Technology Update:
Ultra Tool & Manufacturing's Sensor Automation Program

Ultra Tool's sensor automation program is now in full swing. The ultimate goal of this effort is to supply our customers with zero-defect parts in a mistake-proof environment. This saves everybody money. By combining sensor specialists, technology and processes, we are able to bring our customers the benefits of our knowledge and experience in sensor automation.

What are the pieces to a successful sensor program?

Sensor Application Specialist
A successful sensor automation program starts with the right individuals. Our dedicated sensor application specialists have backgrounds as journeyman toolmakers and specialize in the science of sensor application, selection and testing. Ultra Tool's sensor lab is a dedicated area in the plant where precise tooling simulations and processes are custom built and proven. (see die demo)

Technology
Adding sensor technology to a stamping operation requires an influx of new technology. Sure, sensors are added to the tooling, but the presses must also have the operational controls to receive the electronic information from the tool. This requires computers, software and press controls. Ultra Tool has recently completed updating all its presses with new state-of-the-art process controls.

There are many sensor types and many sensor manufacturers to evaluate. Two types of sensors can be specified for use in a die - digital and analog. Digital sensors are in place for die protection - detecting feed, pulled slugs, part out, etc. Analog sensors measure characteristics of a part within the die like angles. These measurements are vital in a zero-defect environment.

The Process
With a sensor application specialist in place, the retrofitting of old dies and new tool designs become part of a larger solution in the mistake-proof environment required to compete in today's economy. Working with tool designers, the sensor application specialists implement which sensors to use, how many and where. Our press operators are also being trained to know new sensor types, uses, and sensor strengths and weaknesses. Through this process, we are standardizing procedures throughout the plant, creating a mistake-proof environment.

Ultra Tool's Die for Demonstration:
The die simulator seen here demonstrates nine built-in sensors. This die was built for the 2004 MetalForm Show in Louisville, Kentucky and was on display in the Balluff® booth. Balluff is a provider for sensors. A brief description of what each sensor detects follows: A simulator box with two digital meters shows analog measurements in sensors eight and nine. In addition, the remaining sensors are represented by a light at the top of the box indicating sensor satisfaction.

Sensor #1: Feed sensor
Sensor #2: C Frame Photoelectric Sensor
Sensors #3 -6: Stripper Sensors
Sensor #7: Photoelectric Sensor
Sensors #8-9: Analog Sensors - Part measurement sensor looking at important dimensions.

Benefits
The ability to incorporate this technology has paid off for Ultra Tool. Early in 2004, we completed a production tool with 25 sensors that measured and detected die functions. It also had the ability to adjust automatically for incorrect form angles while it was running. We would not have been able to even consider this project before. We have also been able to increase our production speeds on dies retrofitted with new sensor technology. We are now running dies safer and faster - sometimes twice as fast. This creates quicker turnarounds and faster response.

Quality
Another goal of the sensor automation program is quality. "Zero-defects" means prevention of defective parts by accurately measuring the part objectively through standardized measures. This is accomplished by measuring parts in-die and adjusting where needed. In other words, no bad parts to the customer.

The Future
Sensor automation is clearly a strong, mistake-proof idea needed in today's economic climate. Ultra Tool is an enthusiastic supporter of this new technology. Our customers benefit by having higher quality parts, and measurable cost savings. We welcome visits to our plant where you will see an organized, clean plant with sensor automation in progress and people ready to bring innovative solutions to your most complex parts. (<Top)

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