Three Phase Robotic High Tonnage Tandem Press Stamping Line Quick Die Change System
Price:
Negotiable
MOQ:
1
Delivery Time:
60 days
Brand:
Qicheng
Product Description
Robotic Stamping Line Quick Die Change System
For a Quick Die Change (QDC) system within a robotic stamping environment, the focus is on minimizing non-productive time and ensuring mechanical repeatability. In high-mix production, the bottleneck isn't the press speed—it's the changeover.
Smarter Changeovers by Zhejiang Qicheng Intelligent Technology
In modern lean manufacturing, profitability is lost during downtime. Zhejiang Qicheng Intelligent Technology specializes in Automated Quick Die Change (QDC) Systems that transform a multi-hour manual ordeal into a streamlined, five-minute automated sequence. By synchronizing ABB's high-precision robot pathing with moving bolsters and hydraulic die-clamping, we empower manufacturers to handle small-batch orders with the same economic efficiency as mass production.
QDC Performance & Efficiency Matrix
Our QDC solutions focus on the "Internal" and "External" setup time reduction (SMED principles).
| Metric | Traditional Manual Changeover | Qicheng Robotic QDC System |
|---|---|---|
| Total Changeover Time | 45 - 90 Minutes | < 5 Minutes (Full Line Sync) |
| Labor Requirement | 3 - 4 Technicians | 1 Operator (via HMI Command) |
| EOAT Management | Manual Bolt-on / Wiring | Automatic Tool Changers (ATC) |
| Positioning Accuracy | Visual Alignment | ±0.02mm (Mechanical Lock) |
| Process Safety | High Risk (Manual Rigging) | Zero-Entry Zone (Robotic Auto-Swap) |
Technical Foundations of Our QDC Integration
- Automated End-of-Arm Tooling (EOAT) Racking: In a robotic line, the "Hands" must change with the "Die." Qicheng integrates Smart Tooling Racks within the robot's work envelope. Upon receiving the changeover command, the ABB robot automatically returns its current gripper to the rack, disconnects the pneumatic/electrical couplings, and picks up the new assembly for the next part number—all without human intervention.
- Synchronized Moving Bolster Control: We integrate the press's moving bolsters into the robotic control logic. As the press ejects the old die set, the robots are already repositioning to their "Service Mode" coordinates. This parallel processing ensures that the moment the new die is clamped, the robots are ready to begin the first stroke.
- Intelligent Recipe Management (HMI): Our Unified Control Interface stores thousands of product "Recipes." A single selection on the touchscreen automatically updates the robot's trajectory, vacuum parameters, press shut-height, and feeder pitch. This eliminates human error and the need for "trial strokes" after a die change.
- High-Speed Hydraulic & Pneumatic Couplings: To facilitate rapid swapping, we utilize multi-couplers for all utility lines. These auto-docking systems ensure that air, power, and sensor data are reconnected instantly with 100% seal integrity, preventing leaks and signal noise.
Key System Highlights
- Precision Die-Centering Sensors: Integrated laser or inductive sensors that verify the die's seat position before the robot enters the work zone, preventing accidental tool damage.
- RFID Tool Identification: Every EOAT is equipped with an RFID tag. The robot scans the tag before pick-up to ensure it has the correct "Hands" for the "Die," adding a critical layer of error-proofing (Poka-Yoke).
- Modular "Plug-and-Play" Architecture: Our QDC modules can be retrofitted to existing tandem lines, providing an immediate upgrade to your facility's flexibility.
Industry Q&A (Changeover Optimization)
Q: How does the QDC system ensure the robot's "Pick-and-Place" points are still accurate after a die change?
A: We use Dynamic Frame Offsetting. When a new die is loaded, the robot performs a quick 3-point touch-off or vision scan of the die's reference pins. The system then automatically shifts the entire motion program to align with the physical die, compensating for any minor bolster variations.
Q: What is the ROI for adding an automated QDC system to a 5-press tandem line?
A: For plants running 3 or more product changes per day, the ROI is typically less than 12 months. By recovering 2-3 hours of production time daily and reducing the need for specialized rigging crews, the system pays for itself through increased SPM (Strokes Per Minute) yield.
Q: Does the system support "One-Touch" die changes for heavy-tonnage (2000T+) dies?
A: Yes. For heavy-tonnage dies, we integrate high-capacity die-lifters and heavy-duty tool changers for the robots (capable of handling 500kg+ EOAT). The entire sequence is managed via a single "Execute" command on the master control station.
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Company
Zhejiang SAS Intelligent Technology Co.,Ltd.
Location
No. 1668, Yedao Road, Haiyan Economic Development Zone, Jiaxing City, Zhejiang Province, China
Contact Person
Mike