In-Die Installation System for Plain Bearings / Bushings
Assembly under the press in punching and forming tools
The setting head PAB (Permanent Air Bushing) is a fully automatic in-die installation system for plain bearings / bushings. The system is suitable for progressive dies and transfer dies. The punching head is installed in the press to insert such fasteners into sheet metal components during the press process.
Depending on the type of the press tool, there are different applications for the punching head:
- Progressive dies with or without automatic mode signal from the press
- Transfer dies, with or without automatic mode signal from the press and with querying sheet metal in the die or in the gripper
Contact us
Our customer service will help you with any questions!
Advantages of the System
The processing is carried out in two stages. All press-in modules are force-controlled in order not to damage the components during installation.
All important functions in the setting head are sensor-monitored with communication to the feeding system to stop the press in case of a malfunction well before top dead center (TDC) and thus avoid die damage.
The feed cylinder only moves to the set position when a slide bearing bushing is to be installed. Transfer die: If there is no workpiece, the feed cylinder does not move to the set position. It moves when a workpiece is present. The empty part sensor is either in the transfer grippers or in the tool itself. Coil change: When a coil change is required, the feed cylinder remains in the home position and the coil can be retracted as if there were no setting head installed in the tool.
If a plain bearing bushing is in the setting position and still being processed, the next bushing can already be reloaded. The next fastener can therefore be shot into the setting head in parallel with the processing of one fastener. This means that higher processing speeds can be achieved even with long shot hose lengths.
The setting head has quick-release couplings for the shot hose and the multifunction hose for communication with the feeding system. There is no need to connect individual cables. This saves time and eliminates connection errors.
The setting head has a large magazine. This means that there is no one-to-one connection between the punching head and the feeding system. This means that a sporadic separation error does not automatically lead to a malfunction, as with other systems, but is suppressed and the press continues to run. This leads to a significant increase in availability. This is also supported by the pulse shot function (several nuts are shot into the setting head rather than one at a time) and full sensor monitoring.
Installation and Processing
Typically, the plain bearing bushings are inserted into the sheet from the bottom and flanged from the top. The bushings are processed in two stages.
In the first station (1), the bushing is inserted into the sheet metal and the top edge or protruding part of the bushing is folded over 45 degrees, i.e. pre-flanged.
In the second station (2), the bushing is fully applied to the sheet metal. The inside diameter of the bushing is calibrated.
Optionally, a third station (3) verifies the presence of the bushing.
The setting head is placed in the bottom of the tool or in the spring base (4). The bushing is inserted into the pilot hole by the relative movement of the spring base or a lever.
Functionality
Setting process
The setting head is connected to the associated feeding system for press applications and contains a accumulation path with permanent air, as well as an additional slider that holds the plain bearing bushings in the setting position. The slider is retracted to the home position after the transport of the bushing. The press receives a release when a bushing is in the setting position and the slider is in the home position. Without a release signal, the press stops.
Main process
The main process co-ordinates the part request to the feeding system. It ensures that the slide bearing bushings are moved to the setting position on time and monitors the press strokes by interrogating the press cams.
Initialization
After installation, the setting head is ready to operate and goes directly to the main process. There is no initialization routine.
Pressing
The bushings are pressed into a workpiece by the press-in mandrel as the press moves onto the press-in mandrel. On some presses, a bushing may not be inserted on each press stroke as determined by blank sensing. In this case, the slider will remain in the home position so that no bushing is transported to the setting position and no bushing is inserted during the next press stroke.
Air supply
A pneumatic connection on the feed system transfers compressed air to the setting head. This connection supplies the permanent air and the pneumatic cylinder for the slider and, optionally, the press-in mandrel.
Components
Connector plug (1)
The connector plug is used to connect the shot tube to the setting head.
Plunger (2)
The plunger houses the press-in mandrel, which presses the plain bearing bushings into the sheet metal component. The mandrel is actuated by closing the press and transmits the compression force to the fastener. When the press is opened, the mandrel is pneumatically returned to the home position.
Impact piece (3)
The impact piece guides the fastener during the press-fit process.
Accumulation path (4)
The setting head includes an accumulation path. It is used to store additional fasteners in the punching head to compensate for feed fluctuatons. The permanent air is used to move the bushings to the setting position. When the shot air is active, the permanent air supply is briefly interrupted so as not to work against it. When the press is inactive, the permanent air is switched off. The accumulation path ensures consistent production.
Feed cylinder (5)
The feed cylinder pushes the slide bearing bushing into the setting position by means of a slider. The cylinder is monitored by two end position sensors.
Pre-flanging module (6)
The pre-flanging module is the first step in the flanging process. The unit consists of two parts. One is installed in the die pressure pad and the other in the upper part of the tool. Automatic tolerance compensation of the sheet metal and bushing wall thicknesses ensures the consistency and quality of the flanging process. No adjustment is required.
Calibration and flanging module (7)
The flanging process is completed with the calibration and flanging module. Calibration determines whether the inner diameter of the slide bearing bushing is within specification. The tool automatically compensates for the positional tolerances of the sheet metal.
Presence control (8)
The optional presence control detects missing bushings in the component. If a bushing is present in the component, the test mandrel, which rests on the component, is pressed down and actuates a proximity switch. If no bushing is present, the switch is not actuated.
Multifunctional hose connector (9)
All signals are transmitted from the setting head to the feeding system via the multifunctional hose. The multifunctional hose also provides pneumatic supply to the punching head.
Technical Data
Installation width: 100 / 120 mm
Pneumatic supply: 6 bar from feeding system
Control voltage: 24 V / DC from feeding system
Press-in force /path: Tool-dependent
Cycle time: Up to 40 cycles/min*
Interfering edge / Possible component depth: According to customer requirements
Working direction: Vertical upwards from below
*Depending on the fastener and length of the shot hose.
Request for Quotation
Would you like us to call you back? Leave your telephone number or e-mail and we will get back to you as soon as possible!
