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, solvingpressroom production problems and takingadvantage of automation opportunities tohelp our customers excel. Atlas is a full service facility with the tools,talent and experience to provide objectivebasedengineering studies that examinealternatives and find the most productiveand cost effective mixture of manual andautomated operations, specifically tailoredto suit each individualcustomer and their requirements. Atlas has complete in-house capability fortotal system responsibility, mechanical andcontrols design, fabrication, machining,assembly, test and installation. We thenback our equipment with a full one yearwarranty 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.
The World’s Best Die Change Automation Atlas 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 independentpresses, 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 no longerneed to live with potentialcompromises to product quality due to thedown time required to pull dies for checking.
Reasons to Establish a Die Change ProgramAtlas Die Change Systems give you completecontrol of the changeover process for: Faster Response to changing productionschedules or sudden demands, since dies can bechanged over in mere minutes Reduced Inventory Reduce batch size costseffectively, minimize work-in-progress and meetJust-In-Time requirements Greater Press Uptime and UtilizationReducing die change from hours to minutes canadd hours of stamping productivity per daywithout added presses Quality ControlDies can be pulled and checked quickly withoutdestroying your production schedule. Controlledhandling means less chance for damage to thedies
The Principles of Atlas Die Change Many of the steps within a die change are a larger waste of time than you might realize. Some of the largest culprits are organizing tools and people, removal 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
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 subplate makes either powered or manual clamping easier.
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 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.
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.
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 3 pick up and moves the incoming die to station 2, and 2 then into the press 1
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.
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 ofalmost any size to and from presses and dieracks.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.
Single Cart with Two RacksAn Atlas die cart with two racks is 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,pulls the old die from the press and places it onto the empty die rack. The cart then moves intoposition in front of the rack holding the incoming die and pulls it onto the cart. The cart movesback into position and pushes the new die into the press, then returns to the home position. The dieis clamped into position and production begins.
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 into 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.
One Die Cart with Three Racks (two presses)One Atlas die cart used in conjunction with three die racks to service two presses has tow benefits. First, the dies may be fully prepared to enter the press by pre-staging the in-coming dies on the racks while the press is in operation, thereby increasing production time. Secondly, the cost to implement a die change system is dramatically reduced by sharing the automation between the presses.Die exchange is as follows:1. New dies are pre-staged on the racks beside each pres (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 the new 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 position9. Once the dies are clamped into position, press operation may start and the old dies may be exchanged with the next set of in-coming dies.
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 approximately 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 into 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
Die Change Configurations - Domino (single line)Domino die change consists of utilizing one additional cart to the number of presses in the line.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/pullmodule would then latch onto the subplate of the old die and push it out of the press, onto thenext cart while pulling the new die into the press. The carts then travel back to the homeposition. The new dies are clamped into position and the old dies are removed from the cartswhile the presses are in operation. Die change may occur in either upstream or downstreamdirections.
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). The pressesmust share common alignment with each other to implement this configuration. Die racks maybe utilized beside the presses to assist in the pre-staging efforts to ensure the carts are continuouslyavailable for die exchange.
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 intofloor bushings to positively locate the cart and lock it into position3.) The die lifting devices are actuated toraise 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
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 easeof part 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.
Die Transfer CartsAtlas Transfer Carts have been used in hundreds ofinstallations for fast, smooth and safemovement of materials and/or product throughmanufacturing facilities. Based on our worldrenowned die cart technology, Atlas transfer cartsprovide consistently controlled movement of oversizedand heavy loads.Transfer carts increase production by eliminating losttime waiting for material or dies to bedelivered to the appropriate location. They alsoeliminate the need for overhead cranes and fork trucksto move heavy loads throughmanufacturing areas, thereby greatly improving plantsafety and ergonomics and potential damage to diesor material.Atlas Transfer Carts are capable of carrying loads from10,000 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.
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 yourindustry.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