Metalforming

Meet the Challenges of Global Competition

As global competition intensifies, you need to address how equipment effectiveness, production monitoring and predictive maintenance can improve your bottom line. Our dedicated industry team has the experience, process knowledge, products, services and solutions to meet your growing requirements in stamping, forming and fabricating.

While many metalforming presses use different control platforms for each press subsystem — requiring press operators and maintenance personnel to be trained on varying technology and user interfaces — our metalforming automation systems allows you to upgrade pressroom controls to a single open controller platform to reduce training and maintenance requirements and improve your operational efficiency.

Metalforming Industry Rockwell Automation Integrated Architecture — the only integrated control and information platform that runs discrete, motion, process and safety control — assures that different automation technologies work together, so you get the right information to the right place, real-time, so you can make the right business decisions and:

  • Reduce cost, system development time, and installation time
  • Increase system flexibility, operation and expandability
  • Reduce downtime through alarms and diagnostic messages
  • Reduce risk through the use of standard software modules and field proven designs

Learn more about about our Integrated Architecture capabilities.

Metalforming SolutionsFor over 60 years we have been helping some of the world's most successful clients with their metalforming automation control needs. Allen-Bradley first introduced a relay-based clutch/brake controller in 1940. Today we use reliable Allen-Bradley brand logic controllers to safely control presses and the surrounding manufacturing processes found in some of the most modern manufacturing facilities in the world. Rockwell Automation applies some of the most trusted industrial control brands available today in our systems, including Allen-Bradley and Rockwell Software.

Our automation solutions include:

  • Industry Leading Press Control Systems — StamPro

    For clients who want a complete press control system in order to minimize risk and start operation as soon as possible, StamPro is the solution. StamPro is an engineered press control system assembled, programmed, tested, and ready to install. It is available as either a standard or custom system. Rockwell Automation StamPro Systems, help:

    • Meet OSHA and ANSI regulations
    • Reduce cost, system development time, and installation time
    • Reduce downtime through alarms and diagnostic messages
    • Reduce risk through the use of standard software modules and field proven designs
    • OEMs regain their competitive advantage
  • Basic Press Control Systems — Compact PressMaster

    Rockwell Automation also offers Compact PressMaster™ — a standard press control system offering clutch/brake, automation and motor controls in a press mountable, NEMA industrial enclosure. Compact PressMaster offers:

    • Reduced cost without sacrificing functionality
    • Competitive solution for OEMs, rebuilders, and end users
    • Flexibility and expandability
  • Tandem Line Control — TandemPro™

    The TandemMaster™ is a pre-engineered line monitor and supervisory system designed to optimize and synchronize multiple press tandem lines. The system provides tools for production and managerial personnel to help improve line speed and productivity.

  • AxisPro™

    AxisMaster™ systems reduce downtime and setup time as well as increases productivity through the integration of all motion control functions for press and inter-press feeds and part handling systems.

  • Servo Transfer Feed — STFPro™

    Today's stampers are increasingly turning to the use of Servo Transfer Feed Systems for their transfer presses. Servo Transfer Feed Systems provide increased flexibility in die design as well as improved throughput when compared to older mechanically driven transfer systems. Rockwell Automation Servo Transfer Feed Systems:

    • Provide configurable motion profiles that can be adapted to each die's specific needs.
    • Offer a "Smooth Profile" motion path with reduced jerk that increases machine longevity
    • Increase process throughput
  • Flat Metal Lines — FeederPro™

    We have a range of solutions that are adapted to meet your needs. Systems range from low cost simple feeder controls (FeederPro) to highly sophisticated common bus systems utilizing high performance AC drives and motors. Feeder Pro is an "off the shelf" solution for press feed control. Rockwell Automation Flat Metal Line Systems provide you with a global solution for your blanking lines. Rockwell Automation's Flat Metal Lines and Feeder Pro Systems help by providing:

    • Coil Inertia compensation for better control of back tension
    • Turnkey or component solutions to meet your needs
    • Off-the-shelf components that reduce training and inventory needs
  • Hydraulic Press Controls

    Reduce operating costs and downtime for your hydraulic presses with modern, compact, and reliable PLC controls. Rockwell Automation systems can be designed to control almost any hydraulic press application. Our engineered solution provides complete press control, including motor controls, operator interface, die cushion control, and any special control requirements. Rockwell Automation Hydraulic Press Control Solutions are designed to:

    • Help meet ANSI B11.2 and CSA Z142-02 regulations
    • Provide users with reliable and east to maintain controls that support reduced downtime

Metalforming KitsRockwell Automation offers various systems, bundled packages, and kits for meeting the safety-related control standards for the clutch/brake of mechanical stamping presses. These solutions are designed to meet the safety requirements of ANSI B11.1, OSHA 1910.217, CAN/CSA Z142-02, IEC-61508, EN-954 and EN-692.

  • 6556 Clutch/Brake Kit

    The 6556 Clutch/Brake kits are bundled packages consisting of redundant PLC components with application software, wiring diagrams, relays and documentation. Some packages have TÜV certification. Each solution is designed with independent redundant programmable controllers with additional electromechanical components and the application software to provide the necessary monitoring, self testing, security, and verification that make up a control-reliable design.

  • PLC-5/x6 Based Kit

    The PLC-5/x6 based kits come with the clutch/brake software secured in program file #16, and the user can add other logic to other files. The PLC-5-based kits are designed for large presses with extensive automation.

  • Fixed SLC and MicroLogix Kits

    The fixed SLC and MicroLogix kits are pre-programmed with the ladder program locked in flash memory. Certain features in the fixed kits are configurable. The MicroLogix and SLC 5/02 kits provide only the basic clutch/brake functions. The SLC 5/03-based Omega kit, for example, has a variety of standard features to control ancillary functions such as lube and programmable limit switch that can be configured through optional pre-programmed PanelView screens. The fixed kits are easy to use, require no programming, and are designed for small to medium-size presses retrofitted by the user.

  • Modes of Operation

    The following table lists the modes of operation for each Rockwell Automation press control solution.

    Press Modes of OperationMicroLogix (6556-MLCBK)SLC 5/02 Fixed (6556-SCBK2)SLC Omega (6556-SCBK3)Compact Press MasterStamPro System*
    Off X X X X X
    Inch X X X X X
    Micro inch X     X X
    Single X X X X X
    Continuous X X X X X
    Remote modes          

    *Contact your local sales office for pricing and order information.

  • Press Functions

    The table below summarizes the various press control functions available for each press control solution.
    (S = Standard, O = Optional, P = User Programmable, Blank table cell = Function not available).

    Press FunctionsMicroLogixCompact Press MasterSLC 5/02SLC OmegaStamPro
    Clutch/Brake Control S S S S S
    Operator Interface O S O S S
    E-Stop and MCR Relays S S S S S
    Run Station Monitored 1 1 1 1 4+
    Main Motor Control O S   S S
    RCLS Position Capable S S S S O/P
    Resolver Capable O S   O S
    Brake Time Monitor O S   S S
    Variable Speed Top Stop   O   S O
    Production Counters O S   S S
    Maintenance Timers O S   S S
    Programmable Limit Switch   S   S O
    Die Protection Monitoring   O   S O
    Recipe Storage       20+ 30+
    Variable Speed Computer   O   S S
    Lubrication Control O S   S O/P
    Tonnage Monitoring       O O/P
    Auto Counterbalance   O   O O/P
    Shut Height Adjustable Control   O   O O/P
    Variable Speed Drive Interface       O O/P
    Servo Feed Interface         O/P
    Robot Interface         O/P
    Coil Feed Interface         O/P
    Die Cushion Control         O/P
    Die Clamp Control         O/P
    Bolster/Die Cart Control         O/P
    Automation Control         O/P
    Auxilliary Automation Interface S   O   S
    Production Monitoring/OEE         O/P
    Hydraulic Overload Control   O     O/P
    Light Curtain Interface S S     S
    Disconnect/Starters etc. O S   O S

    *Ethernet, DeviceNet, Controlnet, RS232