Die Change     Solutions
Our History….At Atlas, our entire 46 year history has beencentered around the goal of optimizing themovement of sheet meta...
The World’s Best Die Change AutomationAtlas designs and builds the mostcomprehensive range of accelerated diechange soluti...
Reasons to Establish a Die Change ProgramAtlas Die Change Systems give you complete con-trol of the changeover process for...
The Principles of Atlas Die Change               Many of the steps within a die change are               larger time waste...
Subplates            Fundamental to Atlas die change systems is a            common interface between the die, the press a...
Rolling Dies               Rolling a die out of the press reduces frictional forces               so that the die is moved...
Pre-Staging              The third ingredient of an Atlas die change              system is the pre-staging of dies on Atl...
Die Change Configurations
Die T-TableAtlas Die T-Tables are based on our die cart technology and our racks combined. The longrack portion contains a...
Die TablesAtlas die tables utilize a combination of push/pull modules and powered conveyors toautomatically unload and loa...
Die Tables & T-Tables
Die CartsAtlas Die Carts have become the industrybenchmark with over 1000 installationsaround the world. Self-powered andc...
Single Cart with Two RacksAn Atlas die cart with two racks in the perfect way to increase the versatility and output rates...
Single Cart with Two Racks
Dual Position Cart (single press)                              The Atlas dual station (position) die cart eliminates      ...
Dual Position Cart(single press)
One Die Cart with Three Racks (two presses)One Atlas die cart used in conjunction with three die racks to service two pres...
Die Carts with Racks
Dual Position Die Carts                          Atlas Technologies dual position die cart utilizes one cart              ...
Dual Position Die Carts
Die Change Configurations - Domino (single line)Domino die change consists of utilizing one additional cart to the number ...
Domino Lines
Die Change Configurations - Domino (sister lines)Sister line domino die change is identical to single line domino die chan...
Domino Sister Lines
Transfer Press Die ChangeAtlas transfer press die change utilizes two diecarts, one cart on either side of the press. Onec...
Automatic Storage & Retrieval SystemsAtlas automatic storage and retrieval systems(AS/RS) are a high speed, proven, fullyp...
Automatic Storage & Retrieval Systems
Die Transfer CartsAtlas Transfer Carts have been used in hundredsof installations for fast, smooth and safemovement of mat...
Die Transfer Carts
Why Atlas?All automation companies talk a good game. At Atlas we back it up… with results.We understand that excellent tec...
Die Change Systems - Atlas Technologies
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Die Change Systems - Atlas Technologies

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Atlas self-powered die change systems are used in hundreds of installations for fast, accurate and safe die or mold changeover. They provide controlled movement and positioning of dies in stamping presses or press lines, via pendant or line controls.

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Die Change Systems - Atlas Technologies

  1. 1. Die Change Solutions
  2. 2. Our History….At Atlas, our entire 46 year history has beencentered around the goal of optimizing themovement of sheet metal and dies duringstamping processes—in short, solving pressroomproduction problems and taking advantage ofautomation opportunities to help our customersexcel.Atlas is a full service facility with the tools, talentand experience to provide objective basedengineering studies that examine alternativesand find the most productive and cost effectivemixture of manual and automated operations,specifically tailored to suit each individualcustomer and their requirements.Atlas has complete in-house capability for totalsystem responsibility, mechanical and controlsdesign, fabrication, machining, assembly, testand installation. We then back our equipmentwith a full one year warranty and support ourcustomers with 24-7-365 emergency service.You can trust Atlas with your die handlingneeds...after all, we have more installationsaround the world then all of our competitorscombined.
  3. 3. The World’s Best Die Change AutomationAtlas designs and builds the mostcomprehensive range of accelerated diechange solutions in the industry. Systemsutilizing powered die carts and integrateddie racks are used in applications rangingfrom a single press or multiple independ-ent presses, to sister tandem lines.With these systems, handling of diesbecomes highly predictable, manageableand very fast. Die change is reduced fromhours to minutes. Scheduling for reducedinventory becomes practical...Just-in-Timebecomes possible. Stock piles disappearand response time quickens. You nolonger need to live with potentialcompromises to product quality due tothe down time required to pull dies forchecking.
  4. 4. Reasons to Establish a Die Change ProgramAtlas Die Change Systems give you complete con-trol of the changeover process for:• Faster Response to changing production schedules or sudden demands, since dies can be changed over in mere minutes• Reduced Inventory Reduce batch size costs effectively, minimize work-in-progress and meet Just-In-Time requirements• Greater Press Uptime and Utilization Reducing die change from hours to minutes can add hours of stamping productivity per day without added presses• Quality Control Dies can be pulled and checked quickly without destroying your production schedule. Controlled handling means less chance for damage to the dies
  5. 5. The Principles of Atlas Die Change Many of the steps within a die change are larger time wasters than you might realize. Some of the largest culprits are organizing tools and people, removing of the old die and locating the new die within the press. With Atlas Die Change Systems, we strongly recommend three basic areas of consideration to best utilize time and personnel: 1. Dies mounted to subplates for commonality 2. Rolling rather than skidding 3. Pre-staging of the in-coming dies
  6. 6. Subplates Fundamental to Atlas die change systems is a common interface between the die, the press and the die change equipment. The use of subplates provides a common surface for all of your existing dies, allowing them to roll into and out of the press. A subplate is normally the same size as the bed of the press and approximately 2 1/2” thick. Most subplates have a pattern of tapped holes to mount a number of different dies. Die locator pins mounted on the left to right centerline of the subplates are used to locate the various dies accurately on the plate. The subplate is designed to be bolted or clamped in position on the press bolster. The common surface is also the key to fast, consistent die clamping. The consistent location achieved by pre-staging dies on subplates is maintained through the use of a keyway or side guides, which guide the die subplate into the press. The common height provided by the sub- plate makes either powered or manual clamping easier.
  7. 7. Rolling Dies Rolling a die out of the press reduces frictional forces so that the die is moved smoothly and efficiently. To accomplish this rolling feature, Atlas recommends the use of hydraulic lifters (Lif-T-Rols or Max-Rols). These lifters raise the die off of the press bolster and place it on wheels. This reduces the force required to move the die to approximately 1% of its total weight. When Atlas designs die change equipment employing Lif-T-Rols the rolling concept we use a 10 times safety factor and figure on 10% of the weight to be moved. In contrast, when the skidding technique is used, the equipment must be designed for 70% of the weight. These higher forces mean heavier equipment with higher potential failure. Atlas die lifters are designed to fit in T-slots or milled pockets in a press bolster and will raise the die’s subplate just enough to allow it to roll off the bolster with only minimal effort.Max-Rols
  8. 8. Pre-Staging The third ingredient of an Atlas die change system is the pre-staging of dies on Atlas Die Racks. Without this feature quick die change would be impossible. When the in-coming die is pre-staged, all of the positioning work of the next die on the subplate is accomplished prior to going into the press and more importantly, while the press is in operation. Pre-staging removes the crane or other forms of die moving equipment from the die change process, thus greatly reducing the time required to change dies. Shown left, subplate mounted dies are pre-staged on Atlas Die Racks fully prepared for the next die change at a major appliance manufacturer.
  9. 9. Die Change Configurations
  10. 10. Die T-TableAtlas Die T-Tables are based on our die cart technology and our racks combined. The longrack portion contains a conveyance device and is divided by a center die table sectioncomplete with a push/pull module. Atlas T-Tables provide a very cost effective die changecapability in situations where floor space and/or economic constraints prohibit the use of diecarts. Die Exchange is as follows: 1.) The incoming die is delivered to Station 1 and conveyed to station 3 for pre-staging and/or waiting for changeover. 2.) The out-going die is pulled to Station 2 3.) The conveyor indexes both dies to the left to move the outgoing die to Station 1 for pick up and moves the incoming die to Station 2, and then into the press 3 2 1
  11. 11. Die TablesAtlas die tables utilize a combination of push/pull modules and powered conveyors toautomatically unload and load dies to and from a press. They are often mated withelevating die carts for automatic die storage and retrieval. Die tables provide complete,cost effective die change capability in situations where floor space and/or economicconstraints prohibit the use of die carts. Adjustable height tables can service two adjacentpresses of varying heights. The table itself is moved by fork truck or crane.
  12. 12. Die Tables & T-Tables
  13. 13. Die CartsAtlas Die Carts have become the industrybenchmark with over 1000 installationsaround the world. Self-powered andcontrolled either by pendant or remotely,Atlas carts move on floor rails at speeds up to30 feet per minute, transporting dies of almostany size to and from presses and die racks.Precision ballscrew driven push/pull modulesengage die subplates on either end, indexingone or more dies on or off the cart and intoor out of the press. For safety and long life,carts are built to handle much more weightthan your highest load requirements.Die racks become a “close to the press”staging area. Equipped with rollers, they areruggedly built like Atlas die carts. In manyconfigurations, added racks extend theusefulness of each cart, maximizing thebenefit of your investment.
  14. 14. Single Cart with Two RacksAn Atlas die cart with two racks in the perfect way to increase the versatility and output rates of astand alone press. Dies are exchanged in minutes allowing for rapid changes in production andincreasing JIT capabilities. The next in-coming die is pre-staged on one rack while the press is inoperation. When die exchange is required, the die cart moves into position in front of the press, pullsthe old die from the press and places it onto the empty die rack. The cart then moves into position infront of the rack holding the incoming die and pulls it onto the cart. The cart moves back into positionand pushes the new die into the press, then returns to the home position. The die is clamped intoposition and production begins.
  15. 15. Single Cart with Two Racks
  16. 16. Dual Position Cart (single press) The Atlas dual station (position) die cart eliminates the requirement for racks that would typically be used for pre-staging of the incoming die. In this scenario, the pre-staging is done on one position of the cart while the press is in operation. The benefit of this configuration is that the area surrounding the press is left clear. Die exchange would occur as follows: • The die cart moves in front of the press • The die cart pulls “old die out of the press • The die cart is advanced to the second die position • The “new” die is loaded onto the press • The die cart is moved to the home position • The crane removes the old die and pre-stages the next die to be run Racks may be used in conjunction with the dual station die cart if additional pre-staging of dies is desired.
  17. 17. Dual Position Cart(single press)
  18. 18. One Die Cart with Three Racks (two presses)One Atlas die cart used in conjunction with three die racks to service two presses has two benefits. First, thedies may be fully prepared to enter the press by pre-staging the in-coming dies on the racks while the pressis in operation, thereby increasing production time. Secondly, the cost to implement a die change system isdramatically reduced by sharing the automation between the presses.Die exchange is as follows:1.) New dies are pre-staged on the racks beside each press (one rack will be empty)2.) The die cart pulls the first old die onto the cart3.) The old die is deposited on the open rack4.) The die cart picks up the pre-staged new die5.) The die cart pushes new the die into the press6.) The die cart removes the old die in the adjacent press7.) The die cart deposits the old die on the empty rack and picks up the new die8.) The cart then moves into position in front of the receiving press and pushes the new die into positionOnce the dies are clamped into position, pressoperation may start and the old dies may beexchanged with the next set of in-coming dies.
  19. 19. Die Carts with Racks
  20. 20. Dual Position Die Carts Atlas Technologies dual position die cart utilizes one cart with a double push/pull module and four racks (2 pre-staged with the in coming dies and 2 empty) to service two presses. This method of die change is accomplished in approxi- mately 12 minutes due to the die exchange process, yet greatly reduces the costs to automate. Die exchange is accomplished as follows: 1.) The cart moves in position and pulls the old die from the press 2.) The cart travels to the empty racks and unloads the old dies 3.) The cart then moves to the pre-staged racks and picks up both incoming dies 4.) The cart moves to the press and pushes the new dies into position. 5.) The cart moves back to the clear position
  21. 21. Dual Position Die Carts
  22. 22. Die Change Configurations - Domino (single line)Domino die change consists of utilizing one additional cart to the number of presses in theline. All but the last cart would be pre-staged with the incoming die while the presses are inoperation. The carts would then move into position (to include the empty cart). The push/pull module would then latch onto the subplate of the old die and push it out of the press,onto the next cart while pulling the new die into the press. The carts then travel back to thehome position. The new dies are clamped into position and the old dies are removed fromthe carts while the presses are in operation. Die change may occur in either upstream ordownstream directions.
  23. 23. Domino Lines
  24. 24. Die Change Configurations - Domino (sister lines)Sister line domino die change is identical to single line domino die change except two lines ofpresses share the carts used by one line in the first example (7 carts service 12 presses). Thepresses must share common alignment with each other to implement this configuration. Dieracks may be utilized beside the presses to assist in the pre-staging efforts to ensure the carts arecontinuously available for die exchange.
  25. 25. Domino Sister Lines
  26. 26. Transfer Press Die ChangeAtlas transfer press die change utilizes two diecarts, one cart on either side of the press. Onecart is pre-staged with the in-coming die andanother cart is empty. The use of two cartsallows pre-staging of the in-coming die andsimultaneous exchange with the old die.Die exchange is accomplished as follows:1.) The empty cart travels into position in front of the press via pendant controls2.) Once in position, pins are lowered into floor bushings to positively locate the cart and lock it into position3.) The die lifting devices are actuated to raise the die off of the bolster4.) The push/pull module then pulls the old die onto the cart5.) As the old die exits, the pre-staged die on the opposing cart is pushed into place
  27. 27. Automatic Storage & Retrieval SystemsAtlas automatic storage and retrieval systems(AS/RS) are a high speed, proven, fullyprogrammable method of efficiently storingand handling dies, parts, coils and other itemsweighing up to 50 tons. Our customers gainvaluable floor space by utilizing vertical,otherwise unused space. The average leadtime to complete retrieval is less than 5 minutes,which eliminates the time associated withpersonnel searching for lost items. A touchscreen user interface is used to facilitate ease ofpart storage.Automatic operation allows items to bepresented at a common location at theprescribed time. The Atlas AS/RS can span fromone crane bay or building to another,eliminating the need for die trucks. Thecontrolled handling of items, reduces thepotential of costly damage to dies, coils andparts. Our AS/RS systems are available in wirerope or ballscrew lift designs and feature lift andcarry capability.
  28. 28. Automatic Storage & Retrieval Systems
  29. 29. Die Transfer CartsAtlas Transfer Carts have been used in hundredsof installations for fast, smooth and safemovement of materials and/or product throughmanufacturing facilities. Based on our worldrenowned die cart technology, Atlas transfercarts provide consistently controlled movementof oversized and heavy loads.Transfer carts increase production by eliminatinglost time waiting for material or dies to bedelivered to the appropriate location. They alsoeliminate the need for overhead cranes andfork trucks to move heavy loads throughmanufacturing areas, thereby greatly improvingplant safety and ergonomics and potentialdamage to dies or material.Atlas Transfer Carts are capable of carryingloads from 10,000 to 180,000 pounds and haveavailable options such as accurate shot pin floorlocators, self loading/unloading, automaticoperation and safety features such as horns,lights, E-stop, bumpers and lasers.
  30. 30. Die Transfer Carts
  31. 31. Why Atlas?All automation companies talk a good game. At Atlas we back it up… with results.We understand that excellent technical skills aren’t the goal, they’re the price of entry.We will design, build and integrate a solution that will achieve your goals.Our engineering documents will be accurate and complete.Our designs will function as promised.Our manufacturing will be precise and durable.Your project will be spearheaded by a contract manager that is intimately familiar with your industry.Our finished product will exceed your expectations.Every customer. Every project. PERIOD.Contact Information 3100 Copper Avenue Fenton, MI 48430 USA Phone: +1 810.629.6663 Fax: +1 810.629.8145 www.atlastechnologies.com www.pressroomautomation.com

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