ATS Servo In-Die Tapping Units & Controllers
ATS has been designing and building Servo Driven Tapping units for over 10 years with one goal in mind, to be the fastest most durable user-friendly Servo in-die tapping unit on the market today. We constantly strive for perfection. As our latest S-100 SP1 Controller combined with our Servo tapping units will demonstrate.
Our controllers are designed to run with all presses from basic mechanical presses to the latest state of the art servo presses. ATS’ controller is typically a closed loop system with optional grayscale/SSI or press signal input. This gives us the ability to run with any press or as a stand-alone unit. The controller is designed to be the most user friendly available. By following the press speed automatically, the tapping unit keeps in perfect time with the press. Our menu oriented system allows programs to be created in a matter of minutes and changes to be made while the press is running to fine tune the program for optimum performance.
Eliminate Secondary Tapping
For most stamped parts with a tapped hole or holes IN-DIE TAPPING has become the only competitive alternative to secondary tapping. Secondary tapping of stamped parts has always been far more costly then the stamping operation. By combining stamping and tapping our customers are cutting costs as follows:
Initial Cost: The costs of building a tapping die (including the tapping unit) are usually considerably less then building a high speed secondary tapping machine. Secondary tapping machines are usually dedicated to a single part, whereas a tapping unit can be changed from die to die. This reduces the initial cost of subsequent tapping dies, making lower volume tapped stamped parts feasible for in-die tapping.
Labor Cost: By eliminating the secondary tapping operation all labor, related handling and feeding costs are also eliminated. In-die tapping enables the press operator to produce completed tapped parts in one operation, in many cases without sacrificing press speed. Except for inspection and tap changes (with ATS’s twist lock lead screw assembly, tap changes can be performed in seconds) the cost of tapping is reduced to a minimum.
Production Cost: In almost all cases in-die tapped parts are produced at a far faster rate then secondary tapped parts. With ATS’s new high speed tapping units, the tapping unit no longer becomes the limiting factor in how fast a tapped part can be produced. Now the size of the tap and material being tapped will determine the ultimate production rate of a tapped stamped part. Some customers presently are running the new ATS tapping units close to 200 strokes per minute producing millions of tapped stamped parts monthly. Whether tapping high speed brass electrical parts or larger steel automotive parts, ATS’s tapping units have proven to be most competitive in the industry.
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After switching from a competitors tapping unit to an ATS unit, we’ve run millions of parts and substantially reduced maintenance & operating costs. We have since converted all our tapping dies to ATS tapping units.
We’ve used ATS tapping units for the last 20 years, finding service & customer support to be exemplary. We’ve found the latest generation of ATS units too be the most compact, durable and designer friendly we’ve experienced.
After experiencing an alarming number of failures with a competitors tapping unit, we mounted an ATS unit in one of our existing tapping dies, With the ATS tapping unit we were able to increase our per tap numbers from 30 thousand parts per tap to 90 thousand parts per tap and were able to use standard taps priced at $8.00 each, compared to custom taps priced at $30.00 each. We have run in excess of 50 million pcs. lowering maintenance and operating costs to a small fraction of what they were.
We looked at all the in-die tapping options available and only one could meet our specifications. We bought that first 2-spindle ATS unit in 1996 and it paid for itself within the first year. We were so pleased with those savings and the units flawless performance that we have purchased thirteen more units since then with 1,2,3 or 5 spindles. We currently have eight progressive dies in use with eleven “bottom-up” tappers and three “top-down” units tapping up to six million pieces per spindle per year.
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