that affect the stamping production line cycle. Understanding and mastering these factors are crucial for on-site debugging and optimizing production cycles.
(1) Slider Stroke Speed: The speed of the slider movement determines the duration of a stroke cycle. A faster slider speed can increase the stamping production line cycle. However, if the slider speed is too fast, the die experiences excessive force during the forming process, accelerating wear and tear on die components and potentially damaging them, which affects the stability of continuous production. Based on this principle, the slider movement curve of a servo press can be programmed to reduce the slider speed during the forming stage and increase it during the non-forming stage, balancing the stamping production line cycle and die lifespan. Therefore, the cycle of a servo stamping production line is generally faster than that of a mechanical stamping production line.
(2) Automation Transmission Speed and Accuracy: The operating speed of automated transmission equipment between presses affects the stamping production line cycle. The faster the transmission speed, the more compact the stamping process. Additionally, the acceleration and deceleration performance of the transmission equipment is important. Proper acceleration and deceleration settings can prevent workpieces from shifting during transport, ensuring the positioning accuracy and repeatability of the workpieces.
(3) End Effector Setup: A well-designed setup of the end effector can provide more adjustment space for automation curve programmers. By optimizing the space of the end effector and arranging suction cups effectively, the pick-and-place points can be positioned closer to the die component profile. This leaves enough operating space for the automated transmission device, reduces interference risks, and improves the stamping production line cycle.(4) The skills of automated curve programmers: The proficiency of automated curve programmers can influence the cycle time of the stamping production line. This is especially relevant for the curve simulation of servo stamping production lines, where programmers have access to more adjustable parameters and greater flexibility in curve adjustments. If the programmers are highly skilled, they can enhance the cycle time of the stamping production line to some extent.
Post time: Jun-04-2025