The Ultra Report - Sensor Automation Program

Ultra Tool and Manufacturing Wins
Customer's Confidence with Sensor Automation

The Challenge
Recently, a company presented Ultra Tool and Manufacturing with a problem part. This part was being sourced from another metal stamper and they were unhappy with the results.

After hearing about our success applying sensor technology in progressive dies, they were interested in applying this technology on their part. This part was a component of a complex product and critical features of the part needed to be adjustable while maintaining a very tight tolerance (+/- .002”).

Our challenge was to build a die that allowed us to measure these features (e.g. bend angles) on every part and adjust them when needed.

Applying the Right Sensors
We knew from the research we did in our in-house sensor lab that we could select, test and prove the correct sensors for this application.

Applying analog sensors, something rarely
done in a progressive die, gave us the ability to collect data on every single part, analyze this data, and communicate back to the die with necessary electromechanical adjustments. Digital sensors were built into the die to protect it and to ensure proper operation.

If a part did not meet the required tolerance, they were mechanically removed from the tool. Zero defects were achieved and proven to the customer.

A programmable logic control (PLC) was the brain of these processes. A human machine interface (HMI), pictured here, provided visual screens where we could monitor and change features of the part while the die was running in the press.

The Result
Through hard work, we successfully ran a self-adjusting, sensor-automated die equipped with a total of 30 sensors.

This “Smart Die” ran on a Minster 200-ton punch press with an initial production run of 50,000 pieces. Further testing proved that the part’s critical bend angles could in fact be modified up to 8° while running in the press. These modifications were exactly what the customer required for their ongoing development of this particular part. Above all, the customer was finally able to test his product with highly accurate and consistent parts.

Cost reductions occurred from the efficiency of the production run, minimal scrap, and simple tooling adjustments. (<Top)