Contrinex Inductive Ensures Automated Tool-Change on Hydraulic Press Goes Smoothly

This application highlights how the strategic implementation of a single, robust sensor can yield significant improvements in operational efficiency and prevent costly damage to machinery.

The presses at the core of this application are of a conventional down-acting, hydraulic design, a familiar sight across numerous manufacturing sectors. These machines utilise powerful rams to hold the upper tool half, or die, in position as it presses down onto the lower half. This action forms the sheet metal into the required automotive body panel.

A critical, non-productive period in the operation of such presses is the tool-change sequence. This procedure involves detaching the upper tool half from the ram, placing it into the lower half, and then removing the complete toolset from the press bed. 

A fundamental prerequisite for initiating this changeover is ensuring the tool pair is in a fully closed and perfectly aligned position before the ram releases the upper die. This precise alignment is paramount to avoid damage to the costly tooling or the press itself, which would inevitably lead to significant downtime and repair expenditure.

A Customer-Focused Solution

To automate and error-proof this critical step, a robust and reliable sensing solution was required. The DW-AS-603-M18-002 inductive sensor was selected to meet the demanding requirements of this industrial environment. Its proven sensing capabilities and durable construction made it an ideal candidate for the application.

The implementation is elegantly simple. A single inductive sensor is mounted on the lower tool housing via an external angle bracket. A corresponding angle bracket on the upper tool housing serves as the detection target. The system logic dictates that the press control system must receive a confirmation signal from this sensor before enabling the tool-release sequence.

Because the target bracket only enters the sensor's switching range when the two tool halves are fully and correctly closed, any possibility of a premature release is eliminated. The inherent accuracy of the sensor's switching distance ensures that the upper tool half is only detached when the tooling is in the correct, closed position, with all the speed and consistency expected of a modern, automated manufacturing process.

By preventing the press from attempting a tool change with incorrectly closed dies, the automated system effectively eradicates the risk of damage to valuable tooling and the press itself. This straightforward application of proven sensor technology delivers a significant return on investment by maximising uptime and safeguarding critical manufacturing assets.

plusautomation.co.uk