Page 88 - MetalForming October 2012

Tooling Technology
electronic sensors. Then Didricksen fully immersed himself into a rig- orous set of intense experiments that has led to his mastery of induc- tive and photoelectric sensors, among others.
Error Proofing by Committee
enables precise positioning of parts and sensors for experimentation, and thus allows Didricksen to accu- rately determine, with repeatabili- ty and reproducibility, the viability of any given sensor when detecting tooling and part targets.
Kenmode’s toolmakers and pressroom personnel have access to the sensor test cart, built inhouse and providing an oppor- tunity to toolmakers to verify that the sensors are functioning prop- erly before they are installed into a production environment. Likewise, pressroom personnel use the test cart to verify that the sensors are working properly, and also can use it to troubleshoot any issues with the control-system setup. By being able to disconnect the die-protec- tion control while the die remains
As in all of the best metalform- ing shops I’ve visited that have developed a robust sensor pro- gram, Didricksen reached out and formed an Error-Proofing Tech- nology Committee (EPTC), tasked with determining which areas with each die require sensing. The com- mittee comprises members from several company departments, so ideas and opinions come from employees working in the press- room, maintenance and engi- neering areas, among others. The committee’s decisions then are trans- formed into specific assignments for Didricksen, with clear deadlines for their completion.
Of course, without the full support from company management—starting with Moders—all of the good work by Didricksen and the EPTC would be for naught. And Didricksen certainly appreciates the wholehearted support for his program, which has led to sig- nificant recent investment in new press controls that will
help to modernize
the company’s die-
protection pro-
gram.
The sensor laboratory includes this three-axis micro- positioning table, equipped with all of the appropriate ancillary devices including digital micrometers, fixtures and specialized mechanisms to enable precise position- ing of parts and sensors for experimentation.
In parallel, vice president of oper- ations Ken Wojcik maintains a close and extremely supportive role as Didricksen’s immediate boss, further reinforcing the notion that company manage- ment has Didrick- sen’s back when it comes to develop- ing an industry-
Toolroom personnel use the sensor test cart for verification of proper sensor cycling and target directions, before dies are installed in the pressroom.
86 MetalForming/October 2012
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leading sensor program on all fronts.
Top-Notch Instrumentation
Didricksen’s laboratory is fully equipped with the critical equipment necessary for the proper testing of sen- sors before they are applied to a die. To this end, the laboratory includes a three-axis micro-positioning table with all of the appropriate ancillary devices including digital micrometers, fixtures and specialized mechanisms. The setup
in the press, and then connect the sen- sor test cart to the die, it becomes sim- ple to isolate any malfunctions as being sensor- or controller-based.
Next Up: In-Die Measurement
Kenmode Tool and Engineering now has its sights set on developing its in- die sensor expertise to enable auto- matic measurement and part-quality inspection, using analog sensors. This will allow it to monitor 100 percent of stamped parts for critical dimensions.
After that would be the introduction of servo motors in its dies to automatically adjust the tooling based on the measurements from the analog sensors; then per- haps the pursuit of in-die welding.
All in all, Kenmode Tool and Engineering is an excel- lent example of sensor tech- nology, based on the com- mitment of several technical and production personnel, and the wholehearted sup- port of management. I pre- dict that as time moves for- ward, Kenmode will remain
at the forefront of sensor excellence. MF