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Our
Mission: Many hydraulic presses are utilized to clamp an assembly
and subsequently insert other components into that assembly. Neff
has supplied presses to do this type of operation before, however
without any data feedback. The problem that is often encountered
is that even when a component such as a bushing fully inserted (i.e.
the bushing shoulder fully bottoms on its assembly), there is no
assurance that the press fit is correct. Tolerance stack-up in the
bushing size and the mating hole size will sometimes present a too
loose or too tight condition resulting in costly part failures in
the field.
Our Solution: Neff's Force-vs-Distance Measurement and Data Acquisition System was integrated into a special 12Ton column press to rectify this problem. The system allows the machine operator to key in minimum and maximum force set point values and the distance window that these figures will be evaluated within. Each inserted component has its own force and distance feedback plus its own individual set points. Allowable values for maximum and minimum force are determined by doing trial runs with the upper and lower limits of interference fits between the inserted component that was faulty and the amount of force achieved during the pressing cycle. Based upon this measurement, the operator can now make the decision not only that a bad part is present, but also can determine why it is bad, (i.e. the bushing was too large or the mating hole was too small or too large).
The system has successfully indentified failed parts that would not have been caught with previous inspection procedures. The bottom-line story is that these faulty parts could have caused serious problems if they failed in the field.
Special
7-Ton Bench Model Press with Force over Distance Monitoring System
Our Mission: Our customer, a tier2 automotive supplier, was searching for a press that included precise force and linear control for their final quality assurance process. Their current process involved a manual upset to collapse an internal spacer to a specific height. Consistency of parts, production rates, and operator know how, were variables that needed to be addressed.
Our Solution: Neff designed and manufactured a special 7-ton bench model press, and tooling that allowed the ram to travel to a specific distance (repeatability +/- .001”), and develop the required force with a repeatability of +/- 25 1bs. The ram traveled until it generated 500 lbs of force, at this point it was triggered to note the position and then travel .032” and have a repeatability of +/- .001”. This new process allowed for consistent parts, supervisory control of stroke parameters (through the operator interface), and increased production capabilities. Another unique characteristic of this press was its ability to switch from force control to position control midway through the stroke.
12-Ton
Assembly PressOur Mission: Neff's customer, a Fortune 500 automotive supplier, required a press for a precision assembly operation. The customer needed to install multiple pressure sensors on a valve body. The total ram travel distance for the application was 6mm and necessary repeatability was .001". In addition, the press would be going in a "clean room" and the machine could not emit any hydraulic oil mist into the work environment.
The Solution: Neff supplied a 12-ton bench model C-frame press with our Servo Ram Control and Parts Quality Assurance (see PQA tutorial), and a special "leak proof" option for the hydraulic system. The press was controlled by an Allen Bradley SLC 5/03 series PLC via a PanelView 600 MMI and equipped with a load cell, linear transducer and servo valving to provide stroke repeatability to customer's .001" specification. Programmable status outputs were made available for displaying the customer's various run-time conditions.
Neff also modified the press to contain any hydraulic leaks should they occur. The press frame, hydraulic power unit and cylinder were altered to minimize the possibility of a system failure, and enclosed to capture any oil in a worst-case situation.
75-TON C-FRAME WITH SERVO RAM CONTROL 
Final Product: Aerospace Components
Our Mission: Our customer, an east coast supplier of a multitude of aerospace components, needed to upgrade their press equipment with a machine that would combine superior quality control and reduced set-up and change-over time on a large variety of parts.
Our Solution: Neff Press designed and built a special 75-ton C-frame equipped with a 15-ton die cushion with a 3” stroke and 12”x12” pin pad, and a 2-ton knock-out cylinder with a ½” stroke. Using hydraulic servo valving, the stroke of the press is repeatable to .001”. Ram speeds, as well as tonnage on the main ram, die cushion and knock-out are all electronically programmed via the operator interface. The press is controlled by an Allen Bradley SLC 5/03 PLC and allows storage for up to 450 part recipes which can be called up by the touch of a button. The customer also purchased software and programming to allow the recipes to be “dumped” to PC, as well as graph cycle history on a PC-based spreadsheet. In addition, the package included a wireless hand-held scanner to allow operator to scan for part verification or job set-up before running the material.
Neff has over 40 years of experience manufacturing, engineering and integrating industry standard components to solve customers manufacturing needs. Contact Neff Press at 800-325-8612 for further details on this application or on many others.
1200
Ton Coining Press with