Sesco Product Group Utilizes Technologically Advanced Blanking System to Provide Customer with a Unique Integrated Solution
Founded
in 1956, Midway began its operations in Monroe, Michigan. Since that time,
they’ve grown into a corporate manufacturer with plants and facilities
in three states. They have a corporate and engineering technical center
in Monroe, Michigan and part production facilities in Ohio and Indiana.
With a new plant being built and the opportunity to develop a system that
would precisely meet a wide grouping of needed product, Midway Products
Group had a unique blanking line built to increase production and functionality.
The need to optimize output and eliminate any potential computer or human communication errors between dissimilar brands of equipment dictated the desire for a single source supplier. With the ability to design a plant from the ground up, Midway focused on the development of a one source integrated system to meet their processing demands and abolish unproductive costs that can be associated with projects of this magnitude.
Bob
Prucka, Director of Manufacturing, stated, “the plant (now running
for a year) was built because the company needed greater capacity to produce
flat metal blanks for its customers.” Various options and vendors
were considered in order to achieve the needed capacity. Conventional
press blanking procedures limited output ability and adaptability, while
SPG’s in-line shear press technology offered the added flexibility
and velocity to increase production rates, meeting an ever-increasing
demand from the stamping industry to remain adaptable.
Midway turned to Sesco Products Group (SPG), to provide their unique integrated cut to length system because of the success and quality of a similar line at another Midway plant location.
Coil Handling, Straightening, Roll Free Processes
This unique system incorporates a single end traversing pull-off centering reel, capable of handling 60,000 pounds, that utilizes a traversing coil car to pick and place staged coils from a three station coil rack allowing for proper job set up. Top or bottom coil payoff takes place through SPG’s multiple coil-hold down assemblies meeting the customer’s requirements for inner or outer coil presentation on the judgment of production designation. The un-coiler power threading drive presents the leading edge of the coil into the combination coil peeler, assists roll, crop shear and de-kinker assembly for processing. This assembly can also be applied for re-coiling the material for future processing.
The
leading edge of the coil is received by the combination threading and
pull out pinch rolls which are 3M traction chrome finished. Because the
line is processing appearance panels, it is necessary to crop shear the
outer wrap of the incoming coil in order to avoid contaminating the balance
of the line with any surface debris which might have attached to the outside
diameter wrap of the coil. The narrow profile crop shear, with a 6”
opening and stroke, is employed to accommodate the potentially mutilated
leading edge of the incoming coils and is incrementally advanced by the
threading rolls into and through the crop shear. Upon being crop sheared,
the sheared pieces are directed into the crop shear scrap gondola, which
is removable from the line for subsequent unloading.
Prucka allowed for an in-line wash system provision to be incorporated to meet imminent stringent customer demands. A transition table affordably bridges the gap between the crop shear and the straightener while maintaining machine integrity and functionality.
The straightening process consists of seven, four-inch work rolls incorporated within a set of six-inch input and output pinch rolls. The input and output pinch rolls of the straightener open approximately 2”, while the straightener rolls open 6” for easy threading and are traction chrome finished and generously backed up in a four high configuration. All rolls are driven to provide the torque needed to process the .025” to .125” material at 250 feet per minute allowing continuous payoff and replenishment for the feed unit. The rolls are automatically positioned for various metal thickness and material requirements per part number and are stored in the Allen Bradley PLC. The operator also has the ability to manually enter the parameters via the Allen Bradley PLC screen format.
SPG’s
unique single sided-knee type threading platform allows for tail-out in
a production type mode. The platform is raised as run-out or rewinding
coil takes place in order to avoid damage to the material from falling
into the pit, allowing a smooth transition of the tail over the looping
pit into processing. Material is supported in and out of the pit via urethane
catenary rollers that provide a non-marring work surface and are arranged
so as not to put coil set back into the material and avoid tracking the
material inappropriately into the roll feed and shear press.
The heavy duty backed-up roll feed processes the material with a controlled cordon chrome finish to minimize slippage and foreign material build up. A stepped roll furnishes continuous straight traction and minimizes unwanted inertia to provide +/-. 005” continuous accuracy, as well as eliminating possible edge damage to the material. Enclosed oil bath precision ratio gearing with continuous full-mesh engagement of the gearing provides for incredible functionality and longevity of equipment.
Shear…then Stack
SPG’s 50-ton oscillating mechanical shear press processes the material with utmost competence. The fully programmable AC drive and clutch package can save material and scrap by shearing panels with a +/-30º die shear to a “near net shape”. This process substantially reduces the complexity of subsequent operations and provides right and left handed trapezoidal blanks. Midway Products purchased the option to allow the shear die set to be changed over in just one minute. SPG’s die transfer car system with auto loading and clamping allows for minimum downtime and increased production output.
After
shearing, the blanks are transferred on a press-integrated conveyor to
the multi-station air stacking system. The fluid shifting of the diverter
section of the stacker directs the blanks to the proper selected station
for precision stacking. In square cut mode the multiple station stacker
allows for continuous production during stack changes. In trapezoid cut
mode, each station is designated as a left hand or right hand recipient
of blanks for production.
With the need to run “Class A” material each sheet is floated on a cushion of air to prevent damage to the existing stack. Once a stacked pallet is complete, the blanks are lowered away from the stacker using a scissor lift and conveyed to the left for further processing. Empty pallets are staged on the right side of the processing line to keep production interruptions to a minimum.
The optional stack handling system to transfer short progression blanks from one stack to a pallet with multiple stacks is a unique feature of this stacker. Completed stacks are indexed out of the stacking station to the the output side of the stacker with provisions to center the pallet. These stacks are transferred and staged on a special set of lifting forks to produce a pallet with the optimal quantity of stacks, eliminating wasted space and increasing efficiency. The operation of this function is accomplished automatically, where possible, through the existing system control.
Weights,
Speeds, etc.
The coil handling arrangement can easily handle a coil weight up to 30 tons, with coil widths ranging from 8” to 72” and a coil OD ranging from 36” to 72”. Material thickness ranges from .025” to .187”. The feed length ranges from 6” to 96” with a feed length accuracy of +/- 0.005”. Blank stack heights range from 15” to 18” over the pallet.
Prucka said that the system can handle 70 strokes per minute, but the line is usually run at between 48 to 50 SPM. This blanking line, housed in a new 200,000 square foot facility, is used to feed stamping operations at this plant and other Midway plants. Midway, a manufacturer of blanks, stamped components and welded assemblies, is a Tier One supplier to the automotive industry.
Single source integration of a blanking project of this scale provides flawless transition points between components and software. The development of flexible cut to length lines allows for future expansion of a metal stamper’s product line and an ability to meet a more demanding customer base. This strategy has added to the successful installation of this advanced blanking system and depicts Midway Products’ ongoing challenge to produce blanks and stamped parts in the most cost effective means possible.
Success Stories
Sesco Coil Handling/Feeding System Speeds Setup Time While Reducing Scrap for Minivan Part Stamper
