This page contains a Flash digital edition of a book.
88
Reduction of set-up times
on double-blow headers
by Wolfgang Ausländer
WAFIOS Umformtechnik GmbH
Double-blow headers are back on the drawings, a list of tools and a setting data All adjustments must be accomplishable by
popularity list. Ever-increasing cost pressure sheet. A considerable reduction in set-up times the operator
forces manufacturers to produce formed can be achieved when the tooling department This was the first and top priority. A linear
parts on high-speed double-blow headers. carries out an onscreen forming simulation feed system with accessible feed jaws
The production of double-blow parts on beforehand. enables production from the smallest up to
multi-station headers is simply inefficient. WAFIOS Umformtechnik has developed the largest wire diameter without changing
Double-blow headers produce these parts with a program called CACH. It helps the tool feed jaws. The elimination of feed jaw or
a higher output, lower tool costs and shorter developer to quickly generate drawings of roller changes and any need for different feed
set-up times. A two-year study about this operating sequences and to carry out forming rollers considerably reduces both costs and
topic motivated us to develop a tooling time simulations. set-up times.
concept, which can increase our customer’s
production output considerably. Optimising set-up times on WAFIOS headers Control panel allows precise input of
Our development team had to meet a cutting length
Prerequisites for reducing set-up times series of specifications for optimising set-up A shearing system with quick-shearing-
Effective use of production machinery times on double-blow headers. The measures bush exchange and fine adjustment of the
can only be guaranteed if it is operated by for optimising set-up times must not affect the shearing gap, as well as precise tension-
professionally trained specialists. Therefore, output of the machine, the product quality or pressure adjustment of the vertically arranged
it is important that employees of all shifts the availability of the machine. rigid shearing cutter, also reduce costs and
participate in training to exclude fluctuations Double-blow headers of the WAFIOS set-up times.
in production. Our training program includes Umformtechnik series Hilgeland reflect the
suggestions for enhancing preparation for latest in double-blow header technology. The entire forming tool change has been
production, for the provision of tools, as well Set-up times can be optimised a lot easier on optimised
as training the production scheduling and tool these machines than on older ones. A single-screw die wedge clamping
development departments. The first development stage included an system enables quick removal of the die
attempt to integrate the tool-changing systems without slackening the die bolster. An
Optimisation of set-up times can be used for multi-station headers into double- air-supported punch system facilitates the
planned blow headers. However, it soon became clear removal of punches. Expensive coil springs
Smooth logistics in the run-up to production that these systems are not suitable for high- are not required. Pressure-transmitting pins
are a prerequisite for the reduction of set-up speed double-blow headers. Punch-changing can have a more robust design.
times. Preventive and regular maintenance of systems cannot be used at machines with The machine slide stabiliser enables the
machines helps to avoid ‘pseudo’ set-up times tool turrets due to the considerable weight forming slide to run free from play and
that do not belong to the actual set-up process. increase. They would reduce the output of the facilitates the adjustment of punches by
Header operators are specialists completely machine and increase the load on the turret means of a precise XY adjustment.
familiar with the set-up of headers and drive system. The machine operator sets the header
production of formed parts. These qualified Shearing cutter cassettes, which enable the while inside the sound insulation cabin
employees should not need to bother with the adjustment of shearing cutters outside the enabling greater concentration that further
logistics in the run-up to the production or with machine, result in too long and complicated reduces set-up times.
machine maintenance. cutter tools, which increase tool costs. Also, All these measures could be carried out
When starting their shift, they must find due to the bending off of the cutting unit, without reducing the output of the machine,
their machine in perfect condition - with a cutting quality deteriorates. the quality of the products and the availability
clearly defined production order, the required The only reasonable solution that could be of the machine.
material within reach, and the tools used for adapted from multi-station changing systems However, the study showed that the
the last products already removed. was the adjustment of the feeder hand outside training of employees, smoothing logistics
the machine. in the run-up to production, and making
Complete provision of tools After rejecting all multi-station concepts, a appropriate preparations in the factory
The tools required for production must be continuous concept for reducing set-up times contribute most to the reduction of set-up
provided with a job order card, appropriate at double-blow headers was generated. times.
Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76  |  Page 77  |  Page 78  |  Page 79  |  Page 80  |  Page 81  |  Page 82  |  Page 83  |  Page 84  |  Page 85  |  Page 86  |  Page 87  |  Page 88  |  Page 89  |  Page 90  |  Page 91  |  Page 92  |  Page 93  |  Page 94  |  Page 95  |  Page 96  |  Page 97  |  Page 98  |  Page 99  |  Page 100  |  Page 101  |  Page 102  |  Page 103  |  Page 104  |  Page 105  |  Page 106  |  Page 107  |  Page 108  |  Page 109  |  Page 110  |  Page 111  |  Page 112  |  Page 113  |  Page 114  |  Page 115  |  Page 116  |  Page 117  |  Page 118  |  Page 119  |  Page 120  |  Page 121  |  Page 122  |  Page 123  |  Page 124  |  Page 125  |  Page 126  |  Page 127  |  Page 128  |  Page 129  |  Page 130  |  Page 131  |  Page 132  |  Page 133  |  Page 134  |  Page 135  |  Page 136  |  Page 137  |  Page 138  |  Page 139  |  Page 140