FORD DR10-2001 MECHANICAL STAMPING PRESSES《机械冲压机》.pdf

1、 Printed Copies are Uncontrolled Page 1 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 MECHANICAL STAMPING PRESSES NOTE: The following standard is an updated version of the prior standard, and serves as an interim standard until the new global stan

2、dard is published“. 1.0 SCOPE 1.1 The text herein contained shall apply to mechanical stamping presses for use in the Ford Motor Company. All presses shall conform to the U.S. Department of Labor Occupational Safety and Health Administration (OSHA) Standards Section 1910.217, Mechanical Power Presse

3、s, and state and local ordinances. 1.2 These standards apply to the following: A. Single Action Presses of 50 Tons or More Capacity B. Multiple Action Presses C. Automatic Blanking, High Speed, and Progressive Die Presses D. Portable Presses E. Transfer Presses 1.3 These standards shall also apply,

4、where appropriate, to the following related equipment: A. Hydro-Pneumatic, Pneumatic, Hydraulic, and Die Cushions B. Guillotine Shears C. Square Shears D. Die Spotting and Tryout Presses E. Press Brakes F. Air Storage and Surge Tanks 1.4 These standards do not apply to the following: A. Hydraulic Pr

5、esses B. Powdered Metal Compacting Presses C Pneumatic Presses D. Forging Presses E Presses of Less than 50 Tons Capacity Printed Copies are Uncontrolled Page 2 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 1.5 The following type presses are class

6、ified “Portable” by the Ford Motor Company: A. Two-Point Floor Mounted Single Action Presses up to and Including 250 Tons B. Open Rack Inclinable Presses C. Adjustable Knee Presses, Either One or Two Point D. Solid Cap Presses, Either One or Two Point 1.6 Presses listed in paragraph 1.5, but equippe

7、d with any type of strip or coil stock feeder, are not classified as “portable“. 2.0 PROPOSAL PHASE 2.1 This Standard shall be adhered to by suppliers receiving Purchase Orders from the Ford Motor Company for new and refurbished presses and related equipment, unless waivers are granted in writing by

8、 the Division of the Ford Motor Company which is procuring the equipment. 2.2 In addition to the requirements of the Ford Motor Companys “Machinery and Equipment Guidelines“, the following preliminary information shall be furnished by the supplier with each proposal: A. Firm delivery timing from rec

9、eipt of Purchase Order. When extra costs are required to meet requested delivery timing, these costs shall be quoted separately. B. Completed specification form indicating for each item whether the quoted item agrees with the specification or not (see Section 5.1 and 5.1A). Suppliers are encouraged

10、to quote alternate equipment where improvements in cost, productivity, reliability, safety, delivery, or serviceability will results, however, the specified equipment must be the basis for the base bid. Failure to quote directly to the base specification may result in disqualification of the proposa

11、l. NOTE: Any line item for which an alternate is proposed must reference the line, state the logic and the cost indicating an increase or decrease in base price. In any case, the original specification request must be adhered to and remain the basis for the base bid. C. A complete list of the deviat

12、ions and proposed substitutions from this DR-10 standard and/or written requirements. Printed Copies are Uncontrolled Page 3 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 D. Itemize on separate line items each separate cost for all custom clearanc

13、es, import duties and taxes as applicable. E. General arrangement drawings indicating overall lengths, widths, heights, approximate weights and clearances required to assemble or disassemble the equipment. F. Locations of any and all remote equipment. G. Die space drawings. H. A motor list showing t

14、he types, horsepower, frame and RPM of all motors I. Motion and tonnage capacity curves displaying crank angle, tonnages, speeds, distances and relationship of all slides. J. A timing chart created in Microsoft Project displaying suppliers implementation schedule in weeks duration. 2.3 Pricing - the

15、 supplier shall show separate prices summarized for: A. Base machine complete as specified F.O.B. Receiving Plant. B. Break out costs for: 1. Base machine 2. Feeder (if required) - mechanical vs. electrical 3. Engineering and design 4. Link-drive 5. Die cushion 6. Slide Lock(s) 7. Press controls a.

16、Main Operators Station (MOS) b. Main Bolster Operators Station (MBOS) Printed Copies are Uncontrolled Page 4 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 c. Light Operators Station (LOS) d. Oil Fill Station (OFS) e. Pendant Operating Station (POS

17、) / Master Operators Console (MOC) g. Slide Operators Station (SOS) 8. Main motor and slide adjust motors 9. Micro-inch motor (if required) * If any D.C. motors are quoted, include the motor controller. 10. Installation supervision and start-up assistance 11. Itemize each separate cost for equipment

18、 built in foreign locations to include loading, freight, insurance, and unloading free on board inland carrier at port of entry. Port of entry must be identified. 12. As required by specification detailed requests. 3.0 REVIEW OF PRELIMINARY DRAWINGS AND DIAGRAMS 3.1 Within six weeks of receipt of th

19、e purchase order, or specified time on suppliers quote, the supplier shall furnish not less than the following reproducible drawings and/or diagrams to the requisitioning activity. All drawings to contain the standard Ford Motor Co. title block. Approval drawings are to be submitted in both AutoCad

20、(on disk), and reproducible format. Unless otherwise agreed to, supplier is to submit a minimum of three (3) hard copies of all submissions. Supplier drawings to note ALL parts NOT supplied by the press manufacturer. All drawings shall be in the metric measurement system with the inch system in pare

21、nthesis. A. Plan and the four (4) elevation views of the General Arrangement, floor space requirements the relative location of all accessories and the accessibility for maintenance. The foot mounting bolt size, length and spacing for anchoring presses shall also be shown. Printed Copies are Uncontr

22、olled Page 5 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 B. Upright drawings for equipment arrangement. Include sectional view for wireway arrangement. C. Complete General Assembly drawings, including a separate print showing all clearances requ

23、ired for the removal of all press component parts. D. Die space drawings to include the following drawings where applicable: 1. Slide face(s) 2. Bolster face(s) 3. Scrap chute arrangements 4. Adapter plates 5. Upper and lower die clamps 6. Press Shut Height 7. Die Shut Height E. Motion curves. F. To

24、nnage (capacity) and velocity curves at requested strokes per minute, at midrange of spm capacity. G. Micro inch tonnage curve forward and reverse, where applicable, at midrange of spm capacity. H. Read-outs per one degree of crank angle for tonnage capacity, slide and feed bar velocities, slide to

25、transfer position thru 360 deg. for each parameter requested, at midrange of spm capacity. I. Available energy in inch-tons (reference Appendix A, Press Energy Calculation) at midrange of spm capacity. J. Chart in one (1) p.s.i. increments for counter balance capacities and separate diagram of count

26、er balance with sequence of operation and trouble shooting techniques for the automatic and manual systems, at midrange of spm capacity. K. Cushion general arrangements - closed and extended. Printed Copies are Uncontrolled Page 6 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufac

27、turing Standard Rev: 20010307 L. Chart for cushion capacities and separate chart showing relationships between the cushion tonnage, the cushion stroke and the press speed. M. Exit conveyor and destacker pickup station relative to press and transfer feed bars. N. Bolster carriage to include a 3D pict

28、orial drawing O. Bolster carriage track layout and installation details P. All transfer feed bars (rails) general arrangement and layouts Q. Electrical diagrams in accordance with Ford Manufacturing Standard EX-3, and Section 10 of this standard, shall be submitted by the electrical equipment suppli

29、er designated by the Ford Motor Company. R. Pneumatic diagrams in accordance with ISO Standard 4414. Pneumatic circuits and components shall also comply with Section 9 of this standard. S. Lubrication Systems and diagrams in accordance with SAE Standard 1751 and ISO Standard 5170. The type and amoun

30、t of lubrication required and the time intervals of application shall be shown on the diagrams. T. Hydraulic Systems and diagrams in accordance with ISO Standards. U. Piping line layouts (pneumatic, lubrication and hydraulic) V. Sequence of operations - press controls (flow chart) W. Sequence of ope

31、rations - die set rnodes (flow chart) X. A separate index listing all prints, diagrams and read-outs displaying print or document number, heading, date stamp, date submitted, date of return, date approved or not approved and final approval date. Y. ECPL Blacklines layout to be submitted at 50% desig

32、n review for staff/plant approval. Printed Copies are Uncontrolled Page 7 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 3.2 The requisitioning activity will review the drawings and diagrams in accordance with this standard and the press specificat

33、ion data sheet attached to the purchase order. Approval should be shown on the copy returned to the supplier. If changes are found necessary, they shall be shown on the copy returned to the supplier. 3.3 Upon receipt of returned copies, the supplier shall modify the original drawings within two week

34、s in accord with changes requested by the procuring division, and copies of the modified drawings or diagrams forwarded for approval of the particular item or circuit involved. Upon review to assure inclusion of all changes, the drawing will be approved and returned to the supplier. This process wil

35、l continue until approved drawings are achieved. Any revisions and/or changes shall be noted by symbols and the date and must be recorded in the change column. Any corrections, deletions additions or changes to a drawing shall constitute the drawing as not approved for build. 3.4 Progress reports sh

36、all be submitted every four (4) weeks from time of firm purchase order The seller shall furnish a schedule denoting the start and actual finish dates with percentage complete for all major components and the items as identified on the vendor implementation schedule form. 3.5 Compliance - Ford Motor

37、will reserve the right to “hold-back“, not less than 10 % of contracted delivery price until final acceptance at receiving plant. 4.0 FINAL DRAWINGS AND DIAGRAMS 4.1 Scope - The following paragraphs pertain to drawings, circuit diagrams, and data required for installation and maintenance of stamping

38、 equipment by the plant procuring the equipment. All such final information, including maintenance manuals, shall be forwarded to the requisitioning activity no later than the shipping date. Printed Copies are Uncontrolled Page 8 of 75 Standard Number DR10 Issue Date: 19901101 North America Manufact

39、uring Standard Rev: 20010307 4.2 Supplier Responsibilities - Copies of all final drawings and circuit diagrams of the equipment “as-built“ and a disk in the latest version of Autocad will be forwarded no later than two weeks after the equipment has been accepted at suppliers plant for dismantling an

40、d shipping. This set is for the receiving plant. A complete set of the latest electrical drawings shall be shipped with control enclosures and disks of all control programs. In addition, two (2) sets of mechanical drawings, which includes lubrication, pneumatics, and hydraulic layouts are to be subm

41、itted on aperture cards to the requisitioning activity. The final drawings and diagrams shall be identified with the Purchase Order number, serial number(s), 18 and 17ZM drawing numbers and a full description which will identify the particular equipment to which the prints and diagrams pertain to. I

42、f any field changes are required, the changes shall be recorded and new reproducible copies of the changed drawings shall be forwarded for replacements by the press suppliers. 4.3 Final reproducible electrical diagrams, layouts, and electric motor data shall be forwarded by the affected suppliers be

43、fore delivery of the equipment. Latest copy of all control programs shall be shipped to requisitioning activity before starting of the installation. The final copy of all programs, after receiving plant1s acceptance, must be submitted to receiving plant and requisitioning activity. 4.4 Maintenance a

44、nd Operators Manuals - The supplier shall furnish a preliminary copy of these manuals for approval and scope. After approval and not later than shipping date, the suppliers shall furnish two (2) copies to the receiving plant (to use during installation) and one (1) set to division Staff. The manuals

45、 shall contain, but not be limited to, the following data: A. Ford purchase order number, equipment serial number(s) and identification. B. Equipment specifications showing all capacities and adjustments. C. Reduced copies of all prints and diagrams. D. A list of commercially available parts with or

46、iginal manufacturers catalogue. Drawings displaying the location of these parts will be included. E. A list of parts manufactured by the press suppliers and prints showing their location. F. Preventative maintenance recommendations and testing procedures. Printed Copies are Uncontrolled Page 9 of 75

47、 Standard Number DR10 Issue Date: 19901101 North America Manufacturing Standard Rev: 20010307 G. Prints for all wear strips, plates and inserts. H. Recommended spare parts list, I. An illustrated description of the operation and instructions for a step by step procedure for equipment operation - dur

48、ing automatic and manual operating modes. J. Lubrication, pneumatic, hydraulic and electrical equipment layouts each separately superimposed on elevation plan and detail drawings as required to show the location of all pertinent equipment. K. All lubrication points superimposed on elevation plan and

49、 detail drawings as required to display type of lube, frequency and how performed. L. I.O. list, control manuals, documentation and disks. M. A complete list of perishable items, including: all bearings, seals, packings, O-rings, wear strips and wear plates with sizes and locations. N. Detailed assembly drawings of clutch and brake applications. These drawings shall be supplied by the clutch/brake manufacturer. O. Press assembly installation procedures. P. Approved