5 Metal Stamping Solutions for Heavy-Duty Construction | ATD

The construction industry heavily relies on robust, reliable and precisely manufactured components to ensure the safety and durability of its structures. Metal stamping for construction is a critical process in producing these essential components. At Automation Tool & Die, we pride ourselves on delivering top-notch metal stamped construction parts that meet the stringent demands of the industry. Our advanced servo presses, including the 700-ton Aida and 330-ton Aida, are designed to handle the toughest challenges in manufacturing construction components. In this blog, we explore five metal stamping solutions for heavy-duty construction you need to know about and how our state-of-the-art servo equipment supports these processes.

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1. Structural Metal Components

Structural metal components are the backbone of any construction project. These parts must be stamped with high precision to ensure they fit perfectly and perform reliably under stress. Our 700-ton Aida servo press is ideal for structural metal stamping, offering the force and accuracy needed to create components like steel beams, support brackets and trusses. The servo technology of the Aida press ensures consistent precision and quality in every piece, even with the most complex geometries.

2. Construction Equipment Components

Heavy machinery and construction equipment require durable, precisely manufactured parts to function effectively. The 330-ton Aida servo press excels in producing construction equipment components such as chassis parts, reinforcements and mounting brackets. Its servo-driven precision and high-tonnage capability make it perfect for stamping the thick, high-strength materials used in construction equipment. The advanced control systems of the Aida press ensure tight tolerances and consistent output for even the most demanding components.

3. Large-Scale Infrastructure Metal Stamping

Infrastructure projects like bridges, highways and tunnels demand large, complex metal components that can withstand substantial loads and harsh conditions. Our high-tonnage Aida servo presses are specifically designed to handle large-scale infrastructure metal stamping, producing parts like girders, beams and columns. The 700-ton and 330-ton Aida servo presses allow us to deliver components that meet the rigorous specifications required for these massive projects while maintaining the precision and durability needed for long-term performance.

4. Large-Scale Project Stamping

When it comes to large-scale projects, efficiency and precision are crucial. Our Aida servo presses are engineered to manage high-volume production runs while maintaining tight tolerances. This capability is essential for producing the numerous and varied components needed for projects such as stadiums, skyscrapers and industrial complexes. The advanced features of our Aida presses, such as servo control and dynamic balancing, ensure each part is stamped with the utmost precision, reducing waste and improving overall project efficiency.

5. Infrastructure Metal Fabrication

Metal fabrication for infrastructure projects involves cutting, bending and assembling metal components to create finished products. Our servo presses play a crucial role in this process by providing the initial stamping and forming of the metal pieces. The 700-ton and 330-ton Aida presses offer the flexibility and power needed for various fabrication tasks, from forming complex shapes to creating large, flat components. This versatility ensures that we can meet the diverse needs of infrastructure metal fabrication with ease.

How ATD Meets the Demands of Heavy-Duty Construction Stamping

At ATD, we understand the unique challenges of heavy-duty construction stamping. Our state-of-the-art facility and advanced capabilities enable us to handle the demanding requirements of the construction industry. Here’s how we ensure we meet and exceed these demands:

Advanced Equipment

Our 700-ton and 330-ton Aida servo presses are equipped with the latest technology to deliver high precision and reliability. These servo presses can handle a wide range of materials and component sizes, making them ideal for various metal stamping applications. Additionally, our facility houses a full fleet of mechanical presses and a fully functioning tool room, providing comprehensive solutions for any project. 

Precision and Consistency

We prioritize precision and consistency in all our processes. Our presses are maintained to the highest standards, ensuring that every part we produce meets strict quality criteria. This focus on precision helps reduce waste and improve the overall efficiency of construction projects. Our quality lab, equipped with a CMM machine and advanced scanning technology, ensures every component adheres to rigorous quality standards.

Advanced Capabilities

ATD’s facility is designed to support a wide range of advanced capabilities. We utilize the newest CAD simulation software for modeling, allowing us to provide customized and highly accurate solutions. Our innovative laser scanner with reverse engineering capabilities ensures that we can meet the most complex stamping requirements with ease.

Experienced Team

Our team of skilled technicians and engineers has extensive experience in the tool and die industry. We work closely with our clients to understand their specific needs and provide customized solutions that drive success. Our commitment to continuous improvement and innovation ensures that we stay at the forefront of the industry, delivering top-quality metal stamped construction parts every time.

Choose ATD for High-Quality Heavy-Duty Construction Stamping Solutions

Heavy-duty construction stamping is essential for producing the robust and reliable components needed in the construction industry. At ATD, our servo presses are at the forefront of delivering high-quality construction equipment components, structural metal stamping and large-scale infrastructure metal stamping. By leveraging our advanced equipment and expertise, we ensure that every part we produce meets the highest standards of precision and durability.

In today’s competitive stamping industry, manufacturers and customers often demand specific solutions to meet their production needs. With the rise of automation, however, standard equipment such as feeders, levelers, and other peripheral devices are sometimes insufficient to address these specific needs. When such situations arise, businesses need tailored solutions that optimize automation equipment and improve efficiency. This article outlines a customized solution developed for a customer in the stamping industry, focusing on connected control, cost reduction, and labor efficiency.

The Challenge: Meeting the Need for a Customized Stamping Production Line

A recent customer inquiry highlighted a common issue in the stamping industry: the need for a production line that offers better integration, reduced costs, and minimized labor requirements. The customer wanted a stamping press, an NC servo feeder, and a forming machine all working in harmony, with the ability to be managed by a single operator. The goal was to reduce operational complexity and increase control over the entire process.

Our solution involved developing a production line with connected control capabilities, allowing for the seamless operation of all equipment through a centralized system. This innovative approach not only met the customer’s needs but also significantly enhanced overall productivity.

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Design Overview: Connected Control and Speed Regulation

The core of this solution lies in the integration of automation and efficient speed control systems. The solution included a combination of control systems and equipment enhancements to enable synchronized operations.

1. Control of Stamping Press Speed: Achieving Optimal Cycle Times

A key challenge in any stamping operation is maintaining a consistent and efficient speed throughout the stamping press. To address this, we introduced an induction frame positioned between the presses and between the press and the forming machine. This induction frame plays a pivotal role in controlling the speed of the stamping press by utilizing both upper and lower limit sensors. Here’s how it works:

• Press Speed Control:When the material triggers the lower limit sensor, the press slows down.If the material stays within the upper and lower limits, the press runs at the normal speed.When the material reaches the upper limit sensor, the press runs at full speed.This cyclical process continues automatically, ensuring smooth operation without the need for constant press stops or starts. This setup enhances the production flow while minimizing the risk of delays or downtime.

2. Integrated Connected Control: Centralized Operation for Efficiency

To further streamline the operation, we integrated connected control into the entire production line. Through a central control console, the operator can manage the operations of all connected machines, including the press and the forming machine, with just a few clicks.

• Centralized Control Console:The operator can start and stop individual machines or the entire line using the start, reset, and emergency stop functions.This eliminates the need for manual control of the NC servo feeder, further simplifying the workflow and enhancing operational efficiency.

This connected control system allows one operator to oversee the entire production line, cutting down on labor requirements and reducing the chances of operational errors.

Enhancing the NC Servo Feeder: Multi-Stage Feeding for Improved Flexibility

The NC servo feeder is a critical component in any automated stamping production line. Our solution upgraded the NC servo feeder to support multi-stage feeding and enhanced programmable capabilities.

• Programmable Feeding: The feeder can now store up to 20 programmable steps, allowing it to adjust feeding cycles based on varying material requirements. This flexibility ensures that each stamped product is created with high precision, adapting to customer needs and minimizing waste.
• Mold Action Control: In addition, the feeder can control up to three output channels, each responsible for operating solenoid valves. This enables changes to the mold action without disrupting the press’s operation, thus reducing transformation time between jobs.
• Press Speed Integration: The system integrates with the stamping press’s frequency converter to maintain accurate control over the press speed. Through three strategically positioned sensors, the system automatically adjusts the press speed based on the material’s position, ensuring consistent performance throughout the entire stamping process.

The Power of Interconnected Machinery: Seamless Line Control

The interconnected design of the production line was a major improvement, allowing for smoother transitions between each machine in the workflow.

• Interconnected Servo Feeders: The two servo feeders are now linked, enabling synchronized control between the feeders and the forming machine.
• Centralized Control: The operation panel of the NC servo feeder gives operators independent control of each machine, and at the same time, allows for full-line control with the push of a single button. This centralization of control means the operator can stop or start the entire production line as needed, drastically reducing the time and effort spent on manual machine operation.

Cost-Effective and Labor-Reducing Solution

Implementing a connected control system does not require extensive investments in new hardware. The only additional components necessary for this solution are the induction frame, induction rods, intermediate relays, and wiring. These are relatively low-cost additions, making the solution both affordable and scalable.

By integrating these components, the customer benefits from a low-cost implementation that optimizes production, reduces the need for multiple operators, and increases overall productivity.

Conclusion: Tailored Solutions for a Competitive Edge

In conclusion, the customized connected control system we developed for our stamping industry client is a perfect example of how automation can be tailored to meet specific production needs. The solution provides a highly efficient, cost-effective way to control a stamping press, NC servo feeder, and forming machine through a centralized control console.

• Reduced Labor: One operator can now manage the entire production line, significantly cutting labor costs.
• Enhanced Speed Control: The stamping press operates efficiently, with controlled speed adjustments based on material position.
• Low-Cost Implementation: The solution is easy to implement with a minimal investment in additional components.

For more information, please visit Stamping Automation Solutions.