New series of MPX BF MATRIX presses
9 models from 30 to 500 ton
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MATRIX introduces the new
floating table press
Model MPX BF
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
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.
(Patent pending)
Available configurations of the MATRIX presses model MPX BF (Floating table)
Production of low complexity parts
Configuration B
Configuration A
Configuration C
Production of medium and high complexity parts
Configuration D
Configuration E
FP = Fixed Punch
AVAILABLE ON REQUEST
During the compacting phase all the auxiliary axes (X1, X2, Z1, Y, Y1) are moving the punches towards a mechanical stop.
Model
MPX
30BF
200
MPX
50BF
200
MPX
80BF
200
MPX
100BF
250
MPX
125BF
250
MPX
150BF
250
MPX
300BF
300
MPX
400BF
300
MPX
500BF
300
Compacting force [kN]
300
500
800
1000
1250
1500
3000
4000
5000
Counter force [kN]
180
250
400
500
500
750
1500
2200
2200
Ejection force [kN]
150
200
320
400
400
600
1200
1800
1800
Production rate [cycle / hour]
1200
1150
1100
1000
1000
900
750
750
650
Power [kW]
9
11
15
21
25
35
75
85
100
Weight [kg]
5.100
6.200
8.000
Maximum filling height [mm]
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10.000 12.000 12.000 27.000 32.000 40.000
Special version of the MATRIX MPX BF presses, with additional axes, are also available on request
The above information are subject to change without prior notice.
MATRIX MPX BF
MPX BF – Floating table
(Patent Pending)
Filling box feed
Movement to the filling positions
Filling box return
Fast approach
Slow approach
A
B
C
D
E
F
G
H
L
M
Powder transfer
phases
Compacting phases
Delay
Force reduction
Withdrawal
Compacting cycle
N
P
Punch stripping
Part pick up
SIMPLY USE AND PROGRAMMING
The MATRIX MPX 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:
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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.
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MATRIX MPX BF
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:
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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.
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MATRIX MPX BF
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 ± 0.002 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 MPX 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
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MATRIX MPX BF
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.
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MATRIX MPX BF
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.
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MATRIX MPX BF
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 MPX 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 0.002 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 ± 0.002 mm and repeatability inferior to ± 0.008 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.
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MATRIX MPX BF
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.
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MATRIX MPX BF
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 MPX 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)
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MATRIX MPX BF
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.
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MATRIX MPX BF
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.
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MATRIX MPX BF
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 SIMULATORDIE 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.
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MATRIX MPX BF
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.
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MATRIX MPX BF
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.
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