In precision metal stamping, each stroke of the press puts a lot of force on the metal being formed. Without sensors, this can cause problems that are hard to predict over time. Parts can be messed up or not come out right, metal can be fed wrong, and the die or part can be broken. This could lead to parts being thrown away, waste of materials, delays in production, damage to the tools, and overall higher costs. New metal stamping tool and die sensor technology, sometimes known as “in-die protection systems,” is being adopted by tool and die manufacturers in place of the conventional mechanical monitoring methods of the past. This is to help catch any problems before they happen.
Advantages of Metal Stamping Tool and Die Sensors
The newest metal stamping sensors have changed the metal stamping industry in a big way. The sensors are made to work well by being programmed to notice a problem before it could lead to something terrible. When these sensors find something wrong with the press, the press stops. If the sensors are broken, rarely, the machines won’t work. Some of the most important benefits of electronic sensors are the following:
- Clients get their orders on time; the overall quality is better because there are no flaws in the parts; the overall cost of tool maintenance goes down.
- Less money is spent on sorting. Less time is spent setting up and less time is spent not working.
The Way Electronic In-Die Sensors Work
Precision metal stamping is a complicated process, so the die’s electronic sensors must be programmed and set up for each press and process. There are different sensors, but the type used depends on how complicated and extensive the part is.
Most well-known precision metal stamping companies use electronic sensors made just for them. The sensors in the die are linked to the controls of the press, and if something goes wrong, the system stops. The controls are set up well to keep an eye on events that repeat or stay the same. This way, the electronic sensors inside the die help get the best results.
How Do Sensors Ensure Accuracy?
There are many things that the precision metal stamping tool and die supplier needs to consider. Customers only care about the quality of the finished goods, and the quality of the press and die is also at risk. So, the company that does metal stamping needs to have a good plan for checking the metal stamping sensors to make sure they give accurate results. Before the sensors are put in place, the metal stamping company will ensure they are valid and consistent.
The company will check the result and see if the sensor can handle repeated shocks from the press. At different points in the production process, the sensors are checked to find out what went wrong and fix any problems while the press is running. All testing and troubleshooting are done on time to ensure that every part that leaves the production room is accurate.
Different Types of Metal Stamping Sensors
Sensors ensure the stamping process is being watched and controlled. Generally, a sensor’s main job is to look for and report any changes in the process. Usually, it can tell if a material is there or not, and it can also be set up to recognise changes in size, distance, number, colour, and other important aspects of metal stamping. Some of the options that people usually choose are:
- Inductive proximity sensors; digital sensors; analogue sensors
- Sensors that use light and fibre optics
Precision metal stamping is best done with photoelectric and inductive proximity sensors. Photoelectric sensors have the advantage of being able to locate the object being manufactured by use of a beam of light or a fibre. This choice is better than the others because the sensors don’t touch the measured part. On the other hand, inductive proximity sensors turn electricity into a magnetic field and can find metal objects. This method also doesn’t involve touching the thing but can only be used when the object is close by.
As companies in many industries make new products with more complicated parts, sensor technology allows metal stamping tool and die to create complex parts without any problems. Metal stampers can verify that every item is of 100% quality, prevent die crashes, and reduce downtime thanks to the information provided by sensors that detect crucial angles and characteristics on every part that passes through the press.