Revolutionizing Die Change Operations with Custom Engineering Solutions
Revolutionizing Die Change Operations with Custom Engineering Solutions
Align Production Systems has successfully partnered with a prominent metal stamping manufacturer to enhance die change operations. The introduction of a custom-engineered omnidirectional Mold and Die Changer represents a significant improvement in efficiency and safety in material handling processes.
The Challenge of Traditional Methods
In the past, operators relied heavily on forklifts and manual techniques to manage the transfer of heavy dies, which typically weigh up to 36,000 pounds, between presses and storage areas. This method was not only slow but also labor-intensive, often requiring a team of workers to complete the task while posing considerable safety risks. Subsequently, there was an urgent need for a faster, safer alternative.
A Groundbreaking Solution
Recognizing this challenge, the metal stamping manufacturer engaged Align Production Systems to design a customized material handling solution. The outcome was a state-of-the-art die changer that utilizes a magnetic push/pull transfer system, allowing operators to lift and move dies efficiently without the cumbersome reliance on forklifts.
Features that Drive Efficiency
The advanced Mold and Die Changer incorporates several key features to optimize operational speed and safety:
- - Omnidirectional Movement: The transporter is equipped with steerable drives and idlers, enabling it to perform car-like steering maneuvers, crab walking, and zero-point turns for seamless alignment.
- - Hydraulic Lift and Roller System: Capable of raising dies up to 103 inches, this system includes retractable rollers that facilitate smooth and precise transfers.
- - Electromagnetic Push/Pull Mechanism: This innovative feature allows controlled force application for pulling dies from presses and pushing them into place.
- - Lithium-Ion Battery Power: The use of lithium-ion batteries ensures extended runtime and minimal maintenance requirements.
- - Integrated Safety Systems: These systems include automatic speed reductions when the transporter is elevated and sensors that monitor roller angles, thereby enhancing workplace safety.
Transforming Operations
The deployment of two units implemented throughout the facility has drastically reduced both changeover time and manual labor involved in the die transfer process. Operators can now transport and position dies in under a minute with remarkable accuracy. This advancement not only boosts the speed of operations but also significantly reduces workplace injuries and equipment wear and tear, thereby contributing to an overall improvement in workflow efficiency across various stamping lines.
Commitment to Innovation
Align Production Systems has demonstrated a steadfast commitment to delivering finely engineered solutions tailored to the issues faced in modern manufacturing environments. By merging motion control technology, automation, and robust safety features, Align provides manufacturers with the tools to modernize their legacies without sacrificing reliability.
About Align Production Systems
Align Production Systems specializes in crafting advanced material handling and automation equipment for industries globally. Focusing on custom transporters, die changers, and automation systems, Align is dedicated to improving productivity while ensuring operator safety and safeguarding facility infrastructure. For more details, visit www.alignprod.com or contact them for press inquiries at [email protected]
Topics Heavy Industry & Manufacturing）
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