International Automotive Components (IAC) was excited by the punch system LAC proposed and with a strong track record of finesse completed projects, IAC was confident LAC were the team to deliver this innovative automation solution.
“This servo-driven, punch and die tooling approach meant that the desired complex profile to be cut within the parts ensured a repeatable, accurate, clean-cut” explained Will Spensley, manufacturing engineer for IAC.
IAC can review the status of all moving components in relation to their home position and work position enabling the operating team to analyse the running of the machines. Thanks to the servo system used to actuate the punch tooling, speed and depth could be monitored and refined to suit the materials being cut. CAD cut tooling with integrated sensing meant that parts were easily and accurately positioned, informing the operator that the system was ready to run.
Will Spensley describes what the challenge presented “We needed a system that could accurately handle the cutting of two complex profiles within a D pillar and substrate parts, in order to accommodate the introduction of an air vent for the cooling of an MHEV battery, not an easy accomplishment, yet LAC pitched a system that could provide the right solution”.
The machine frameworks were designed with flexibility in mind to offer a platform that could be modified with ease to handle future product changes. The punch tooling system was made with precision cutting to ensure no permanent damage or marking on the parts.
With IAC putting health and safety as a paramount requirement, LAC wanted to make sure the system exceeded the minimum requirements. The punch tooling system has a human-machine interface (HMI) which shows all failures including sensors for analysis. The HMI enables the review of all moving components in relation to their home position and work position.
“We were able to go on-site to test the machines with our own engineers and operational staff to make sure they met the standards and requirements set out before having them installed at our site. IAC now have automation systems that meet our product output requirement, minimised our risk for error, and monitors the processes every move for us to reduce further errors. LAC impressed us by not missing a single aspect of detail, exceeding all quality requirements, and meeting every point of sign off criteria within the timeline set” Spensley explained.
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