May 2023 Volume 5

MAINTENANCE

MAINTENANCE

Synchronization of Robot and Press Walking Beam Transfer Robotics and walking beam technology are highly effective tools in the forging process. Ongoing cleaning of all the mechanical drive components is important. Motors, sprockets, chains, servo-drives, and linear actuators maintenance are critical. Usually, the cause of failure is simple. The bolts/brackets holding a drive component in place loosen and allow the components to come out of alignment. The misalignment then causes excessive wear and component failure. Bearings and electrical/communication cable failure are also areas of important maintenance. Spare bearings and cables must be kept in stock at the facility so that if there is a failure, downtime is minimized. You can consult with the manufacturer of your equipment to determine what items you might need to keep in Just as important as the transfer machines, is the tooling that is used to grip the parts during the process. Due to the extreme conditions that the grippers experience during the production cycle, maintenance of the grippers and the operational hardware is critical. I recommend that a visual inspection be made of the grippers at the beginning of each shift, so that the necessary parts and tools can be gathered during the shift and then the grippers be changed out at the end of the shift, thus minimizing downtime and the effect on production. This is a simple inspection requiring only a few minutes. Sensor Maintenance Due to the environment that the sensors must operate within, protection and cleaning of the sensors is critical. When adding sensors to an operation, care should be taken in the placement and protection of the sensor itself. Protection of the sensor cables is also critical. If the cables are not cleaned and protected, contamination will build up combinedwith heat and the cables will fail prematurely. Die Lubrication Systems Die lubrication systems are a necessary part of any forging process. Normally a blast of air followed by application of lubricant is used to keep the die areas free of contamination and to keep the parts from sticking to the die. Often the blow off and die spray are combined with walking beam or other robot transfers. Part of the critical functions for the air blast and spray systems are the injector maintenance and the spray tubes and nozzles. One of the issues is the care taken in the mix ratios of the lubricant so that the nozzles and injectors do not become clogged. Leaving an open bucket of mixed fluid just sitting on the floor next to the press greatly increases the chances of contamination entering the system. Care should be taken to protect the die lube that is going to be put in the system. Part Removal and Storage There are different methods of quick die change. On their website, Fagor offers die change systems for forging operations. Quick die stock, as they know the items that might be needed. End of ArmTooling andMaintenance

change systems are valuable when they are needed. Often forging companies may use a hydraulic die set. The die sets remain in the press and different tool components are clamped into the die sets. Based on my experience, work cell organization and die changing work instructions with the proper training and equipment/tools at the machine contribute greatly to improving the die setting process. Remember the entire process is about minimizing down time. Part storage is also critical to profitability. Every time you touch the parts, cost is added to the part. It is also critical that other employees and visitors to the facility are protected against the danger of burns from contact with hot parts. Cooling areas should be set aside and marked with "Caution Hot Parts" signs to help protect others from the hazard. Process flow charts should be designed and engineered for maximum profit and safety. Jeff Fredline Sales Engineer MECO Email: fredline.jeff@gmail.com

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