&#;The team and I had a fairly evolved view of how we wanted the overall process to flow, but what we lacked was the press-hydraulics knowledge and controls expertise to see it through,&#; one metal former told us. Another credited the ability to apply our past experiences during an automation design/build project that ultimately improved the overall design of the cell.

If you are looking for more details, kindly visit tpypress.

Another option: Work with a generic automation house or systems integrator. While this may be beneficial for non-press projects, these sources may lack the specific product knowledge gained from years of working with hydraulic presses, tooling, dies and related product handling.

Not all third-party automation companies have worked with or even understand hydraulic presses and metal forming production, but most world-class press manufacturers have worked with and can deliver effective automation solutions.

Proper Approach for New-Press Automation

A partnership is vital. As providers, we must understand a metal former&#;s goals and then offer press solutions that not only meet, but often exceed, expectations. Working side-by-side as a partner enables us to become an extension of the metal former in a sense&#;sharing/owning the same stated goals. 

The challenge: Identify the &#;right size&#; for the automation solution&#;addressing today&#;s and tomorrow&#;s production needs while keeping within the project budget. This makes tailoring automation offerings to fit a range of applications very important. This holds true for everything from basic hydraulic-press automation, such as electrically integrating a material feeder with the press, to large multi-press, multi-robotic, autonomous workcells.

For example, we recently were approached to build a rotary automated cell. The metal former&#;s stated goal: Purchase three separate presses then connect them with the framework and subsystems once onsite. We worked with the metal former to improve the press-line concepts and deliver all three press functions in a simplified working cell with a smaller footprint. After delivery and install, the metal former noted that cost analysis revealed better value in having a single source for design and build of the complete integrated solution. Doing so had simplified the operational side of capital-equipment purchases, which reduced the metal former&#;s headaches and costs.

Automation Approaches for Existing Presses

A press manufacturer/system integrator can assist a metal former with one or more presses already in place by defining current and future automation needs. Automation may be a new concept and might challenge a metal former as to where to start, or what options and functionality are available for a particular application. In these cases, technical expertise from the supplier provides the key to moving projects in the right direction.

Metal formers may have many reasons to automate their hydraulic presses. Most of the time, it&#;s not because a press runs slowly, but instead results from other factors, some of them surprising:

• Parts demand has increased beyond the capacity/capability of manual labor to keep pace.

• The geographic location of the metal former does not offer adequate or available personnel resources.

• Conditions require operators to staff other areas of the facility.

• Automating an underutilized press proves more cost-effective than purchasing another press.

• The metal former requires more consistent product quality and quantity.

• Personnel face difficulties in handling sharp-edged or hot parts, or delicate parts, or handling of such parts would place personnel at risk of injury.

Options to meet these challenges include providing engineering support, designing potential automation solutions, developing detailed floor-plan layouts and targeting achievable future cycle rates. Different pricing options exist for each. Then, after acceptance and installation, a press manufacturer/system integrator can provide onsite startup, and operator and maintenance training&#;crucial to bringing the automation solution successfully into production.

Upstream and Downstream Opportunities

Opportunities exist for productive automation well beyond the hydraulic press itself. For example, we worked with a manufacturer to automate the repetitive loading and unloading of one of its presses, and engineered a solution to integrate seamlessly into the existing press and work within limited floor space. However, the return on investment (ROI) fell short of the manufacturer's goals, so it reluctantly considered canceling the project.

Knowing that this manufacturer needed the automation in order to retain its product line, we asked if we could examine processes located upstream and downstream from the press. Careful study yielded solutions. Parts could be reoriented upstream to reduce transfer times. Also, one downstream process could be eliminated by expanding automation at the press to directly feed the next process.

Exploring upstream and downstream options resulted in elimination of product transfer and handling bins, and reduction in part-transfer times and overall floor space. The solutions exceeded expectations and reduced ROI times to within required limits. The manufacturer ended up saving the product line and increased margins on each piece.

The manufacturer&#;s key comment on the project: &#;It was easier for us to relay the process intent than to create it internally.&#;
This perfectly summarizes the effectiveness in working with a press manufacturer that also provides system integration.  MF

 

See also: Greenerd Press & Machine Co.

Technologies: Pressroom Automation, Stamping Presses

INTELLIGENT WORK FORUMS
FOR ENGINEERING PROFESSIONALS

Log In

Come Join Us!

Are you an
Engineering professional?
Join Eng-Tips Forums!

• Talk With Other Members
• Be Notified Of Responses
  To Your Posts
• Keyword Search
• One-Click Access To Your
  Favorite Forums
• Automated Signatures
  On Your Posts
• Best Of All, It's Free!

Join Us!

*Eng-Tips's functionality depends on members receiving . By joining you are opting in to receive .

Posting Guidelines

Students Click Here

Promoting, selling, recruiting, coursework and thesis posting is forbidden.

Eng-Tips Posting Policies

Contact US

How can I automate a manual hydraulic machine?

2

thread404- Forum Search FAQs Links MVPs

• Forum

• Search

• FAQs

• Links

• MVPs

  Are you interested in learning more about automated hydraulic press? Contact us today to secure an expert consultation!

How can I automate a manual hydraulic machine?

How can I automate a manual hydraulic machine?

ze2ez

(Mechanical)

(OP)

19 Jan 16 12:48

Here the structure so far:



I would really appreciate if any of you guys could share any ideas, that would be awesome :)

can you guys help me, giving some ideas on how to automate a manual hydraulic machine that uses a hydraulic jack, or we can use other type of component to press any object.Here the structure so far:I would really appreciate if any of you guys could share any ideas, that would be awesome :)

Replies continue below

Recommended for you

RE: How can I automate a manual hydraulic machine?

mcgyvr

(Mechanical)

19 Jan 16 13:53

automate how?
actuator to replace the human pumping the handle? motor on the release screw?
replace with other hydraulic/servo press?

you don't give any details on its function/forces involved/budget/cycle times/etc.. so an alternate suggestion is impossible.

RE: How can I automate a manual hydraulic machine?

BrianPetersen

(Mechanical)

19 Jan 16 14:18

Replace the bottle jack with a normal hydraulic cylinder actuated by directional valves and a hydraulic power pack.

Be very careful. A mechanism like this is potentially subject to safety standards that apply to power presses. Due to the significant potential of someone having fingers, hands, or arms flattened, these standards are very stringent. If you don't have experience with this sort of thing, it is likely time to call in the experts - there are plenty of companies that specialise in power presses and would know what needs to be done.

RE: How can I automate a manual hydraulic machine?

Tmoose

(Mechanical)

19 Jan 16 14:45

How much force is really needed? Maybe a motorized screw could be substituted?

RE: How can I automate a manual hydraulic machine?

Jboggs

(Mechanical)

19 Jan 16 16:32

Check Enerpac cylinders. Control with standard solenoid valves, flow controls, and switches to achieve the motion desired. DO NOT ignore BrianPeterson's advice above! Be aware of all safety requirements (OSHA, etc).

RE: How can I automate a manual hydraulic machine?

tbuelna

(Aerospace)

20 Jan 16 02:56

It would likely be cheaper and less hassle to purchase a hydraulic press that already has the control capabilities you require.

When using a hydraulic press with high force capability, you need to be careful. It is very easy to damage parts being assembled when applying several tons of force. A manually operated hydraulic cylinder is actually a good idea in one respect, since it allows some feedback when cycling the pump lever.

RE: How can I automate a manual hydraulic machine?

moltenmetal

(Chemical)

20 Jan 16 12:58

If all you want to do is to reduce the amount of manual pumping required, you can buy a pneumatically driven manual jack for very little money.

If you truly want to automate it, you will need to do a lot of work or a little, depending on what the intended purpose is.

RE: How can I automate a manual hydraulic machine?

gruntguru

(Mechanical)

21 Jan 16 04:39

Of course pneumatic over hydraulic is another story.

Using a pneumatic cylinder or bellows loses the displacement control inherent in a hydraulic system due to compressibility of the working fluid. I shudder at the thought of using a pneumatic actuator to press a bearing out of a housing!Of course pneumatic over hydraulic is another story.

je suis charlie

RE: How can I automate a manual hydraulic machine?

moltenmetal

(Chemical)

21 Jan 16 13:00 If you read my post, what I suggested was pretty clear:

Such a device is, in every meaningful way, STILL a hydraulic jack, with no significant worries due to the compressibility of the working fluid since it is merely used to operate the jack pump mechanism.

The term "air over hydraulic" does not properly describe the device I suggested in my opinion.

If you read my post, what I suggested was pretty clear:Such a device is, in every meaningful way, STILL a hydraulic jack, with no significant worries due to the compressibility of the working fluid since it is merely used to operate the jack pump mechanism.The term "air over hydraulic" does not properly describe the device I suggested in my opinion.

RE: How can I automate a manual hydraulic machine?

gruntguru

(Mechanical)

25 Jan 16 03:44

Great photo - havent seen one of those before - gets a star.

True, I didn't read your post carefully enough - apologies!Great photo - havent seen one of those before - gets a star.

je suis charlie

RE: How can I automate a manual hydraulic machine?

moon161

(Mechanical)

25 Jan 16 16:24

The jack shown in the first post has a problem as shown. The guide rod blocks access to the bleed screw.

RE: How can I automate a manual hydraulic machine?

chicopee

(Mechanical)

26 Jan 16 01:24

Enerpac has literature on single and dual stroke hydraulic jacks. In your case you have to figure out if the threaded fittings which one is apparent in your pictures will lend to hose connections to the hydraulic pump which Enerpac also sales. Make sure that the jack maximum allowable working pressure is compatible with the hydraulic pump maximum delivery pressure.

RE: How can I automate a manual hydraulic machine?

verymadmac

(Mechanical)

26 Jan 16 21:54

The jack layout shown in the first post, could possibly be improved by placing the springs on the same axis as the guide rods because at the moment if the sring tension is uneven it might cause the platform to tilt slightly and possibly jamming on the guide rods when retracting.

Red Flag This Post

Please let us know here why this post is inappropriate. Reasons such as off-topic, duplicates, flames, illegal, vulgar, or students posting their homework.

Red Flag Submitted

Thank you for helping keep Eng-Tips Forums free from inappropriate posts.
The Eng-Tips staff will check this out and take appropriate action.

Reply To This Thread

Posting in the Eng-Tips forums is a member-only feature.

Click Here to join Eng-Tips and talk with other members! Already a Member? Login

News

If you are looking for more details, kindly visit Hydraulic press industry uses.