MATRIX introduces the new floating table press Model MPX BF (Patent pending)

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Osborne Byrd
6 years ago
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New series of BF MATRIX presses 9 models from 30 to 500 ton! No more pit below the press! No need for the die guide! Powder compacting and sizing with the same machinery!

1 New series of BF MATRIX presses 9 models from 30 to 500 ton! No more pit below the press! No need for the die guide! Powder compacting and sizing with the same machinery! Faster adaptor change: the filling box has not to be removed (50% faster)! Self-centering and self-aligning of the tool adapter! Faster tool change! Increase in the working space for the tool change (>30%)! Cut in power consumption (>30%)! Increase in the productivity (>25%)! New electronic system! High resolution (0,002 mm) of the position measuring system! New hydraulic unit with energy saving control! Closed loop control of position and pressure on the main axes! Graphic programming of the part shape! Intuitive man machine interface! Continuous check of the actual process parameters! Real time process diagnostic! Supervisory control and data acquisition! Off-line programming! Network connectivity! Knowledge base driven trouble shooting! Short machine downtimes for tool change! Pretensioned enbloc mainframe MATRIX introduces the new floating table press Model BF (Patent pending) From the beginning to the end of the compacting phase, the main axes transfers the force and speed needed for the piece compaction to its own punch directly, in proportional way to the sections and thickness values of the piece to be compacted.

Available configurations of the MATRIX presses model BF (Floating table) Production of

medium and high complexity parts Configuration D Configuration E AVAILABLE ON REQUEST

Y1) are moving the punches towards a mechanical stop.

200 200 200 250 250 250 300 300 300 Compacting force [kn] 300 500 800 1000 1250 1500

force [kn] 150 200 320 400 400 600 1200 1800 1800 Production rate [cycle / hour] 1200

2 Available configurations of the MATRIX presses model BF (Floating table) Production of low complexity parts Configuration A Configuration B Configuration C Production of medium and high complexity parts Configuration D Configuration E AVAILABLE ON REQUEST FP = Fixed Punch During the compacting phase all the auxiliary axes (X1, X2, Z1, Y, Y1) are moving the punches towards a mechanical stop. Model 30BF 50BF 80BF 100BF 125BF 150BF 300BF 400BF 500BF Maximum filling height [mm] Compacting force [kn] Counter force [kn] Ejection force [kn] Production rate [cycle / hour] Power [kw] Weight [kg] ! Special version of the MATRIX BF presses, with additional axes, are also available on request! The above information are subject to change without prior notice.

BF Floating table (Patent Pending) Compacting cycle A B C D E Filling box feed Movement to the filling positions Filling box return Fast approach Slow approach F G H L M Powder transfer phases

Windows CE operating system, installed in a control panel on mobile pedestal, combined with a simply machine control push-button panel.

3 BF Floating table (Patent Pending) Compacting cycle A B C D E Filling box feed Movement to the filling positions Filling box return Fast approach Slow approach F G H L M Powder transfer phases Compacting phases Delay Force reduction Withdrawal N P Punch stripping Part pick up SIMPLY USE AND PROGRAMMING The MATRIX BF man-machine interface is realized by an operator panel, based on Real Time Windows CE operating system, installed in a control panel on mobile pedestal, combined with a simply machine control push-button panel. The high technology of used component, as the solid estate hard disk, grants to mobile control panel a resistance to:! powder and water jets! shocks from impact up to 15 g (IP65)! vibration up to 1 g The operator panel, based on a 64 bit RISC CPU, has an 11 graphic colour screen LCD TFT and it is built with TOUCH SCREEN technology.

4 This solution permits the information visualisation and an intuitive data introduction and it simply function just touching the screen with a finger. In fact, a transparent film, sensible to pressure, covers the graphic screen. In spite to use a pointing device, as a mouse or an optical pen, it can be used a finger to point directly the object on the screen. Then able to select the functions, change parameters, simply touching the right image on the screen. The using of the operator panel is simple and intuitive, information and function buttons are visualized with graphical symbols, conforms to ISO7000 and Microsoft Windows standards. Exploiting the fonts of defined characters on UNICODE international standard, it results possible to realize the interface on desired country language, without any limit on alphabetical characters to use: from which necessary for occidental languages to ones for oriental Asiatic languages. Besides are contemporaneously available on the machine, up to 5 different languages, selectable with the simple pressure of one key. Programming of producing cycle Also the programming of production cycle is graphically executed, following two simple steps:! selecting the piece shape in a predefined shapes library! inserting the required geometrical and technological data The piece dimensions to program are simply getting out from a piece-dimensioned draw and they are referred to the piece coordinates system ( ) and not to axis (machine coordinates system). The transformation from one coordinates system to the other it is automatically executed using the parameters stored during the auto-learning procedure, executed at die change time. Compacting forces are directly programmed on kn and not as pressure referred to cylinders sections of different axis.

Axis control Hydraulic axis movements are effected using only one servo valve for each axis and two pressure transducers, one for each cylinder chamber.

5 Axis control Hydraulic axis movements are effected using only one servo valve for each axis and two pressure transducers, one for each cylinder chamber. This permits to grant the continuous and complete speed control of real force applied by the axis on whatever using condition. The position transducer is of absolute type, with high resolution (0.002 mm). In this way it is granted the exact knowing of axis position in whatever situation, also if the axis undergo some movement at switched off machine, or after a die change executed in a station external to the press. The position transducer is built with magnetostrictive technology, which exploits the ultrasounds coupling to magnetic fields; this grants the contact absence behind mechanical parts and consequently a prolongation of component life. The axis electric control is completely digital and parametrable. Exploiting the most advanced control technics, suitably devolved and optimised for hydraulic axis, it is realised a real closed ring control of position, speed and force. Then on manage both to position the axis always to required position (with an error of ± mm), to really move the axis at the programmed speed (with an error inferior to 1.5%) and to really apply the programmed force (with an error inferior to 0.1%) without uncontrolled force peaks. Press integration into factory automation The BF MATRIX presses can be connected into industrial Ethernet network at 10 or 100 Mbit/s speed, with TCP/IP protocol to:! share programming data of producing cycle! print production reports, programming data and diagnostic messages! acquire data for process statistic control and store them separately for each produced piece (identifiable by an univocal progressive number with 9 digit)! acquire data for the supervision of producing process (hour producing, quantity of produced discards)! monitor and registry all the modification brought to the producing cycle programming! execute the OFF-LINE programming of cycle data from a remote computer! exchange information and data between separately productive units

Automatic adjustment of loading depth To follow the variation to which the powder density is suggested, the filling depth can be automatically modified with regard to the measured weight on

Then, the correction is not calculated on the basis of a single date, but in relation to the run that measure put on.

In case the position and force values being out of the programmed values windows to accept the piece, this is declared as discard and separately treated by the piece drawing device.

6 Automatic adjustment of loading depth To follow the variation to which the powder density is suggested, the filling depth can be automatically modified with regard to the measured weight on previously produced pieces, or with regards to the force applied on the previously effected cycles. Then, the correction is not calculated on the basis of a single date, but in relation to the run that measure put on. Real time process control The significant process parameters are constantly controlled at every cycle. In case the position and force values being out of the programmed values windows to accept the piece, this is declared as discard and separately treated by the piece drawing device. If the IN-PROCESS feedback function of discard piece is enabled, at reaching of the final cycle position (referring position) if the applied force is out of the programmed window, the press further tries to compact the piece, in the attempt to make re-enter the applied force inside the programmed window. During the first producing cycle the compressibility curve is automatically detected, sampling the position and the force used to execute the powder compacting. These data are after used to execute a continuous monitoring over the applied force on all following cycles; if the applied force is getting to exit from the programmed zone, the machine cycle is interrupted.

We have thus eliminated the traditional guide col-umns usually positioned between the upper presser and matrix, which results in a larger die-access area, more space for pick-up equipment and the

7 PRESS STRUCTURE Features pre-tensioned enbloc main frame to minimise deformation during pressing. Four Chrome TMP steel columns are fixed to the outer walls to serve as permanent guides of the matrix holder and upper presser. We have thus eliminated the traditional guide col-umns usually positioned between the upper presser and matrix, which results in a larger die-access area, more space for pick-up equipment and the certainty that punch-matrix alignment is permanently guaranteed by the press structure and not by external equip-ment. FLOATING TABLE (Z AXIS) This is a mobile table positioned below the main presser. This element is driven by two hydraulic cylinders positioned on the outer sides of the press structure and slides along the press 4 permanent columns. In the centre it has a truncated cone-shaped recess into which the top truncated coneshaped part of the die holder adaptor is introduced. The locking of these two truncated cone-shaped parts guarantees a safe and repetitive centring condition of the die-holder adaptor with the press central axis. Furthermore, the upstroke and downstroke movement of the floating table determines the die filling height, the forming of the pressed piece and enables locking in the desired position in order to perform piece in matrix work and nor-mal controlled downstroke during pressing.

THE HYDRAULIC UNIT is realized with the most modern REXROTH components, inserted on modular stainless blocks, grouped in the superior press part.

8 THE HYDRAULIC UNIT is realized with the most modern REXROTH components, inserted on modular stainless blocks, grouped in the superior press part. This solution, in addition to reduce the dimensions on press base, permits a direct connection of tube holder blocks to various uses, eliminating many pipes, with consequently elimination of oil blow-by and relative flow resistance, then permitting a strong improvement of overall plant efficiency. An accumulator set, suitably dimensioned, can store the necessary oil for the press cycle, so that all axes made use of the instantaneous energy necessary for own movements. Our thirty-year experience, lived directly on the field, has permitted us to realise this new technologically evolved, simply, safe and reliable plant type, suitable for very rapid cycles for continuous shifts, endowed with an high efficiency, absorbing less energy, under the same done work, with less installed power. SPEED AND PRECISION The main axes of the MATRIX BF presses are controlled in every moment in position and pressure with closed control loop, with a modern system of electronic cards for axis control (Rexroth), coupled to high frequency servovalves (Rexroth Moog) and interfaced with ultrasound linear position transducers with resolution of mm. The ensemble of those elements, governed by a modern PLC (Siemens) fitted with a suitably structured software, permits to operate press axis on all operative cycle phases, with precision of ± mm and repeatability inferior to ± mm on position, and ± 0.6 bar with repeatability inferior to ± 2.1 bar on pressure. The reachable speeds, with total axis control, reaches 1.0 m/s with acceleration of 20 m/s², with the purpose to reduce the cycle times.

and safe centring of the adaptor with the press. The central part is constituted by the fixed table on which the lower fixed punches are installed.

9 TOOL ADAPTOR A matrix-holding recess has been made in the top plate. Externally this plate has a truncated-cone shape so as to match perfectly with the truncated cone-shaped recess of the floating table, thus creating an automatic and safe centring of the adaptor with the press. The central part is constituted by the fixed table on which the lower fixed punches are installed. Axes Y-Y1 for the activation of the lower mobile punches are lodged on the same fixed table. The lower end part of the adaptor, made of a steel plate on to which axis Z1 is fixed, is joined to the upper matrixholder plate by 4 steel columns held in line by the fixed table.

THE POWDER FEEDER GROUP is made up of a linear unit connected to the floating table and positioned on the righthand side of the press.

consequential elimination of the usual, well-known problems.

Pressed pieces exit (pushed or picked up) from the left-hand side of the press; in this way the front and rear of the press are kept free to enable the installation of a feeder

10 THE POWDER FEEDER GROUP is made up of a linear unit connected to the floating table and positioned on the righthand side of the press. This solution makes it possible to replace the die-holder adaptor unit without having to re-move the powder feeding unit from its position, with substantial savings in time and a consequential elimination of the usual, well-known problems. On the front of the powder drawer one may attach various pressed piece grip or resting elements, simple pushers or specific equipment on request. Pressed pieces exit (pushed or picked up) from the left-hand side of the press; in this way the front and rear of the press are kept free to enable the installation of a feeder unit for calibration operations. This solution brings considerable advantages to MATRIX BF presses users as:! simplifies the die construction with consequent costs reduction! reduces the punches high with consequent reduction of relative deformation! reduces the programming times of press cycle thanks to the selflearning system (setting the piece dimensions and not axis strokes)

ACCESSORIES OPTIONALS Picking-up, rotation and placement device This accessory can be furnished in two versions, to satisfy two specified necessities.

pick-up the piece, lift it up and carry it outside the press.

11 ACCESSORIES OPTIONALS Picking-up, rotation and placement device This accessory can be furnished in two versions, to satisfy two specified necessities. The most simple version consists in a double adjustable air gun, directly fixed on the front of the feeding box, provided with an optical sensor to control the piece presence, it has the task to pick-up the piece, lift it up and carry it outside the press. The most complete version is formed by an independent group, external to the press, and directly constrained at the front of the matrix-holding table and a slide, driven by a BUSHLESS motor, placed on the front side of picking-up and rotation gun to pick-up, turn and place the piece on desired positions. This device permits an increase of press productive rate. Conveyor belt Formed by commercial modular elements, it can be furnished with the length and width required by the customer; the driving is given by a geared motor with inverter. The entire group is fixed externally to the press on a flexible support for a rapid release of front press; the height adjustment of belt working plate is adjustable by a manual handweel.

Hopper level adjustment device This accessory permits a constant powder flux upon variation of matrix-holding table working level.

that feeds the feeding box, was always on optimal condition, over all working levels taken by matrix-holding table.

of mould and punches, simulate the work strokes, verify sliding and acquire all necessary data to be charged to the press cycle.

12 Hopper level adjustment device This accessory permits a constant powder flux upon variation of matrix-holding table working level. Thanks to the vertical excursion, motorised by a screw jack, it is possible to vary the vertical position of the hopper in way the hose curve, that feeds the feeding box, was always on optimal condition, over all working levels taken by matrix-holding table. Dies-trial simulator By this device it is possible to install the die in the adaptor outside the press, control the position and the orientation of mould and punches, simulate the work strokes, verify sliding and acquire all necessary data to be charged to the press cycle. Realised with electro-welded tubular, a wire system with rapid release, permits a smooth insertion in the adaptor; a hydraulic gearcase, with a set of manual lever distributors, permits the drive of all axis.

Quick adaptor-change device To reduce machine downtimes during the adaptor change, we have realized a system of adaptor-holding trolleys on rails, where the face is lined up with the fixed plan of

As received the adaptor, the trolley is carried to a turntable platform, that will be oriented or towards a parking station, or towards the SIMULATOR- DIE group, thus releasing the passage on press

13 Quick adaptor-change device To reduce machine downtimes during the adaptor change, we have realized a system of adaptor-holding trolleys on rails, where the face is lined up with the fixed plan of the press. A trolley is carried in the front of the press and locked on position, the adaptor on the press is translated on the trolley with manual push, thanks to sliding over spheres. As received the adaptor, the trolley is carried to a turntable platform, that will be oriented or towards a parking station, or towards the SIMULATOR- DIE group, thus releasing the passage on press front where a second trolley, carrying the new adaptor, will do the inverse process for the insertion on the press. Double-die adaptor (Split-die) To produce under square pieces, normally not extractable from usual moulds, we can supply a special adaptor in which the matrix-holding table is divided on two parts (one superior and one inferior). Each one of these two parts houses a die portion, the division of these two moulds is done at the under square line. Thanks to the independent drive of two moulds, the contact between them is maintained during filling, transferring and compression phases. During the expulsion phase the die upper part will rise to the high, knocking out the upper part of the piece, the mould inferior part will descend knocking out the inferior piece part, which will be drawn in the space formed between the two dies.

Weighing device We have several types of automatic pressing devices available, from the most simple ones, with electronic balance connected to the producing cycle on postprocess, for the survey of

Horizontal padding device This accessory becomes indispensable for the production of BIMETALLIC pieces, composed by two different powder qualities.

The doser unit is translated to right or left by the die axis, in way to deposit the A powder or the B powder, this in alternated way; the powder quantity deposed and regulated by the vertical

14 Weighing device We have several types of automatic pressing devices available, from the most simple ones, with electronic balance connected to the producing cycle on postprocess, for the survey of productive quality, statistic, tendency, etc., to more complex devices working in-process, able to send to the press the automatic weight correction signals. Horizontal padding device This accessory becomes indispensable for the production of BIMETALLIC pieces, composed by two different powder qualities. The system is formed by two separates dosers, each one connected by a hose to a own independent hopper. The doser unit is translated to right or left by the die axis, in way to deposit the A powder or the B powder, this in alternated way; the powder quantity deposed and regulated by the vertical position taken by the die in feeding phase. For a clear separation of two layers it is possible to execute a first compacting after having deposited the A powder, then deposit the B powder and execute the final compacting. The possible combinations are A-B / A-B-A / A-B-A-B / etc. Helical-gears device It is an accessory unit, constructed under specific customer indications, for the pressing of helicoidally gears (max. helix inclination 22 ). This unit is inserted in the tool-holder adaptor and permits the presser punches rotation, in phase and syncronism, with the compacting action.

Collection-bunching device To give a continuous productive rate, also in temporarly operator absence, we can supply a device with revolving platform, able to automatically

For a continuous operator absence we can supply an handling station completely automated, ables to collect the piece from the press, place it on the balance, collect it

15 Collection-bunching device To give a continuous productive rate, also in temporarly operator absence, we can supply a device with revolving platform, able to automatically collect the press piece in arrive. For a continuous operator absence we can supply an handling station completely automated, ables to collect the piece from the press, place it on the balance, collect it again and place it on a chamfering mechanical working station, collect again the piece and place it on a conveyor belt with inching feed, all programmable and adaptable to piece dimension and geometry. Names and marks mentioned in this text are generally deposed or registered by respective manufacturing companies.

GRM SERIES. Mechanical stamping and forming machines GRM 80E / GRM 80P

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