Stamping and Forming Process MonitoringFor reliable tool protection

Use Stamping and Forming Tools Efficiently

A stack of sheet metal has destroyed the wiper and necessitated a com-prehensive tool repair.

A feed fault is causing cracks to form in the tool. The tool fails. Production comes to a standstill.

Feed■■ Slippage■■ Wrong feed■■ Tool jams

Possible weak areas in stamping and forming

Part ejection■■ Parts not ejected■■ Parts not detected■■ Conveying system failed

Signal connection to the controller■■ Damaged cables■■ Damaged connectors■■ Forgetting to disconnect

Slug and waste ejection■■ Slug pullback■■ Failure to eject after each stroke■■ Unintended stops

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The chipless metalworking industry has been continually optimizing their machines and tools in recent years and made significant technical progress. With the consequence that cycle rates are rapidly increasing. Along with this however comes the risk for tool damage, especially when faults occur unexpectedly.

The remedy is automated protection of the tools. This can be reliably accomplished using sensors for process monitoring. High-quality technology from Balluff offers a variety of solutions for various requirements. Use this proven quality for your individual needs.

Reliable tool protection prevents■■ Punch breakage■■ Sticking centering mechanisms■■ Bent strippers■■ Cracked dies■■ Feed errors■■ Slug pullback, or■■ Faulty part ejection

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Application Solution

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Feed monitoring■■ Belt end doesn't contact stop■■ Allows for coil memory■■ Detect too short and too long feed■■ Detect various punch geometries■■ Universal sensor mounting: on, below, side, adjacent or at right angles to the belt

Inductive sensors with fixed stop■ Precise and adjustable■ Insensitive to impact■ Various plunger types

Inductive Global sensors■ Detect the front edge of the belt■ Threaded shape of the sensors

allows adjustable switchpoints■ Space-saving cable connection

Slot and angle sensors■ Strong infrared light for high function

reserve even in oil mist■ Simple to install■ Stable, rugged housings

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Detect parts■■ For fast-moving objects■■ For large ejection channel■■ When there is little space in the ejection area

Optical window sensors and light grids■ Variety of sizes and shapes■ Non-contact sensing principle

means no jams■ Detect even small objects

Photoelectric Global sensors■ Strong infrared light for high function

reserve even in oil mist■ Various optical and

function principles and ranges■ Space-saving cable connection

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Monitor ejection of small slugs■ Ensure correct slug ejection■ Detect slug pull back even with

very small dimensions

Inductive ring sensors■ Various inside diameters■ Signal-pulse extension

for fast-moving objects■ Can be installed with

distance from metal

Detect waste material■ No sticking of the punch waste

on the tool■ Detect any geometric shape■ Detect buildup of punch waste

Through-beam with aperture attachment■ Strong infrared light for high function

reserve even in oil mist■ Aperture attachments increase precision■ Aperture attachment protects the lens

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Connecting sensors■ Prevent cable breaks■ Use cable ducts■ Simple maintenance and repair■ Economical connectivity

Rugged connectors■ Cable jacket made of stainless braid■ Flexible cable protection conduits■ Sensors with cable or connector

Passive splitters with quick-disconnect■ M12 connections for sensors■ M23 connection for the controller■ State of the art in forming tools

Channel with cover

Belt

Cable

Mold platen

Tool

Passive splitter

Controller

Die stamp

Scrap

Sensor Sensor

Opening

Die stamp

Slug

Ring sensor

Belt

Sleeve Flat fitting Sensor with fixed stop

Die

Sensor

Belt

Check forming Check stamping

BeltFront edge

Sensor

Die

Belt

Side view

Top view

Feed too long

Feed too short

Photoelectric sensor

www.balluff.comDoc. No. 924609/Mat. No. 248909 EN I15; Subject to modification.

Object Detection

Linear Position Sensing and Measurement

Condition Monitoring and Fluid Sensors

Industrial Identification

Industrial Networking and Connectivity

Accessories

Systems and Service

Headquarters Balluff GmbH

Schurwaldstrasse 973765 Neuhausen a.d.F.GermanyPhone +49 7158 173-0Fax +49 7158 5010balluff@balluff.de