The manufacturing floor is no longer just about horsepower; it’s about processing power. Welcome to the era of the Smart Stamping Plant, where every press stroke is informed by data, efficiency is maximized by robotics, and the entire operation is unified by the Industrial Internet of Things (IIoT).
At Amada Press Systems, we believe the path to Industry 4.0 starts right here, on the bolster plate. It’s a shift from simply forming metal to intelligently forming business value.
1. The Engine of Intelligence: Unmatched Servo Control
At the heart of a Smart Stamping Plant is a press that can adapt. Traditional mechanical presses rely on a fixed crank mechanism, but Amada’s Servo Press models are changing the rules of metal forming by providing unparalleled precision and control.
Unlike fixed motion, the servo drive allows for real-time adjustment of ram speed, position, and force throughout the entire stroke. This programmable motion profile is a game-changer for several reasons:
- Defect Prevention: Optimized material flow minimizes the risk of cracking and tearing, which is crucial when working with high-strength or sensitive materials (like those used in the aerospace industry).
- Reduced Scrap Rates: Superior control minimizes inconsistencies, leading to significant cost efficiency, especially when stamping with expensive specialty materials.
- Extended Tool Life: The ability to precisely control impact speed and force minimizes shock and wear on tooling, leading to significantly longer die life and reduced maintenance costs.
This flexibility allows a single Amada press to master complex drawing, forming, and blanking operations that once required multiple, less adaptable machines.
2. The Data Advantage: Monitoring and Optimization
A truly smart press system doesn’t just operate—it communicates. Amada utilizes advanced press controls and powerful software solutions to turn raw production data into actionable intelligence, maintaining a “digital thread” across the entire production line.
This continuous stream of information provides critical real-time feedback:
- Proactive Maintenance: Computers use data analytics to monitor factors like tool wear and press tonnage. By detecting minute variations before they become major problems, the system reduces the risk of unplanned downtime.
- Process Optimization: Amada’s software solutions allow operators to visualize power usage and track energy savings compared to traditional machines. This level of transparency is essential for continuous improvement.
- Quality Assurance: Real-time diagnostics ensure that every part meets rigorous standards for consistency, minimizing the need for lengthy post-production inspections.
Amada’s Software Suite: Intelligent Control for the Pressroom
Amada’s commitment to the Smart Stamping Plant is powered by a suite of dedicated software, creating a digital network for central control and monitoring of stamping press machines.
SOFTWARE
APINES (Visualization)
CORE FUNCTION
Operation and Production Monitoring
KEY BENEFITS
Provides real-time monitoring of machine status, production history, and stop factors. It performs maintenance control by alerting users to consumables life and inspection times, and securely backs up all important machine data and parameters.
WANMS (Waveform Analysis)
Pressure and Motion Analysis
Monitors peak pressure in real time and samples detailed pressure and motion waveforms. It allows for advanced analysis and comparison of force applied during processing, ensuring quality assurance by detecting deviations from standard pressure and energy values.
SMAPS (Off-line Setup)
Servo Motion Creation & Editing
Enables off-line creation and editing of complex motion programs for servo presses. Users can use processing type samples to simplify setup and run detailed simulations—checking cycle time, speed, and material feeder interference—before the program ever runs on the machine.
3. Efficiency and Sustainability Go Hand-in-Hand
In the modern competitive environment, efficiency must extend beyond simple speed to include resource management and environmental responsibility. For the Smart Stamping Plant, sustainability in manufacturing is not an option—it’s a core business strategy.
Amada is at the forefront of this trend with innovations that drive down costs while reducing environmental impact:
- Energy and Noise Reduction: Our latest ECO and Silent release mechanisms can significantly reduce air consumption by up to 75% compared to conventional press models, while also cutting noise levels.
- Resource Conservation: Amada’s servo press models have earned the prestigious MF Eco Machine certification from the Japan Forming Machinery Association, recognizing outstanding contributions to environmental impact reduction and workplace improvement.
- Automation for Throughput: By integrating robotics and automated material handling with Quick Die Change Systems, a smart plant minimizes the time spent on manual setup and changeovers, maximizing throughput and Overall Equipment Effectiveness (OEE).
Ready to Build Your Smart Stamping Plant?
The future of metal forming is precise, efficient, and interconnected. By leveraging Amada’s advanced servo technology, powerful software, and dedication to sustainable production, you can future-proof your manufacturing floor, reduce long-term operating costs, and secure your competitive edge.
Contact Amada Press Systems today to learn how our equipment can transform your operation from a production facility into a Smart Stamping Plant.