PROCESS EQUIPMENT UPDATE
run it and calibrate it all to our specific needs,” says Ferguson. According to Ferguson, Modern Forge will also shortly be installing a robot on its trim press to handle production delays that were impacting the quality of the trim removal. After observing operators to determine how long it took to trim each part, the team was able to determine that when they got tired, the work would slow considerably and they would get behind. When too much time passed between parts, the platters would cool off enough to making trimming difficult. Now, after the hammer operator completes the forging, the robot will pick up the item and trim it consistently each time. “Forging companies like us are
increasingly considering how we automate our presses to help our operators,” says Ferguson. “Tere is only so much an operator can do. With automation, robots and other motorised devices can move the part through the various stages of the process with more speed, safety and accuracy.”
Ajax-CECCO upsetter
AUTOMOTIVE APPLICATION At the Eaton Corporation forging operation in Kearney, Nebraska, the company operates 26 Ajax-CECO 100 to 1,300-ton forging presses. Eaton remains one of the top producers of engine valves and precision gears for the North American automotive industry. Te Kearney facility also manufactures precision-forged parts for agriculture, marine, ATVs, automotive and heavy duty.
As part of a two-stage process for An upset press prior to remanufacture
creating its engine valves, a round steel slug is formed into an “onion-head” shape using a forging die press.
Te item is then transferred to a re- strike die where it is formed into the final product. For many years the transfer from the first to the second stage of the process was performed manually (by an operator at the machine). Approximately four years ago, Eaton undertook a project to automate so that the operator only needs to push a button and a robotic arm completes the transfer. Te upgrade was applied to 15 of the Ajax-CECO presses that were used specifically to produce the engine valves. Te primary driver for automating
was worker safety, according to Randy Kreutzer, lead maintenance manager at Eaton. “You have a person sitting in front of a press that theoretically could be injured if something went wrong,” explains Kreutzer. “Now, we have them out of that scenario. Tey’re still there, but they are behind protective shields and only there in case adjustments need to made.” Kreutzer adds that there was a benefit
Solid die ball forger 10
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in increased productivity as well, because it allowed Eaton to run two presses instead of just one. “We are constantly updating our equipment. Te industry is moving past the mentality of having a man or a woman do all the manual labour and instead letting technology take over. Tat’s the drive in the market right now.”
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