A returning customer brought AIM-Joraco® a new manufacturing challenge, a blowout forming operation on various size cups. Our engineering team delivered a customized Toggle-Aire® 2530 press with interchangeable tooling, an automated pneumatic slide tray for part loading, and sensor-based safety features to prevent tool collision.
Process
Our engineering team faced several unique challenges in developing a system for this process.
The design of the slide tray for part loading and unloading was complicated by the geometry of the cups. The shape of the blowout made the forming operation challenging and prevented the formed part for being removed from the press in the same way it was loaded. To address this our team designed an expanding tool that forms the blowout after reaching the plate and integrated a stainless steel trap door that opened over a chute to allow for automatic removal and collection of the finished parts. The system also had to be able to process six different cup sizes. To accommodate this the tray nest was designed for the largest cup and five attachable adapter plates were designed for each of the smaller cup sizes. The nature of the slide tray design with interchangeable tooling meant a high risk of tool collision. To address this sensors were added and programmed to create multiple safety measures.
Results
The press produced accurately formed cups in multiple diameters while improving operator safety and efficiency. A stainless-steel trap door released each formed cup into a collection chute without contacting the tray’s sliding components. Protective guarding supported operator safety, while integrated sensors and programmed controls helped prevent tool collisions. A tray nest with five interchangeable adapter plates accommodated six-part sizes maintaining alignment between each workpiece and its forming tool. Standardized tool shanks and a split-collar adapter simplified tool removal and changeover. Precise shut height enabled reliable tool adjustments to meet required blowout dimensions.
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About Joraco Press Company
Joraco Press Company has been an innovator in the pneumatic press industry since 1947. The trademarked TOGGLE-AIRE® Series has been the core product of Joraco Press for over 60 years having been installed in thousands of manufacturing facilities all over the world. The past 20 years have seen Joraco Press expand its benchtop pneumatic press products to cover more applications and more force ranges than ever before. Joraco Press Company is a division of Automated Industrial Machine, Inc located in Smithfield, RI. Our products are designed, fabricated, and assembled at the AIM headquarters and as always, the same people who build our presses are always available to help troubleshoot your press.