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Products with large openings with over 100% increased efficiency

05/10/2022

A large American manufacturer of HVAC products was looking to speed up their manufacturing process with the help of new punching technology. The company had previous experience with a Pivatic punching line installed in 2007, and had been punching some of their parts with the old line. The line delivery however allowed to replace existing standalone Turret Punch Presses to manufacture the parts with large openings with over 100% increased efficiency – reducing cycle times from 4-5 minutes down to 2 minutes. 

Customized solution to meet the client’s needs

The final layout solution for the line was customized based on the experiences from the first punching line. We were able to match the requests for the line with newly developed options in the last decade, or with a few small cost-efficient development projects. A modular line system was chosen to allow the components to be placed so that the space allocation in a cramped production hall would be optimal.

Significant improvement in productivity with new solutions

The highly efficient cycle times compared to previous systems were possible due to fully automated production from coiled sheet metal to punched and formed parts, and with the chosen punching technologies. A standard PivaPunch TT (Thick Turret) station equipped with A-F size tools pre-set in quick change cassettes were used to punch the smaller holes and the perforation needs. An indexable tool was used to prepare the edges for the large openings. A customized PivaPunch HT (Hard Tool or Press Tool) station was used to punch the large opening with 1 hit or 2 hits. For parts with no large openings, the press tooling can be changed to large Thick Turret tooling with forming capabilities. HT Station has two tool activators on both side for increased flexibility.

Read more about Pivatic solutions for the HVAC industry and punching technologies that we offer. 

Are you interested in learning how Pivatic machines can increase your efficiency? Contact us today!

Latest News

EuroBLECH in Hannover, Germany on the 25 – 28 October

Meet us at EuroBLECH 2022 – Stand E136, Hall 11! We will be showcasing a fully automated servo-electric coil punching, cutting and pressing line on the stand. Highly efficient and indexable Thick Turret punching combined with a separate cutting station and a press tool station of 1200 kN punching force allows jobs like hole group, embossing, corner notching and trimming to be flexibly produced. Energy consumption for the full line is between 12-18 kWh, depending on the use of the big press, which is 60-70% less compared to traditional systems. This supports Pivatic’s low-energy product solutions well toward global sustainable development.

The line is bought by a German manufacturer who will receive the line after the exhibition with two coil cars, a turning drum, and a stacking device that are not present at EuroBLECH. The line is made in custom blue line color.

Why double punch?

Pivatic double punching technology was a product of developing the mechanical structure of the tool cassette technology and cycle time of the punching line.

TAKE A GREEN LEAP

Lower your energy costs and intensify your production with Pivatic line solutions. Thanks to servo-technology you can save up to 60-70% in electricity compared to traditional systems, lowering your maintenance costs and total noise level. By using standard coils less scrap is produced in both your production and your steel suppliers.

An article in the Finnish sheet metal magazine Ohutlevy goes in depth about the start of the Pivatic brand, punching technology, and what are our modern capabilities. Starting page 45, read here: https://digiplus.fi/www/Ohutlevy/2022_No1/index.html#p=45

The Pivatic PivaPunch System – How Does it Work?

The PivaPunch may be best described as a hybrid between a turret punch press and a coil-fed stamping press. he PivaPunch system utilizes standard “Thick Turret, Amada-Style” tooling mounted in precision-machined tooling cassettes. The number of tools required, and their sizes is dictated by an evaluation of the application. Cassettes can hold up to 26 tools (52 tools total because there are two (2) cassettes in a standard PivaPunch system.)  In cases where even more tool capacity is required, readily available multi-tool holders that can hold up to nine (9) individual tools can be installed in specific stations to increase the tool capacity to up to 100 total. Individual tools up to “F” size (6” diameter) can be accommodated, and up to two (2) tool stations can have auto-index capability.

Products with large openings with over 100% increased efficiency

A large American manufacturer of HVAC products was looking to speed up their manufacturing process with the help of new punching technology. The company had previous experience with a Pivatic punching line installed in 2007, and had been punching some of their parts with the old line. The line delivery however allowed to replace existing standalone Turret Punch Presses to manufacture the parts with large openings with over 100% increased efficiency – reducing cycle times from 4-5 minutes down to 2 minutes.

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