Industrial Robotics: ISE 5314

Mid-Term Report
Rotex Punch

Carlos Santos
Jaime Ubidia
Table of Contents

1. Introduction

2. Objective of study

3. Understanding Rotex Punch Press

4. Rotex Punch Press Previous Mistakes

5. Rotex Punch Automation

6. Determination of Angles

7. Linkage lengths and simulation

8. Linkage Design

9. Waste Disposal Chute

10. Bill of Materials

11. Punches

12. Function Diagram

13. Process Mapping

14. Conclusions and Final remarks

15. Reference
Introduction

The course Industrial Robotics ISE 5314 sets as the objective to design and build a sheet
metal flexible manufacturing system (FMS) at the Industrial Automation Lab located in
Durham Building. The Rotext turret punch press is a vital part of this system and as
such needs to be ready to operate and ideally should be automated.

As the team in charge of the modifications to the Rotex turret punch press, we set as our
objectives to find an optimal method for the punch to function, eliminate accumulating
scrap material from punching and ensure the safety of those operating the machine.

The Rotex turret punch press should operate in a constant, fast and reliable way so that
the overall cycle time for the FMS system can be minimized. More specifically the
mechanism should cause the machine to lower the die and retract it without exceeding
the restrictions related to the punching distance and retracting distance.
No bits of metal should accumulate on the press or be left on the metal sheet.
Objective of Study:

The purpose of the study was to try and set-up a working Rotex Punch and the project
mainly had the following tasks:
1. Automate the turret press by using a appropriate method
2. Automate the right angle punch rotation
3. Remove and correct measurement and design problems from previous groups.
4. Integrate the Punch with the rest of components of the FMS system.

As noted in the PDR, the functions to be performed by the machine are being addressed
in different ways. The availability of several kinds of punches, the changes being made
to the functioning mechanism and the waste disposal chute have as an objective to
produce accurate holes and reduce the overall cost to produce this result. The solutions
the design team has been working on target the two most important requirements of
product design: compliance with the 180º constraint and removing metal bits from the
hole after punching. The constraint has changed and therefore the design complies with
the new measures.

The Rotex Punch Co., Inc. was contacted and a request for the new catalog was made
since it’s not available online. Although the response took some time and the arrival of
the catalog even more time, it finally arrived on Friday the 19th of March, 2010
(Appendix 1). Most of the punches and dies needed are available and already aligned in
the turret press. A round edge punch for the corners of the parts has been installed in the
turret as well as the die and has also been aligned. This punch is a cross-like punch with
the capacity to punch four Meccano corners at the same time.

Over Travel Problem

The over travel measures taken previously by other groups were not correct and due to
this, the initially proposed mechanical model had to be forgotten. The operation system
used for the punch takes the over travel constrain into consideration and therefore the
operation of the punch doesn’t rely on sensors to work properly.
Understanding the Rotex Punch

For future modifications or upgrades to the equipment, first we needed to understand

what past groups have done to automate the Rotex Punch. In this process we had to
identify all the changes made by previous groups, how does the rotex punch work with
these new changes and what difficulties we are going to encounter because of these new
modifications.

Original Rotex Punch

The punching ram

The punching ram is the piece of the machine that needs the most force to move. This
device is what transmits the punching force to the sheet that is being punched. Previous
groups have made changes to the punch such that it can be automated. Such changes are
the following: Large 3 phase motor, mounting frame for the motor, a cam mechanism
and rotational input shaft with a modification of a sprocket and roller chain which was
selected by a previous team as a cost effective and efficient method of transmitting
torque from the motor to the input shaft. Other of the innovations that came in with the
new mechanism was the implementation of micro switches so that the motor would only
manage to make the rotation necessary so that the punching ram wouldn’t move more
than necessary and create any damage. Unfortunately these switches where found by
our group not being in the right position which had lead to the problems encountered by
other groups.
The turret locking pins

The lock pins are used to properly align the punch and die for the punching process. A
spring on each pin produces the force to locate the turret in the correct locked position.
For the automation of this piece on the punch previous groups mounted an air cylinder
(Pneumatic Cylinder) near the manual lever, this device has the sufficient force to
quickly release the pins using the supplied shop air. The force of the springs will return
the piston and pins to the starting position once pressure is removed.

The punch and die turret

Is the mechanism that allows for punch and die combinations to be easily changed so
different sized holes can be made without a major tool change. The turret punch was
equipped with a hand wheel, gear synchronized turrets option, which allows a
synchronized movement of both the punch turret and the die turret, using only one
input. This simplified the work for previous groups because they would only need a
motor to rotate the turret. A 120VAC 1/10 Hp 1800 rpm motor was implemented. This
motor has a 14:1 gear head that is useful to provide the necessary torque and speed
without needing a large pulley ratio. The motor is equipped with a dual round belt
pulley; the final component for this turret drive system is the belt (A 23 inch urethane o-
ring belt)
Sensors

There are three parts on the turret press that are required to move during operation, and
therefore need feedback sensors or switches:

1. The punching ram: two SPDT micro-switches without rollers were placed to
provide feedback at either end of the ram’s range of motion. A wiper is attached
to the back side of the input shaft to engage the switches at either range limit.
The wiper would engage the switches to give the commands to the motor to stop
at certain limit.
2. The turret locking pins: Two SPDT micro-switches with ¾ “roller levers are
located at the top of the pin locking linkage.
3. The punch and die turret: micro switches.

Rotex Punch Press Previous Mistakes

In past reports it was noted that the angle restriction for the punching mechanism was
180º. Taking into consideration the implementation of a new system, as a group this
measure was taken again. As Image-1 shows, the total range of the machine is over
180º, but this includes a portion of movement that has no actual impact in the punching
mechanism. The actual limit the punch has is close to 210º which gives the motor, a
buffer zone or a space for the motor to stop and change direction when retracting the
punch.

The sensors used to avoid damage on the machine while punching (for compliance with
the 180º constraint) proved to be placed erroneously and served no purpose at all.
Previous groups had assumed (according to the positioning of the sensors) a movement
of the punch 180º, this was not correct.. After manual tests, the punch rotation was
determined.

Rotex Punch Automation

As applied to the Notcher machine (shown in Image-4), a linkage system was a safe
option to implement taking advantage of the constant movement of the motor. The only
difference is that in the case of the Rotex punch press, the arm would be connected to
the side of the punch instead of being on top.

A model was made to simulate the motion first, without previous calculation of the
linkage sizes and this resulted in a punch that would go beyond the desired limits. After
retrieving information from several different sources and consulting with Dr. Sturges,
the system that was found appropriate for the Punch was a four bar crank-rocker linkage
system.

A four bar crank-rocker linkage system consists of four rigid links, each attached to two
others by single joints or pivots to form a closed loop. Two of the links are grounded,
meaning they don’t move, one is the input link and one is the follower link. In the case
of the Punch, the input link can rotate 360º and therefore is called a crank, while the
follower link can only rotate from a set 0º to 113º and back to 0º, therefore it’s called a
rocker.
 Image -4

Determination of Angles
Linkage Lengths and Simulation
Courtesy of Dr. Robert Sturges
 D= 38 cm = 15 in
Crank Rocker
Coupler
r (in) R (in) Size (cm) Coupler Size (in)
1 1,19920494 37,9585643 14,94431665
2 2,39840989 37,8339849 14,89526964
3 3,59761483 37,6254359 14,81316375
4 4,79681977 37,3315102 14,69744494
5 5,99602472 36,9501702 14,54731111
6 7,19522966 36,4786748 14,36168299
7 8,3944346 35,9134732 14,13916267
8 9,59363955 35,2500582 13,87797567
9 10,7928445 34,4827617 13,57589045
10 11,9920494 33,6044687 13,23010579

The determined coupler size could be modified by using the simulation tool. Trying to
find a point at which the angle of rotation wouldn’t be altered too much but that would
allow for a smooth movement away from the locking point (point where the rocker and
coupler were in a straight line).
Some of the different computer simulations can be found in the attached CD, including
the final simulation with the calculated linkage lengths.
Linkage Design

Applied moment = 71272.73*25.4 = 2299111.48.4 Nmm

M.I=20431.71mm4.
Bending σ = bending M = 112.5N/mm2.
I of the cross section axis

With this, the material and width of the shaft can be found to be one that withstands this
bending strength.

Torque required = 71272.73*2.933*25.4=5309.7Nm

The available motor is 0.75HP.

Waste disposal Chute

In the past metal scrap from punching has been either accumulating or simply being
scattered around in the floor, creating a dirty and dangerous environment where workers
are exposed to sharp metal scrap. For this reason a waste disposal chute was created and
partially implemented. It will direct waste to a bin located at the bottom of the punch
press.
Utilizing 2” PVC tube and a matching elbow was the safest, longest duration, cheapest
and easiest to clean option.
Bill of Materials

VENDOR DESCRIPTION PART # QTY PRICE STATUS

Plain Spherical Female Rod End,
Grainger Thread Size 3/4-16 Inch, Right Hand 6G177 1 27,45
Thread, PTFE Race NEW

McMaster-Carr 12L14 Carbon Steel Square Bar 2" 6547K413 1 49,94

Square, 1' Length NEW
ASTM A193 Grade B7 Alloy Steel
McMaster-Carr Threaded Rod Plain Finish, 3/4"-16 98957A409 1 5,95
Thread, 1' Length NEW
Ultra-Coated Grade 8 Steel Hex Nut
McMaster-Carr 3/4"-16 Thread, 1-1/8" Width, 41/64" 93827A267 1 8,84
Height NEW
Grade 8 Alloy Steel Hex Head Cap
McMaster-Carr Screw Zinc Yellow-Plated, 3/4"-16 91257A877 1 3,12
Thread, 3" Length NEW
Plain Spherical Female Rod End,
Grainger Thread Size 3/4-16 Inch, Right Hand 6G177 AVAILABLE IN
Thread, PTFE Race 1 - SHOP

Grainger 12L14 Carbon Steel Square Bar 2" 1 AVAILABLE IN

Square, 1' Length - SHOP

Punches

Slot letter Slot # Size Shape

K 1 EMPTY EMPTY
J 2 size not shown Circle
I 3 19 SQ Square
H 4 7/16" Circle
G 5 3/8'' Circle
F 6 5/16'' Circle
E 7 9/32'' Circle
D 8 1/4'' Circle
C 9 7/32'' Circle
B 10 3/16'' Circle
A 11 5/32'' Circle
12 BLADE
Q 13 EMPTY EMPTY
P 14 1 1/2'' Circle
O 15 1 1/4'' Circle
N 16 1.0*1.25'' Rectangle
M 17 1.25*1.0'' Rectangle
L 18 Cross Cross
 Function Diagram

Four Bar crank-

Apply Torque Motor rocker linkage
system

AC power
AC power
supply
Energy Supply
24 V AC\DC
DC power
converter

Sensor
ROTEX
PUNCH Selecting Punch
COMPONENTS
Pneumatic
Cylinder
Process

RAM Apply torque

Hazard Label

Prevent RAM Prevented by the

Safety
collision linkage system

Waste disposal
Scrap
chute
Process Mapping

Punching Procedure

1. Release the safety lock on the rotex punch.

2. Select the desired punch and swing the punch turret into the punching position. The
corresponding die should also swing into position by the gearing mechanism. Return the
safety lock.

3. Punch work by actuating ram.

FMS involving Rotex Punch

1. Gripper will pick the sheet from the Snuffleupagus.

2. Gripper will transport either to notcher or Rotex punch.

-If sheet was transported to notcher it will then be transported to rotex punch

3. Griper will place sheet in the exact position for Rotex punch to the process that is
commanded.

4. A signal will be sent by the proximity sensors for the system to know on what punch
is the turret currently located if this is not the punch needed this sensor will send the
signal to move to the punch needed.
-If is another punch that is needed the Pneumatic Cylinder is activated to release safety
lock and permit the gear synchronized turrets be moved by a motor until the proximity
sensor sends a signal to make it stop in the correct punch selection.

5. When the punch needed is placed and the sheet is ready a command is given to start
the motor so it can give torque to the crank which in turn moves the coupler and
translates into a punch motion by the rocker. This way the punch can be made.

6. When the punch is made the ram returns to its highest point where the motor is given
a command to stop. The gripper then will move the sheet for another punch until all the
punches needed are accomplished.
-If a different diameter or shape punch is needed in this process it will return to
step 4.
-When finished, the gripper will remove the sheet and continue to the notcher if
the notcher has to make more cuts.
 Flowchart
Gripper: Place
sheet on Rotex
punch

Punch needed NO YES

Do we have the No changes
will be put in
punch we need? made
place for usage

PUNCH THE HOLES

INTO THE SHEET

Gripper will take sheet and take to finished

products or to notcher for final cuts

Conclusions and Final Remarks

The Rotex punch press hasn’t functioned since 2006, and this has been due to several
problems related to the punching system and its automation. The method selected is
highly appropriate and will serve to prevent malfunction and excessive rotation of the
punch ram.
Several parts of the Punch still need work but this project has been a great opportunity
to venture into different fields of engineering. The steps in the process may have not
been followed strictly enough but it has been a unique learning experience.

References

- Rotex Product Information. The Rotex Punch Company, Inc. website,

http://www.rotexpunch.com
- Rotex Product Instructions Manual. The Rotex Punch Company, Inc.
- ISE 5314 reports from previous years.
- Constant guidance and help by Dr. Robert Sturges
- Beer; Johnston. Mechanics of Materials. McGraw Hill. Second Edition. 1992