Stamper’s flexibility hinges on servo press

ER Wagner installed a Minster FX2-600 servo press to expand its capabilities, die space, and tonnage.

ER Wagner's components and assemblies are what allow drivers to pop the hood, shut the trunk, access the center console, adjust the head rest, sift through the glove compartment, and open the doors of their vehicles.

The company is a manufacturer of engineered, stamped metal vehicle hinges and components for the automotive industry, as well as for the material handling, food service, defense, and marine industries. The company also performs contract stamping at its Menomonie Falls, Wis., and Brookfield, Ill., plants.

"For more than 100 years, we’ve been creating custom-engineered solutions for automakers that add value to their vehicles and allow them to be globally competitive," the company states. Its components are in every type of vehicle: autos, trucks, recreational, semis, and military.

Considering that the company's components and assemblies are made to flex, it's no surprise that flexibility was required in its manufacturing operations as well. It purchased a new Minster FX2-600 servo press to reinforce its versatility and flexibility.

Tooling Development Manager Jeremy Simonson explained why the servo press was needed. "We make a wide variety of complex stampings, and not every mechanical press is suited for every type of tooling that we put into the press. So the servo press gives us the ability to adapt to different parts and different tools without buying an additional press."

The flexibility and versatility of the press were actually bonuses. Initially the company wanted a larger press with a long press bed and high tonnage because it had acquired work that required more die space and higher tonnage than it had in capacity. Once the decision to purchase a new press was made, company management looked at what else they could accomplish with a new press.

Chief Sales and Marketing Officer Brad Gador said, "We’re a contract manufacturer, so whenever we look at capital assets, we’re always trying to broaden the capability of what we’re able to make. We looked at the Minster servo press as an opportunity to broaden the capabilities of what we do now and what we can quote in the future."

The Minster FX2 series has a robust design based on its E2 HeviStamper press. It is equipped with a low-inertia drive, liquid cooling technology, and a planetary gear system.

"From the technical side what that means is faster stopping times and acceleration, so we can react to die protection errors quicker, which means you can run faster in the end," Simonson added.

The press's inching handwheel has made it easier for press operators to perform setup and operation. "I run four or five other presses here and the FX2 amazes me in what it can do and what it's capable of compared to the other presses," Press Operator Lenard Hicks said.

ER Wagner specializes in manufacturing engineered, stamped metal vehicle hinges and other components for the automotive industry. Expanding its flexibility hinged on installing a servo press. Photos courtesy of ER Wagner, Menomonie Falls, Wis.

The stamper has realized some production speed gains by running jobs it had been running on a mechanical press on the new servo press and taking advantage of its programmable slide motions. By customizing the stroke profile, the crew is producing a particular part faster. It had been running at 15 to 20 strokes per minute (SPM) on a mechanical press. "On this same part, we can increase the stroke speed in excess of 50 SPM in certain less critical areas and then slow it down and form it at 15," Simonson said. The maximum speed programmable for that part will be about 40 SPM with the profile that has been developed.

The press's addition has expanded the company's overall stamping capabilities dramatically, reinforcing its "American-made; globally available" market strategy.

The company supplies OEMs in 16 countries in Europe, Asia, North America, and South America.

"We have a number of new types of technology in our factory, and this 600-ton Minster servo press is kind of the crown jewel of our new technology strategy," Gador said. "We needed that press for certain projects we won, but as part of a bigger picture, we will be able to expand on several levels and continue to grow our business."

ER Wagner, www.erwagner.com

Nidec Minster, www.minster.com