Progressive Die Protection for Tool Rooms

Stop tooling damage from misfeeds

Stop the Press
Before Damage Occurs
In most tool rooms, tool and die makers are spending the majority of their time fighting fires
and repairing damaged tooling, such as: sheared punches, snapped pilots, bent strippers,
cracked sections, and smashed stop blocks. Management demands for faster repairs to
meet manufacturing schedules and idle welders puts added pressure on the tool room’s
limited resources. Damaged tooling coming into the tool room is routinely blamed on a
variety of issues like misfeeds, part out detection, and wiring damage.

With Die Protection, the goal is to identify an issue with enough time to stop the press before
tooling damage can occur. Sensors are used to detect issues like short feed, over feed,
slug stacking, or part ejection failure. In order to utilize the solutions presented in this guide,
a press controller capable of accepting sensor inputs is required. Balluff is an experienced
die protection partner for this industry and provides a wide range of technologies for die
protection applications. Ten hit pile-up destroyed the stripper window
and caused major tooling repair.
Are you repairing tooling due to any of these issues?
n Sheared punches n Short feed
n Snapped pilots n Long feed
n Bent strippers n Slug stacking
n Cracked sections n Part ejection failure

Misfeed Detection Cracked tooling from a feed issue caused lost

production and increased tool room stress.
n Slip during feed progression
n Short feed and long feed
n Sticking pierce or punch

Die Connections Slug and Scrap Out Part Out

n Damaged cables n Slug stacking n Parts don’t leave
n Damaged connectors n Not ejected every stroke n Missed part detection
n Forgot to disconnect n Nuisance stops n Conveyor system off
 Application Considerations

Physical Feed Detection PlungerProx Sensors

n Contacts end of strip n Precise and adjustable Paddle
Plunger Prox
n Allows for coil memory n Survives overfeed Strip

n Detects short feed n Variable tip configurations

Feature – Form Feature – Hole

Feature Feed Detection BES Global Inductive Sensors
Sensor Leading Edge
n Detects from side or under strip n Watch feature leading edge
Die Strip
n Uses form, hole, or slot n Distances vary by material, Block
Misfeed

Die
n Detects long feed or short feed sensor size, feed tolerances Block
n Typically cable-out sensors Strip
Sensor

Through-beam Sensors for Feed BGL Fork and BWL Angle Sensors Side View
Short Feed
n Detects over feed and short feed n Burn through lube with infrared Strip
Over Feed
n Uses two sensors in one place n Easy through-beam alignment
n Detects from top, side, or bottom n Rugged housings Top View

Ejected Part Out Detection BOW Windows and BLG Arrays

n Works with unpredictable trajectory n Variable sizes and shapes
n Utilizes an array of sensors n No hung part nuisance stops
n Detects motion n Small and fast parts
Part Out

Gravity Part Out Detection
n Used for predicable exit
n Protect during installation
n Install to look up and out
Strip
BOS 5K Global Diffuse Photo Sensors
n Burn through lube with infrared
n Typically cable-out sensors
n Variety of styles and distances

Small Slug Out Detection BES IKV Inductive Ring Sensors Punch
n Verifies slugs leave the die n Variety of inside diameters
n Allows for 2-3 slugs to stack n Delay output for fast parts
Slug and Scrap Out

n Stops major slug stacking issues n Metal-free mounting

Ring Sensor
Slug

Scrap Out Detection BOS 5K Through-beam with Apertures

Punch
n Verifies scrap leaves the die n Through-beam burns through lube
n Detects random shapes n Apertures add precision
n Recognizes stacking or tangling n Low chance of part contact
Sensor Sensor

Aperture Scrap

Sensor Connectors and Cables BCC High Durability Cables

n Prevent breaks in standard cables n Stainless braids Strip
n Protects with channels n Flexible conduit Cable
n Stop replacing good sensors, with n Connectors vs cable out
Die Connections

broken cables
Channel with Cover

Sensor Junction Boxes BPI Quick Disconnect Blocks

Die
n Easily repair sensor cables n M12 connectors for sensors Junction Block Protection
n Uses one connection to die n M23 umbilical connectors Die
System

n Easily troubleshoot wiring n Typical for die protection

Bolster
 Systems and Services

Industrial Networking and Connectivity

Industrial Identification

Object Detection

Linear Position Sensing and Measurement

Fluid Sensors

Accessories

USA Canada Mexico

Balluff Inc. Balluff Canada, Inc. Balluff de México SA de CV
8125 Holton Drive 2840 Argentia Road, Unit #2 Anillo Vial II Fray Junípero Serra No. 4416
Florence, KY 41042 Mississauga, Ontario L5N 8G4 Colonia La Vista Residencial.
Phone: (859) 727-2200 Phone: (905) 816-1494 Querétaro, Qro. CP76146
Toll-free: 1-800-543-8390 Toll-free: 1-800-927-9654 Phone: (++52 442) 212-4882
Fax: (859) 727-4823 Fax: (905) 816-1411 Fax: (++52 442) 214-0536
E-Mail: balluff@balluff.com E-Mail: balluff.canada@balluff.ca E-Mail: balluff.mexico@balluff.com

Doc. no. 922915/Mat. no. 247052 EN

F15; Product specifications, availability, and
pricing are subject to change without notice.
www.balluff.com