May 2024 Volume 6

AUTOMATION

Understanding Automation in the Context of Hydraulic Presses In the realm of hydraulic press operations, the integration of auto mation and its inherent intelligence has been nothing short of revo lutionary. This transformative shift goes beyond mere technological upgrades, heralding a new era of manufacturing efficiency, preci sion, and safety. Automation introduces a system of operations that can significantly surpass human capabilities in speed, consistency, and endurance. “Automation has revolutionized how we think about and operate hydraulic presses,” says Jeff Walsh, Director of Business Development at Macrodyne. “The level of speed, consistency, and endurance we can achieve now was unimaginable a decade ago.” Its impact is multifaceted, streamlining production to enhance effi ciency and productivity. Through the continuous and unwavering operation of automated systems, manufacturers enjoy a substantial increase in throughput, achieving more in less time and with greater consistency. For starters, unlike human operators, machines do not tire, allowing for non-stop production that can dramatically increase the volume of output. This is particularly crucial in industries where demand can spike unexpectedly, requiring a rapid increase in production capacity. Automated hydraulic presses can be programmed to run 24/7, with maintenance activities scheduled during non-peak hours to avoid disrupting production. This capability ensures that manufacturers can meet their production targets faster and with greater consistency. “The capability of automated hydraulic presses to operate continu ously, without staff tending it, is a game-changer for production,” says Kevin Fernandez, president of Macrodyne. “This means compa nies are not just prepared for unexpected spikes in demand, they’re always ahead of them. By scheduling maintenance in off-hours, companies can ensure production lines are running smoothly 24/7, making targets not just goals, but guarantees.” Moreover, the consistency brought by automation is another key factor in enhancing productivity. In manual operations, variability in performance can lead to inconsistencies in product quality. And mistakes cost money. According to a report by the National Institute of Standards and Technology (NIST), manufacturing scrap and rework can cost companies between 5% and 30% of their total manufacturing costs. These costs are often the result of human errors in manufacturing processes. Yes, to err is human, but in the realm of manufacturing, where precision is paramount, the capacity of automation to miti gate these errors transcends mere efficiency. It becomes an essential strategy for cost reduction and quality assurance. Automation ensures exact precision based on pre-defined parameters. This repeatability means that every product manufactured under these automated systems meets the same high standards of quality, reducing waste and rework. The precision that automation brings to hydraulic press operations is unparalleled. The meticulous monitoring and adjustment of opera

tion parameters by sensors and control systems ensure that products are manufactured with exacting standards, significantly reducing the margin for error. This level of precision not only improves product quality but also contributes to the overall reliability of the manu facturing process.

Two Macrodyne 300 Ton Metalforming Presses with automatic die handling, automatic die clamping, robotic loading/unloading and die storage and retrieval system. The technological landscape of manufacturing, particularly in hydraulic press operations, is increasingly influenced by the inte gration of the Internet of Things (IoT). This synergy between automation and IoT technologies heralds a new phase of indus trial efficiency, characterized by enhanced connectivity and smart manufacturing processes. IoT-enabled devices and sensors embedded within hydraulic press systems offer real-time data collection and analysis capabilities, transforming raw data into actionable insights. This integration facilitates predictive maintenance, a proactive approach that predicts equipment failures before they occur, signif icantly reducing unplanned downtime and extending machinery life. By analyzing data trends and patterns, manufacturers can schedule maintenance only when necessary, moving beyond routine or calendar-based maintenance schedules to a more efficient, condi tion-based regimen. Moreover, IoT technology enhances the operational efficiency of automated hydraulic press systems by enabling precise monitoring of production processes, which allows for the adjustment of press parameters in real-time, optimizing performance and ensuring product quality consistency. This level of control and visibility extends beyond the shop floor, enabling remote monitoring and management of manufacturing operations, a feature particularly beneficial in today’s global manufacturing landscape.

FIA MAGAZINE | MAY 2024 44