Summary

A metal stamping manufacturer needed an efficient solution to replace the slow, labor-intensive process of changing heavy dies using a forklift. Align Production Systems designed and delivered a custom omnidirectional Mold and Die Changer with integrated lift, rollers, and push/pull functionality, capable of handling up to 36,000 lbs. The system significantly reduces changeover time, increases safety, and provides precise positioning for dies across multiple presses.

Key Highlights

Omnidirectional Movement

Steerable drives and idlers allow car-like steering, crab walking, and zero-point turns for easy alignment.

Integrated Lift and Roller System

Hydraulic lift raises dies up to 103 inches, with retractable rollers for smooth transfer onto presses.

Custom Push/Pull Mechanism

An electromagnet system pulls dies from presses and pushes them into position, allowing for fast die changes.

"Aligning the transporter with the die is about as easy as it can get. Once you’re in position, you just push it on – it’s a very smooth process."
-Blake Ringger, Product Engineer

The Problem

Before implementing the Mold and Die Changer, the manufacturer relied on forklifts to move dies, requiring slow manual alignment and multiple workers to push the die into place. This method created downtime, safety risks, and inefficiencies, especially when moving heavy dies weighing up to 36,000 lbs. Accurate positioning was difficult, and the process required significant time and labor.

The Solution

Align created a die changer to transport dies within the facility, from production to storage. The machine features:

Omnidirectional steering for easy alignment.
Hydraulic lift to accommodate varying rack heights for storage.
Retractable rollers for smooth die transfer.
An electromagnet-based push/pull system, designed to meet the force requirements for the manufacturer’s dies.
Lithium-ion battery power for longer operation and low maintenance.

Safety features included reduced travel speed when the die is elevated and sensors to monitor roller angles during operation.

Implementation & Results

Two units were deployed to service multiple presses across the facility. The transporter now moves one die at a time from storage racks directly to presses, with quick and precise alignment. The omnidirectional movement eliminates difficult positioning, and pushing a die into the press can now be done in under a minute. The integrated safety and control systems ensure smooth operation and prevent equipment damage or accidents.

IMAGE & DETAIL GALLERY

CONCLUSION

By replacing forklifts with Align’s custom Mold and Die Changer, the manufacturer reduced downtime, improved operator safety, and achieved faster die changes across their facility. The tailored design – including lift height, push/pull force capacity, and movement capabilities – demonstrates Align’s ability to customize solutions to meet exact customer requirements.

Case Study: Die Changer Cuts Downtime and Increases Safety

Quick Die Changer solution

Key Highlights

"Aligning the transporter with the die is about as easy as it can get. Once you’re in position, you just push it on – it’s a very smooth process."
-Blake Ringger, Product Engineer

CONCLUSION

Key Highlights

"Aligning the transporter with the die is about as easy as it can get. Once you’re in position, you just push it on – it’s a very smooth process." -Blake Ringger, Product Engineer

CONCLUSION

"Aligning the transporter with the die is about as easy as it can get. Once you’re in position, you just push it on – it’s a very smooth process."
-Blake Ringger, Product Engineer