Overview & Challenge

 

The requirement was to allow end trimming pairs of Stretch formed components for the Ford S- Max project. The 1st challenge was to accommodate the trimming of 2 different variants with different section, geometry, and compound angle cut conditions. The 2nd challenge was due to the component material, which was a special grade of stainless steel, which imposed specific cutting speed and feed constraints.

 

The Solution

 

The component variations were accommodated through the use of component specific type change tooling nests, with integrated presence sensing.

Multi axis mounting brackets, allowed each saw head to be indexed/locked into predefined positions, thus achieving the correct component specific compound angle cuts.

The use of proximity sensing integrated into the saw assemblies, and component nest confirms both the presence of / and type of tooling nest, correct saw index position and component presence. This ensures that machine operation is only permitted if all required conditions are achieved.

This Poka-Yoke, through the use of sensors, simplified operator interaction, improving productivity and machine utilisation by eliminating the risk of damage to the machine/tooling which would result from incorrect setup.

Operator safety was maintained through the use of fully enclosed and interlocked guarding. Hinged poly-carbonate doors on 3 sides allowed easy access for type change or TPM activities. Normal operator access is provided via an interlocked, counter balanced vertical rising door. The rising door lock mechanism is automatically latched during machine operation, and is only released once the saw blades have stopped rotating, allowing the door to open in a controlled manner, under the action of the counter balance. This results in improved operator interaction, and productivity. Interaction with the door is limited to manually lowering, after component loading and removal has been completed.

Operator interaction is further improved through the use of an integrated unloading mechanism. The sawn components are automatically removed, from the tooling nest, and while the saw rotation comes to a stop, are transferred to a park position, awaiting manual removal. This ensures that the load area is clear to receive the next component pair.