How Automation can increase your production & make the process operator independent

There are usually 2 x types of machine configurations possible with the Single Station PF1 Series.

  • Standard Economic Option: with Manual Sheet Loading, Welded Fixed Frames for Sheet, Bolt type tool frame clamping

  • Automatic Option: with Autoloader for Sheet Loading, Universal Frames for Sheet, Pneumatic tool clamping

What are the advantages of choosing the automatic option and when does it make an economic sense to invest in automation?

Let us make some assumptions

  • Max. Part Size: 2700 x 1150 x 300 mm

  • Number of Product change-overs in a day: 2 - so 2 x times the operator shuts the machine and does a tool and sheet size change-over

  • Number of working hours/day: 10 hrs

Now, below is a list of cycle times

  • Sheet Loading & part unloading - takes 80 seconds if done manually by an operator whereas it takes only about 20 seconds if done automatic by the sheet loader. Also with the sheet loader - there is a parallel process possible - so when the sheet is being loaded, the previous sheet is already being heated by the machine and the sheet before that which has formed is being unloaded by the machine - this saves at least 60 seconds in each cycle

  • Tool loading & centring - takes 60 minutes if done manually by an operator whereas it takes only about 20 minutes if done automatic by the pneumatic clamping system. Also in the pneumatic system there is a negative recessed cut-out on the table where the positive CNC machined part below the tool sits and automatically centres the tool. So this method saves at least 40 minutes in each product change-over

  • Sheet size change-over - takes 60 minutes if done manually by an operator - he has to first unbolt the previous frame, then take it out with a fork-lift; then load a new welded frame & fix it with bolts on the machine. Whereas it takes only 10 minutes if done automatic by the universal type frames - where the operator enters the sheet size on the touchscreen HMI & the servo motors below the CNC machined universal plates size it according to the set size. So this method saves at least 50 minutes in each product change-over

The machine downtime in the standard economic configuration would be almost 4 hours/day and with the automatic option - just 1 hour/day. So, the PF1 3020 with max. forming area of 3000 x 2000 mm can produce approx. 3000 parts per month with the standard economic configuration and 7500 parts per month with the automatic option - almost doubling the output and making the process operator independent - thereby saving the company the operator cost as well.

To know more about Machinecraft’s PF1 Series and how it can help you process materials like ABS, PMMA, PC, TPO, HDPE, etc for applications like parts for automotive interior / exterior, EV parts, Commercial vehicle parts - Agriculture Equipment - Off Highway Vehicles, Sanitary Bathtubs, Medical Device Coverings, Refrigeration Liners, Aerospace Interiors, Train Interiors, etc - get in touch with us or visit our PF1 section by clicking here.

Rushabh Doshi