February 2022 Volume 4

AUTOMATION

Forge Automation-The Basic Considerations By JimMorris

Are you interested in automating your forging line but do not know where to start? This paper will discuss several items that you should consider for your automation project. Why automate? Automation will produce a more consistent forging when properly adjusted and operated. At the same time, it is not unusual to see a 30% increase in productivity. This benefit requires investment in equipment and your workforce. You may have to retrofit your press, heating equipment, and die spray to get the full benefit. Let’s talk about what you need to get ready and give a few examples. Getting Ready Before you begin the project, verify your cell is ready for automation. Perform the value engineering to find a forge with a part family that is geometrically similar, and the volume loads up the press. A fool-proof, consistent method for locating the bottom dies is necessary unless you want to teach points for a job change. Automation loves consistency, so get this in place and your setup teamwill look like heroes. Is your process stable? Does the press function properly? What is your process to prove proper die setup? Do you have a good “recipe” for billet heating so you can change jobs easily? Does your die spray work well? Ensure you have a good handle on the basics before moving forward. Your automation package will need a way to communicate to the press and automatic die sprayer, if equipped. Consider retrofitting a PLC to the press as part of your automation project. We use a PLC to perform traffic management. The automation will need to know when it is safe to enter the forge, and the forge will know when it is safe to make a hit. Use redundant signals and create safety zones that verify the robot and tooling are out of harm’s way. FANUC robots have Dual Check Safety software; we use these safety rated inputs and outputs to protect the automation and forge tooling. We have seen many smashed tools due to errantly fired digital outputs. DCS safety outputs are not easily defeated. We always like to have an encoder or smart sensor that monitors ram position. This signal is constantly monitored by the automation, and if we see the ram starting down when it should not be, we jump into an emergency retract program. Pay attention to how you mount the robot. Ideally, put the robot on an isolated foundation from the press. We have designed removable mounting plates for the robot to allow maintenance access. The robot can be removed and replaced repeatably to avoid touching up points.

We recommend to novice users that they start with simple forge or trim press loading projects to ensure their first one is successful. Also, understand that you will need to identify the automation champion to be successful. Enable this person and provide him or her time to be properly trained. Case Study #1

Our customer wanted to improve his forging operation. Their shop did not have any automation on their older but fully functional mechanical presses. We started the project by identifying the project goal: provide us with a forge loading package that is flexible and easy to change over. This particular forger was a job shop, and they identified about 30 part numbers, which all had different billet sizes (1-3” diameter range and 4-7” length range). We developed a project scope, which included conveying hot parts to the loader and monitoring the billet temperature. Cold parts were to be saved, hot parts scrapped, and just-right parts advanced to the forge.The forge setup was a 3-hit process-bust, forge, and finish.The customer wanted to have us load the forge and advance the billet from bust to forge station. We designed a transfer conveyor that had an air operated diverter to send cold billets to a salvage bin. The conveyor had a breaker wheel at the load end to separate billets that welded together, and quick- change, adjustable side rails to accommodate the diameter change. A clever pick nest was added to accommodate the billet variety. We used a forge duty robot for this application. Forge duty robots have better seals on the robot joints, epoxy finishes, and stainless fasteners. All the motors are covered to prevent over-spray from sticking to the motor/encoder.

FIA MAGAZINE | FEBRUARY 2022 30