6 Ways Innovative Quick Die Change Systems Minimize Downtime

The capability to produce a variety of parts is essential for metalworking operations ranging from specialty shops to large-scale manufacturers. However, die changes require downtime, which is extremely costly, and can be dangerous due to the size and weight of some dies.

Metalworking operations that implement processes to reduce the labor and time required to exchange dies while minimizing safety hazards and damage can see a significant improvement in operational efficiency and cost reduction.

With metalworking operations in mind, SERAPID used its proprietary Rigid Chain Technology to develop a quick die change (QDX) system that drastically reduces downtime with enhanced safety.

In this blog post we’ll look at six ways metalworking operations can see a large return on investment with quick die exchange systems.

1. Improve efficiency throughout the die change process

Rigid Chain Technology uses interconnected links in a chain that create a continuous, unyielding bar when extended. Rigid chain push/pull systems are mechanical heavy load linear actuators that can be guided or used with table and rolling elements for powerful, precise linear movement.

In addition to avoiding high-pressure hydraulics, this innovative push/pull system has many advantages:

Compact design: the retracted portion of the chain is held out of the way so that users can maneuver heavy loads quickly and efficiently.

Durability: the push/pull system withstands heavy loads and frequent use with minimal maintenance.

Flexibility: highly customizable push/pull systems can be tailored for straight-side presses, side loaders, and other applications and requirements.

Here’s how the system works in the die-change process.

SERAPID QDX system with Rigid Chain Technology for Quick Die Change

2. Reduce die transport time

Moving dies to the press and back to storage can be one of the most time-consuming elements of the changeover process. With efficient transporters, quick die change systems streamline the die transfer process, reducing transit and handling time.

Powered by SERAPID Rigid Chain Technology, GPO Die Carts are designed to transport heavy loads.  Multiple options suit different metalworking shop needs.

3. Minimize labor with optimal die clamping

Automated clamping greatly reduces labor requirements. However, some applications may be better served with adjustable, removable clamps that an operator can easily place by hand. To suit specific die change requirements, multiple clamp options are available, such as:

• Fully retractable
• Sensor-equipped
• Embedded single and dual-function
• Fixed mounting
• Permanent mounting (option with standardized tools)

Die exchange clamp selection is dependent on several factors:

• Press tonnage and stripping forces
• Max. die weight, both upper die and total die weight
• Bolster and Ram dimensions (front to back, and left to right)
• Die shoe dimensions (front to back, and left to right)
• Die shoe thickness (both upper and lower)
• T-Slot size, number of T-Slots, and distance between

4. Prevent damage when positioning dies

If dies are improperly handled or even dropped in the exchange process, the die and press can be damaged. Misalignment can also result in damage to the die, press, and parts.

Optimized die rollers and lifters use smooth, controlled motion for precise positioning. Proper roller size can reduce wear on the die shoe, bolster, and press components.

SERAPID QDX Quick Die Change Rolling Element options include the following:

Roller Balls allow flexible and highly accurate positioning. Roller balls are ideal for manually positioned dies, because the die can be moved in any direction at any angle.

Cylindrical Rollers accommodate higher capacity loads than balls. These rollers are ideal when a straight-line rolling path is required and are often paired with SERAPID Rigid Chain Systems.

Roller Bearings offer low rolling resistance. These needle bearings can be fitted with waterproof and dustproof seals and paired with SERAPID Rigid Chain Systems.

Rolling elements are available as separate individual cartridges, or in bars that fit into slots in the press bolster. Either option can be installed in any desired configuration depending on the application.

5. Avoid die exchange incidents with enhanced safety features

Quick die change systems designed for safety include features such as the following:

• Intuitive interface that allows users to easily follow safe die exchange procedures
• Cam limit switch to ensure that components are in the correct position to prevent potentially hazardous movements
• Remote control options that permit users to maintain a safe distance
• Fully automated exchange that reduces operator risk
• Emergency stops and redundant systems to help prevent safety incidents

6. Minimize maintenance with innovative push/pull systems

The smooth, controlled motion of rigid chain push/pull systems reduces mechanical stress, and prevents uneven wear on components for enhanced durability and less maintenance required. 

Unlike conventional chains and belts, rigid chains don’t stretch, so they don’t require tensioning. The rigid chain push/pull system is designed for frequent use, with high reliability. The minimal maintenance needed for SERAPID QDX systems reduces labor requirements and downtime.

See the push/pull system in action here:

SERAPID PPS uses dual SERAPID RollBeam units to position dies.

Increase production efficiency and improve safety with a quick die exchange system

By minimizing downtime, preventing misalignment and safety issues, and optimizing die transport and handling, quick die change systems are a strategic investment for metalworking operations. Proprietary Rigid Chain Technology in SERAPID QDX systems reduces maintenance and optimizes die movement and transfer for even better return on investment.

Check out the many ways metal forming and stamping companies are using SERAPID’s Rigid Chain Technology.