Progressive Die Protection for Tool Rooms
Stop tooling damage from misfeeds
Stop the Press
Before Damage Occurs
In most tool rooms, tool and die makers are spending the majority of their time fighting fires
and repairing damaged tooling, such as: sheared punches, snapped pilots, bent strippers,
cracked sections, and smashed stop blocks. Management demands for faster repairs to
meet manufacturing schedules and idle welders puts added pressure on the tool room’s
limited resources. Damaged tooling coming into the tool room is routinely blamed on a
variety of issues like misfeeds, part out detection, and wiring damage.
With Die Protection, the goal is to identify an issue with enough time to stop the press before
tooling damage can occur. Sensors are used to detect issues like short feed, over feed,
slug stacking, or part ejection failure. In order to utilize the solutions presented in this guide,
a press controller capable of accepting sensor inputs is required. Balluff is an experienced
die protection partner for this industry and provides a wide range of technologies for die
protection applications.
Ten hit pile-up destroyed the stripper window
and caused major tooling repair.
Are you repairing tooling due to any of these issues?
nShort feed
nSheared punches
nLong feed
nSnapped pilots
nSlug stacking
nBent strippers
nPart ejection failure
nCracked sections
Misfeed Detection
nSlip during feed progression
nShort feed and long feed
nSticking pierce or punch
Die Connections
nDamaged cables
nDamaged connectors
nForgot to disconnect
Slug and Scrap Out
nSlug stacking
nNot ejected every stroke
nNuisance stops
Cracked tooling from a feed issue caused lost
production and increased tool room stress.
Part Out
nParts don’t leave
nMissed part detection
nConveyor system off
Misfeed
Application
Considerations
Physical Feed Detection
n Contacts end of strip
n Allows for coil memory
n Detects short feed
PlungerProx Sensors
n Precise and adjustable
n Survives overfeed
n Variable tip configurations
Feature Feed Detection
n Detects from side or under strip
n Uses form, hole, or slot
n Detects long feed or short feed
BES Global Inductive Sensors
n Watch feature leading edge
n Distances vary by material,
sensor size, feed tolerances
n Typically cable-out sensors
Paddle
Plunger Prox
Strip
Feature – Form
Feature – Hole
Leading Edge
Sensor
Strip
Die
Block
Die
Block
Strip
Slug and Scrap Out
Part Out
Sensor
Through-beam Sensors for Feed
n Detects over feed and short feed
n Uses two sensors in one place
n Detects from top, side, or bottom
BGL Fork and BWL Angle Sensors
n Burn through lube with infrared
n Easy through-beam alignment
n Rugged housings
Ejected Part Out Detection
n Works with unpredictable trajectory
n Utilizes an array of sensors
n Detects motion
BOW Windows and BLG Arrays
n Variable sizes and shapes
n No hung part nuisance stops
n Small and fast parts
Gravity Part Out Detection
n Used for predicable exit
n Protect during installation
n Install to look up and out
BOS 5K Global Diffuse Photo Sensors
n Burn through lube with infrared
n Typically cable-out sensors
n Variety of styles and distances
Small Slug Out Detection
n Verifies slugs leave the die
n Allows for 2-3 slugs to stack
n Stops major slug stacking issues
BES IKV Inductive Ring Sensors
n Variety of inside diameters
n Delay output for fast parts
n Metal-free mounting
Side View
Short Feed
Strip
Over Feed
Top View
Strip
Punch
Ring Sensor
Slug
Scrap Out Detection
n Verifies scrap leaves the die
n Detects random shapes
n Recognizes stacking or tangling
BOS 5K Through-beam with Apertures
n Through-beam burns through lube
n Apertures add precision
n Low chance of part contact
Punch
Sensor
Sensor
Scrap
Die Connections
Aperture
Sensor Connectors and Cables
n Prevent breaks in standard cables
n Protects with channels
n Stop replacing good sensors, with
broken cables
BCC High Durability Cables
n Stainless braids
n Flexible conduit
n Connectors vs cable out
Sensor Junction Boxes
n Easily repair sensor cables
n Uses one connection to die
n Easily troubleshoot wiring
BPI Quick Disconnect Blocks
n M12 connectors for sensors
n M23 umbilical connectors
n Typical for die protection
Strip
Cable
Channel with Cover
Junction Block
Die
Bolster
Die
Protection
System
Systems and Services
Industrial Networking and Connectivity
Industrial Identification
Object Detection
Linear Position Sensing and Measurement
Fluid Sensors
Accessories
USA
Balluff Inc.
8125 Holton Drive
Florence, KY 41042
Phone: (859) 727-2200
Toll-free: 1-800-543-8390
Fax: (859) 727-4823
E-Mail: [email protected]
Doc. no. 922915/Mat. no. 247052 EN
F15; Product specifications, availability, and
pricing are subject to change without notice.
Canada
Balluff Canada, Inc.
2840 Argentia Road, Unit #2
Mississauga, Ontario L5N 8G4
Phone: (905) 816-1494
Toll-free: 1-800-927-9654
Fax: (905) 816-1411
E-Mail: [email protected]
Mexico
Balluff de México SA de CV
Anillo Vial II Fray Junípero Serra No. 4416
Colonia La Vista Residencial.
Querétaro, Qro. CP76146
Phone: (++52 442) 212-4882
Fax: (++52 442) 214-0536
E-Mail: [email protected]
www.balluff.com