Existing Tooling Simulation & Optimization

 Summary:

This document explains what we need from you in order to complete a T-SIM on existing tooling that is currently running in production. In addition, it explains what we will be providing back to you in the form of deliverables. If you have any questions after reviewing this document, please do not hesitate to reach out to us for clarification.

Prerequisites:

In order to complete any simulation and optimization in T-SIM, we will walk you through our press collection process, and have you complete a customer intake form for your facility.

What we need to get started:

1. Completed RFQ Form
   
2. CAD Data (May require tooling verification media)
   
3. Existing Recipe
   
4. Video of the tool running in production
   
5. Tool Summary
   

 

CAD Data:

Please include the most up-to-date CAD data you have for both the tooling and the automation (if available). It’s crucial that the CAD matches the actual tooling and automation for us to be able to provide accurate simulation results. If you cannot guarantee the CAD is an exact match to the physical tooling (100% confident), be sure to include the Tooling Verification Media as described below. Note: T-SIM / 3D cannot be held liable for any injuries or damage to tooling or equipment resulting from inaccurate information being provided to us.

It’s important that we have the current recipe and SPM so we can establish a baseline for the acceleration and velocity of the various transfer motions. Recipe can be shared off setup sheets or by pictures of the values displayed in the controller screens of the press (preferred).  Items required include the following:

·         Start and stop angles for each axis (clamp, lift, pitch).

·         Start and stop positions of transfer bars.

·         Travel distances for each axis (clamp, lift, pitch).

·         Gripper close / open timing.

·         Any auxiliary movements timing (air lift, servo shuttle, part rotations, etc.).

·         Please run at current production SPM.

·         Pause and focus on each station for a few strokes.

·         Try to include a perspective from the end of the press line so we can see the clamp stroke clearly (minimum of 3-5 strokes from this view).

·         Be sure to video from both front and rear of the press if possible.

 

Tooling Summary:

The best way we can help you with your existing tooling is to understand what is preventing you from running at an even higher SPM rate. We ask that you explain this in as much detail as you can so our technicians can make the most out of your experience with T-SIM.

1. The transfer bars are shaking during clamp in motion if I go any faster than XX SPM. 
   
2. The panel is not consistently locating properly in the first trim station during drop off if I go faster than XX SPM.
   
3. The incoming blank sags too much during lift-up motion if I go any faster than XX SPM. 
   
4. Our servo motor for the pitch axis is worn out. If I go any faster than XX SPM it’s too hard on the motor and it overheats and stops.
   

 

Tooling Verification Media:

In situations where you are unable to guarantee the CAD is 100% accurate to the physical tooling, we will require some additional pictures and videos that can be reviewed and compared to the CAD data. It is our experience that many tools and automation are often modified during their lifetime to improve their performance during production, to implement ECs, or they were never accurately built to the CAD in the first place. This extra step helps ensure the accuracy of the results we provide, and significantly reduces the risks to the tooling and automation.

 

Outside of the press:

·         Pictures or Video “walk around” of Upper and Lower Die open on the bench.

o   This typically provides much better lighting than we see in the press and allows up-close, more detailed videos.

While tool is in the press:

·         Pictures or Video of both front and rear automation at clamp in stop (“Pick Up location”) for each station.

o   We need to clearly see where the fingers are picking up on the panels.

o   If possible, include the gripper part number for each station (photo or BOM).

o   If collar clamp mounts are used, try to include a view from directly behind the gripper so we can match the position / rotation in the CAD for simulation.

  

What we provide (Deliverables):  

·         Optimized Press Settings (1-3 variations)

1.       (E1) A new press recipe with optimized settings without physical changes to the tooling.

-  Maintain current G-Forces from existing recipes or higher G-Forces from sample recipes, if they were provided to us.

-  If T-SIM verified press, settings will be based on 80-90% system capabilities factoring in currently known issues with existing settings. We may reduce G’s in some axis based on panel characteristics and past experiences with similar parts.

2.       Optional-(E2) A second press recipe with optimized settings and supporting CAR for simple changes that may improve SPM or part control (if applicable). 

-  Changes that can be accomplished by most tool rooms (simple clearance pockets, shortening gages, adding chamfers, re-locating existing automation, etc.).

3.       Optional-(E3) A third press recipe with optimized settings and supporting CAR for more significant changes that may improve SPM or part control (if applicable). 

-  These would include modifications such as:  adding lift to a station, extensive machining to tooling, re-location of components (guide media, stop blocks, heels, or gages), alteration to trim lines, switching type / brand of automation to improve SPM etc.).

·         If your company has T-SIM in-house, we also include the T-SIM file with the press package. This allows you to have full access to make any additional tweaks to the settings while it is in production.

 

Important Info:  

While we are more than happy to provide this service to our customers, we have found that customers who use T-SIM in their plant to optimize existing tooling have the highest resulting gains in production. Often you can complete it in less time internally because you have complete access to the tooling and press. This prevents additional time spent in back-and-forth communication. If you’d be interested in learning more about how you can use T-SIM in your facility, let us know, we’d love to show you how you can become a T-SIM user yourself!