A pneumatic toggle press is a type of mechanical press that utilizes compressed air power to perform pressing operations. It is commonly used in various industrial applications for punching, embossing, crimping, riveting, and assembly operations. It got its name due to its mechanism consisting of mechanical linkages amplifying the force generated by the pneumatic system.
The advantages of these presses include their compact size, high force output, and quick operation. They are often preferred for applications requiring repetitive pressing tasks with consistent force and speed. However, their specific design and characteristics may differ depending on the manufacturer and the intended purpose.
Incorporating pneumatic toggle presses into manufacturing processes offers many advantages, greatly enhancing overall efficiency and output. Here are several benefits of these machines that make their integration into a production line indispensable:
1. Compact Design and Optimal Space Utilization
A pneumatic toggle press is renowned for its compact size, making it ideal for maximizing the available workspace. Its space-saving nature allows for efficient placement within limited manufacturing areas or when multiple machines need to coexist in a confined space. Moreover, it becomes more convenient to navigate and maneuver around the devices because of their compact footprint.
2. High Force Output and Improved Performance
Pneumatic toggle presses offer remarkable capabilities in force generation, allowing manufacturers to carry out various pressing operations with utmost precision. They are designed to deliver substantial force, providing the power to accomplish multiple tasks effectively and efficiently. Below are examples of processes and activities that are frequently optimized by presses:
Assembling: joining multiple components together to create a finished product or assembly
Crimping: creating a secure and tight connection between two materials by folding, bending, or compressing them together
Deforming: altering the shape or form of a material through the application of force, often used to achieve desired shapes or fitment
Dismantling: taking apart or disassembling components or structures, typically for repair, maintenance, or recycling purposes
Marking: applying symbols, logos, or identification marks onto a surface for labeling or identification
Numbering: assigning sequential or customized numbers to products, components, or items for identification or tracking purposes
Riveting: fastening materials together using a rivet, which involves inserting and deforming a metal pin to create a secure joint
Staking: permanently joining or securing components together by using pressure to deform or displace the material
Stamping: impressing or imprinting a design, symbol, or information onto a surface using a die or engraved tool
Swaging: reshaping or reducing the diameter of a workpiece by applying force, typically used for forming connections or creating desired shapes
3. Swift Operation and Time Efficiency
A pneumatic toggle press provides rapid operation cycles, decreasing overall processing time and boosting productivity. Its fast press strokes and return movements also ensure that production processes can meet high-volume demands. This results in streamlined and efficient operations.
4. Consistent Force and Speed
The ability of these toggle presses to provide an accurate fixed dimension that is repeatable to a high accuracy while applying a reaction force necessary for completing the process. This uniformity eliminates variations in final products, decreasing the likelihood of defects such as incomplete presses and irregular connections. This enables manufacturers to achieve reliable and predictable results.
5. Versatility for Diverse Applications
A pneumatic toggle press exhibits exceptional versatility and can seamlessly accommodate various applications spanning multiple industries. Whether the objective involves cutting, forming, shaping, or joining materials, it can be outfitted with multiple tooling and fixtures. Furthermore, its adaptability renders it invaluable for production lines requiring flexibility to meet evolving needs.
AIM Joraco: Your Trusted Partner for Pneumatic Toggle Presses
AIM Joraco specializes in precision pneumatic toggle presses, semi-automatic rotary indexing machines, and assembly tooling. Our product lines — including the TOGGLE-AIRE®, DIRECT-AIRE®, and HYDRO-AIRE — are renowned for their exceptional quality and unparalleled performance.
Contact us today to learn more about our products and how they can elevate your production capabilities!
In metal fabrication, punching and shearing are two distinct metalworking procedures. Metal punching is a cutting technique in which the material is removed from a metal sheet by exerting sufficient tearing power. On the other hand, metal shearing removes excess material from sheet metal without using heat or generating waste in the form of chips.
Punch and shear processing devices are metal fabrication machines that combine the functionalities of punching and shearing equipment. Typically, they are used to cut shapes and punch holes into metal sheets simultaneously.
In this article, we will take a deeper look at one of AIM Joraco’s projects which focuses on punch and shear applications.
AIM Joraco’s Punch & Shear Application Using Servo-Driven Feeder
AIM Joraco designed and constructed a highly automated multi-press punch and shear system to produce transformer core sheets. The project’s objective was to achieve precise tolerances of 0.002 in. around the burr of the punched hole in the steel sheet. Moreover, the client generally used the system in electrical transformers.
Engineers designed, fabricated, and rigorously tested the punch tools to ensure dimensional accuracy in the stack core transformer design for the client. Various in-house tests were also conducted to confirm that the tools consistently generated holes of the desired size and shape.
AIM Joraco delivered this automated fabrication technology with a set of carbide tools that we precisely honed. Due to carbide’s ability to keep its cutting edge even during high-speed punching, the tooling achieves exact tolerances and delivers accurate components during long production runs.
Capabilities Applied and Processes
To achieve the exact tolerances required, AIM Joraco applied the following processes:
Punching: Metal punching stamps a shape onto a surface via pressure or percussion using a steel punching tool. This method removes material from a metal sheet by exerting sufficient cutting power.
Shearing: Metal shearing cuts through a metal sheet using a blade attached to a tool or machine. A squaring arm controls the placement of the cut, allowing a metal sheet to be placed in a precise area.
Servo Feeding: The servo feeding process uses a machine motor that powers the feed roller via a synchronous belt wheel. It also utilizes the release signal supplied by the punch cam to discharge the generated error through the cylinder.
Equipment Used To Manufacture and Overall Dimensions
The following machines and devices are used to fabricate the multi-press punch and shear system:
2x Toggle Aire 2530 Press: The Model 2530 Press from AIM Joraco has a repeatability of 0.001 inches and can cycle up to 80 strokes per minute — faster cycle times with shorter-than-standard strokes.
Carbide Tooling Package: The precision-sharpened carbide tooling package enabled the system to create accurate components across extended production runs while preserving its cutting edge.
Servo Motor: A servo motor is a rotary or linear actuator that permits exact control of position, velocity, and acceleration. It consists of an efficient engine coupled with a position feedback sensor.
The overall part dimensions of the system are 29.5 in. (width) x 30.75 in. (depth) x 63 in. (height).
Partner With AIM Joraco for Custom Automation Systems!
AIM Joraco has over 70 years of service experience, allowing us to provide presses that satisfy various specific requirements. We produced the TOGGLE-AIRE®, DIRECT-AIRE®, and HYDRO-AIRE® lines of pneumatic and manual toggle presses, semi-automatic rotary indexing machines, and assembly and fabrication tooling.
AIM Joraco provides diverse solutions with its benchtop pneumatic presses for clean rooms. The company’s goal is to meet the ever-demanding clean room standards while remaining the number one provider for toggle press. We manufacture TOGGLE-AIRE®, DIRECT-AIRE®, and HYDRO-AIRE® precision pneumatic and manual toggle presses for various applications.
What Is A Clean Room?
A clean room is a secure and controlled environment where critical components are manufactured. They are required in the pharmaceutical industry, nanoelectronics, and biotechnology to eliminate possibly hazardous toxins or compounds from the products or equipment. Clean rooms are also needed in industrial applications that demand an uncontaminated working environment.
Clean Room Press Specifications
AIM Joraco’s clean room press series specifications include the following:
Particle density for a particle of 0.3 µm or larger is less than 3.5 particles
Press noise silencing effect of 40 dB (A) or more
PTFE – No Lubrication Bearing Surface
400 Series Stainless Steel (includes all fasteners, ram, and precision ground platen)
Internally contained lubrication for ram
Clean Room Press Attributes
AIM Joraco also offers the following press attributes:
Compliance Equivalent to Class 100
An ISO 5 Class clean room, also identified as a Class 100 clean room, is a manufactured structure with soft or hard-sided walls that use High-Efficiency Particulate Air (HEPA) filtration systems. HEPA systems are required to maintain air cleanliness levels of up to 100 particles (≥0.5 µm) per cubic meter of the inside air.
Quiet Operation (Noise Level Reduction of 40 dB (A) or More)
The noise level should not exceed 60 dB (A) in a laminar clean room and 65 dB (A) in a turbulent one. AIM Joraco developed a clean room press that meets and reduces noise standard levels.
Lubrication-Free Wear Services
Clean room lubricants require specially distilled oils to remove the more volatile, lighter particles that may evaporate quickly. In addition, some standards require special thickening agents that do not contain metals, reactive compounds, or other large particles.
Stainless Steel Construction
Stainless steel is known to be sturdy and can withstand the most rigorous cleaning process. Mainly, Grade 304 stainless steel is unreactive to most acids and alkalis, which aids in the prevention of corrosion-related contamination.
Ram Wiper System
Clean room wipers differ from regular wipers because they contain less lint to protect against pollutants. They also have greater absorption capacity, resistance to chemicals and abrasion, and better cleaning capabilities. AIM Joraco provides a press series with an upgraded wiper system for various applications.
The mission of AIM Joraco is to provide superior-quality presses to various markets and industries. The following are four industries the company is targeting:
Pharmaceutical Industries
Pharmaceutical manufacturing necessitates a high degree of cleanliness and germ-free environments. Clean rooms can provide streamlined processes wherein products are protected from contaminants, such as dust, airborne pathogens, and atmospheric emissions.
Life Sciences Industries
A clean room is a functional necessity in the life sciences industries. It is vital to control any particulate and microbial contamination to ensure the product or output quality. Additionally, preserving the highest quality standards possible guarantees high efficiency and reputation.
Regenerative Medicine Industries
A strict clean room and clean room press are required to maintain the quality of cell-based medicinal products since the process involves living drugs.
Surgical Industries
All surgical industries use clean room technology to reduce airborne contaminants and maintain an antimicrobial setting in securing the safety of both patients and surgeons.
Applications of AIM Joraco’s Clean Room Press
Aside from the standard applications of clean rooms and clean room presses, some uses of AIM Joraco’s press include the following:
Tissue Cutting/Sampling
Clean rooms are constrained areas where filters and cleaning can control particle count and microbiological levels. This minimizes microbial contamination and prevents contamination levels from rising during tissue cutting and sampling.
Implant Assembly
Implant placement requires a high level of sanitation to avoid potentially dangerous infections caused by contamination. Clean rooms also help to reduce implant failure and disease progression by maintaining hygiene during the assembly process.
Medical Device Assembly
Medical device fabrication is a highly controlled industry in which companies strive to create quality products without endangering a patient’s health. They are designed for use in healthcare settings where hygiene and the need to prevent contamination are of the utmost importance.
AIM Joraco: The Best Toggle Press Innovator
Thanks to our 70 years of service experience, AIM Joraco provides quality presses that meet a wide range of special requirements! Tell us your project specifications, and we can quote a custom solution for your application.
Powder compaction is gradually becoming an essential industrial manufacturing technique for producing components with complex shapes and structures. It is the process of tamping powder particles in a die using high pressures. The tools are typically held vertically, with the punch tool forming the bottom of the chamber. After that, the powder is compacted into a shape and ejected from the cylinder.
A powder compacting press compresses granular and powdered raw materials into various standard and custom-shaped units. It can suppress a wide range of products with high product density specifications and can compact multiple pieces at once, making it ideal for large production industries. In addition, the press requires innovative integrated machines, electricity, liquid, and gas control, as well as an automatic feeding and discharging device.
This article will discuss the different types of powder compacting presses and the product developed by AIM Joraco.
Types of Powder Press Machines
The four most common types of press machines used to compact powder material are as follows:
Hydraulic Press
A hydraulic press generates compressive force by using a hydraulic cylinder. It is appropriate for the industries of carbides, powder metals, ceramics, polymers, and other particulate materials. Furthermore, hydraulic presses are commonly used in factories that manufacture powder products.
Mechanical Press
Mechanical presses are frequently used in manufacturing technical ceramics, but they are also well-suited for other commercial processes. Compared to hydraulic press machines, mechanical powder presses have limited maximum compaction forces that are typically greater than or equal to 5000 kN.
Electric Press
Electric powder presses are servo-powered machines that compress materials at extremely high pressures. Because of their servos, they can regulate the placement and response time of the output shaft instead of keeping a constant press cycle speed. Moreover, electric metal presses can perform several functions and use a closed-looping feedback mechanism to enable a more precise cycle rate and load regulation.
Isostatic Press
Isostatic presses enable users to produce uniform-density components using a dry bag design, simplifying and improving powder filling, compaction, and ejection. These machines are typically used in ceramics, carbides, composite materials, pharmaceuticals, and explosives.
AIM Joraco Compacting Press
AIM Joraco developed a compacting press for the world’s leading provider of technology for the oil and gas industry. It is the outcome of the need to design an explosion-proof mechanism with an integrated safety capacity. It must also adhere to industry standards, legal requirements, and the company’s clear and specific guidelines.
The company designed and built this compacting press entirely in-house. This included reinforced machine guarding, a robust protection system, integrated safety features for operators and equipment protection, and a process control system for capsule consistency.
Capabilities Applied
The following are features highlighted in the developed compacting press:
Compacting: The press is intended to pack explosive substances into capsules for oil well-perforating processes.
Force Monitoring: The force monitoring system determines the compaction work of delicate substances and reinforces the proper press operation. It also offers control signals, alarm systems, real-time inspection, and quality assurance data recording.
Equipment and Specifications
Direct-Aire® Model DA-400T is an AIM Joraco benchtop pneumatic press with a capacity of 2300 lbs. of force. It includes a straight pneumatic cylinder for applications that require full force throughout the stroke.
The overall part dimensions are 13 in. (width) x 18 in. (depth) x 42 in. (height) for the press and enclosure.
Choose AIM Joraco for Your Compacting Application
AIM Joraco’s competitive success and reputation in the benchtop pneumatic press industry allow us to consistently offer our customers solutions that provide accurate results. Contact us for more information about this project or our custom pneumatic press-building capabilities!
AIM-Joraco had the overarching goal of building a sophisticated high-tech production line. With this, we developed an automated press-fitting hub assembly cell system for a major tractor manufacturer by combining our expertise in pneumatic press engineering and industrial automation. This custom press solution is designed to precisely press fit bolts into tractor wheel hubs.
Click to Expand
How Does the Assembly System Work?
This assembly system features two 8-ton AIM Joraco Hydro-Aire® presses, a rotary electric motor mounted on top of a pneumatically powered linear slide, and an optical sensing system.
As the operator activates the system and loads the hub into the press with loosely inserted pins, the linear slide moves the wheel into position. Next, the optical sensors guide the electric motor as it rotates the wheel hub until one bolt is accurately located under each press. The presses then activate simultaneously with precise force to insert the perfectly aligned bolts into the hub. Once that is done, the motor moves the succeeding two bolts into position, and the process repeats until every bolt is in its place. Lastly, the part is manually ejected after the slide retracts.
AIM-Joraco Wheel Hub Assembly Machine
AIM-Joraco constructed the assembly machine by incorporating two of its HP8 Series Hydro-Pneumatic Presses into a custom-built press frame. As a result, the machine takes up only 7.5 square ft. of floor space, with a footprint of 45 in. long x 24 in. wide. A safety light curtain has also been installed to protect operators from machine motion injuries.
PLC Control Unit provides control and logic verification to ensure the bolts are pressed to the correct depth and that all the bolts are processed.
Linear Slide System then shuttles the finished hub assembly to allow the operator to remove and repeat the process.
Capabilities Applied
Press Fit Bolts: These are used to connect flange couplings.
Rotational Positioning: During installation, the bolt is positioned in the coupling holes in a clearance condition, and the sleeve expands by drawing the bolt through the sleeve to provide a proper interference fit.
Optical Sensing for Positioning: Position sensors detect movement or determine an object’s perceived position relative to a known reference point.
Equipment Integrated into Solution
2x Hydro-Aire 8 Ton Presses: An AIM-Joraco alternative to the hydraulic press featuring a rapid motion with automatic power stroke and is fully contained with no hydraulic lines or fluid reservoirs. With presses ranging in capacity from two to 16 tons of force, it also produces accurate and reliable results.
Optical Sensors: Electronic components that detect incident light rays and convert them into electrical signals.
Electronic Motors: Devices that convert electrical energy into mechanical energy.
Linear Pneumatic Cylinder: A mechanical device that converts the energy in compressed air into a linear reciprocating motion.
Light Curtain: An electro-optic device used to protect personnel in the proximity of potentially hazardous machinery.
AIM-Joraco – Number One in Service and Innovation
Our 75+ years of service experience enables us to provide quality presses that meet a wide range of special requirements. To learn more about this system or our other custom product assembly solutions, contact AIM-Joraco today!
A hydropneumatic press, or air over hydraulic press, combines compressed air and hydraulic oil into one system. As a clean, reliable alternative to hydraulic presses, air over hydraulic presses are used for a wide range of industrial tasks, including punching, bending, riveting, forming, and more. This type of press offers a wide range of benefits that make them suitable for various industries and applications.
Air Over Hydraulic Press Overview
Used to perform a wide range of functions, the air over hydraulic press delivers the powerful force of a hydraulic press combined with the enhanced control and efficiency of a pneumatic press. The air over hydraulic press is initially driven by compressed air. When it encounters resistance, the hydraulic power is automatically activated. This innovative technology can help you save space, reduce your energy expenditure, and so much more.
Air Over Hydraulic Press Benefits
The advantages of using air over hydraulic presses include:
They’re small and lightweight, and there’s no need for a hydraulic power pack.
With compressed air as their primary power source, they allow for a quicker approach and retraction.
They use up to 50% less energy when compared to fully hydraulic and pneumatic systems.
They offer an overall savings of up to 70% over traditional hydraulic systems.
With simple sealing components and pneumatic elements, air over hydraulic presses are easy to use.
These presses eliminate the need for expensive hydraulic oil and other hydraulic components.
Air Over Hydraulic Press Applications
Air over hydraulic presses are commonly used for a wide range of industrial tasks, including:
Bending
Riveting
Forming
Marking
Clamping
Punching
Straightening
Shearing
Die setting
Embossing
Forming metals and plastics
Featured Air Over Hydraulic Presses
At AIM-Joraco, our air over hydraulic presses are available in a variety of sizes and configurations to meet the needs of your application. These presses are manufactured from steel plate in the United States. Our featured air over hydraulic presses include:
Hydro-Pneumatic (HP) Press Series. This press is available in C-Frame and H-Frame configurations with a standard 4’’ stroke with ½’’ power stroke, providing anywhere from 2 to 16-tons of force. It offers clean, reliable, and accurate results, with optional features like the EZ-Dial Precision Force Regulator and custom height, stroke, and other options.
Hydro-Aire (Model HP-16H). With up to 16 tons of force, this unit features automatic stroke adjustment without any messy hydraulics. Our standard model features 8’’ open height with 4’’ stroke with up to ½’’ power stroke, though the model is customizable to suit your needs.
Hydro-Aire (Model HP-8H). This eight-ton model is ideal for punching, marking, and staking, and can include optional accessories like a dwell timer and force monitoring.
Hydro-Aire (Model HP-4H). This four-ton version is made of just three moving parts (no springs!) and can be PLC ready for automated set-up.
Air Over Hydraulic Presses from AIM-Joraco
For more than 70 years, AIM-Joraco has been a trusted manufacturer of precision pneumatic and manual toggle presses, semi-automatic rotary indexing machines, and assembly and fabrication tooling. Our presses are time-tested and field-proven, and we aim to provide personalized, high-quality solutions at competitive prices. As a leading supplier of pneumatic presses, including air over hydraulic presses, we can deliver the solutions you need. For more information about our selection of air over hydraulic presses, contact us today.
When cutting a particular shape from a material, die-cutting makes the process more efficient and accurate than cutting by hand. Die-cutting uses a die and a machine to cut, which produces more consistent results in less time, making it great for a variety of applications. Due to die-cutting’s ability to cut intricate shapes from paper and other materials, it’s frequently used for the fine arts and medical industries.
Using Die-cutting Machines
A die-cutting machine is used to cut custom shapes from different materials, including paper and vellum. The machine consists of cutting plates and rollers, which apply pressure to a die to press it through the base material, creating the desired shape. Using a custom die featuring nearly any shape imaginable, you can cut the same shape repeatedly with more efficiency and minimal risk of mistakes.
There are two main types of die-cutting machines available: manual or digital die-cutting machines. Digital machines, which often use laser technology to complete die cuts, connect to computers. Designs are cut either from scratch or designs created in software. Laser die-cutting machines offer more accuracy, precision, and efficiency than other types of die-cutting machines.
Cleanrooms provide a controlled environment with minimal exposure to contaminants. They are used in a variety of industries where dust and debris, microorganisms, chemical vapors, or aerosolized particles might impact the efficacy of a process or product. Selecting equipment designed for use in cleanrooms is critical for maintaining the sterilization and cleanliness standards of the environment.
WHAT LEVEL OF CLEANROOM DO YOU HAVE?
Cleanroom levels vary depending on the needs of the application. The requirements for each class of cleanroom are determined by ISO 14644 standards, as well as corresponding FED STD 209E standards. These guidelines set specific rules regarding the number of particles that can be present in the cleanroom’s air supply, as well as the size of those particles. ISO Class 1 has the highest purity standards, while ISO Class 9 is roughly equivalent to the air quality of standard rooms.
At AIM Joraco, we offer pneumatic presses for use in cleanrooms. We have three levels of pneumatic press available to suit varying cleanroom levels:
Level 1 (Cr-1)
· Exhaust air cleanliness: Equivalent to ISO Class 5 (FED STD Class 100); particles of 0.3 µm or larger (3.5 particles/ℓ or less)
· Downstream cleanliness: Particles of 0.3 µm or larger: 100 particle or less/ft³ (35 particles or less/10 ℓ ANR)
· Element life: One year from first use (or when upstream pressure reaches 0.1 MPa, even if less than one year from first use)
· Element life indication (saturated with oil): Element color indication (replace if red dots appear on the element surface, even if less than one year from first use)
· Element construction: Worry-free two-stage element construction prevents external discharge
· Silencing effect: 40 dB (A) or more
LEVEL 2 (CR-2)
· Exhaust air cleanliness
· Stainless steel contact surfaces: Stainless steelbolster plate and ram with wiper system
Industries That Benefit From Cleanroom Pneumatic Presses
Pneumatic presses for cleanrooms offer an ideal solution for use in a variety of industries. Our presses are currently used in industries such as:
· Pharmaceutical
· Life science
· Regenerative medicine
· Surgical
Cleanrooms with pneumatic presses play a central role in creating a variety of life-saving products and equipment. Some cleanroom applications for pneumatic presses include:
· Tissue cutting and sampling
· Implant assembly
· Medical device assembly
Tons Of Force No Matter Which Press
Our presses are available in a broad range of tonnages to suit varying application needs. At AIM Joraco, we offer three different series of pneumatic presses to suit cleanroom needs:
· Toggle Aire Series:½–16 tons
· Hydro-Pneumatic Series: 2–16 tons
· Direct-Air Series: 15–5,000 lbs.
If you’d like to learn more about our pneumatic presses for cleanroom applications, contact us today to speak to a customer service representative.
Aim Joraco Provides Solution For World’s Leading Provider Of Technology To The Oil & Gas Industry
At AIM Joraco, we are pleased to offer the highest quality precision pneumatic and toggle presses, rotary indexing machines, and fabrication tooling for a wide range of applications. Our toggle presses offer superior accuracy and reliability, so you can be sure that your manufacturing and assembly processes are running as smoothly and efficiently as possible without the mechanical complications common with hydraulic and power presses.
WHAT IS A TOGGLE PRESS?
A toggle press is a metal fabrication tool used to bend or indent metal stock or sheets. Rather than using electrical power, a toggle press relies upon pneumatic power to exert force through a series of strategically placed levers.
The mechanism consists of toggle lever connected to a secondary toggle, which manipulates the compressing piston by pressing it downward into flat material fastened to the press table. The use of toggles significantly increases the pressure placed on the material by multiplying the force. As such, toggle presses often exceed the available force of other common bending methods such as hammer striking. Incorporating pneumatics into the system enables an exponential increase in available force, significantly increasing pressure while reducing manual strain on operators.
Aim Joraco’s Toggle Presses
AIM Joraco provides superior toggle presses that meet the diverse needs of customers across manufacturing verticals. Our press capacities range from ½ ton up to 16 tons at 100 psi, ensuring that we have an appropriate machine for nearly any application.
· 16-ton press– TOGGLE-AIRE® Model 3530 Benchtop Pneumatic Press
· 10-ton press– TOGGLE-AIRE® Model 2530 Benchtop Pneumatic Press
· 5-ton press– TOGGLE-AIRE® Model 1530 Benchtop Pneumatic Press
· 3-ton press– TOGGLE-AIRE® Model 1030 Pneumatic Press with Toggle Action
· ½-ton press– TOGGLE-AIRE® Model 500 HP Manual Press
Aim Joraco: The Pneumatic Toggle Press Innovators
Since 1961, AIM Joraco has been dedicated to the production of reliable and innovative presses and indexing machines with simple, safe designs that are easily controlled and maintained. Our knowledgeable engineers provide in-depth analyses of new and existing equipment to better integrate our press into your cell or automated line.
All of our equipment is manufactured using top-of-the line castings and weldments at our Smithfield, Rhode Island facility. Our equipment is accurate, dependable, and cost-effective. For more information on our press products and services, contact us today!
Pneumatic presses offer a range of benefits in a wide range of applications. These machines are great due to their:
power
speed
cleanliness
low maintenance
Pneumatic presses generate a force greater than manpower( manual press usually known as an arbor press) alone can supply. It can be used for pressing, squeezing, forming, and other actions. Removes the potential for repetitive strain on the operator, increases efficiency, and pressing repeatability resulting in better quality parts and reducing costs over time.
HOW DOES A PNEUMATIC PRESS WORK?
The potential force of a pneumatic press comes from compressed air pressing against a piston inside an enclosed cylinder, The area of the piston multiplied by the air pressure determines the force generated by the press. The actuation of the press comes from either an air or electric signal, typically generated by an operator when running manually, or by a PLC in an automated system setup. The signal to the press can be configured to create a complete cycle for each signal sent. It also can be configured for Constant Signal Required (CSR) whereby the operator is required to maintain the input signal for the press to actuate, staying down, applying force until the operator removes the signal, then the press would retract. Operators typically use an anti-tie down controller which requires two hand operation to insure the operator’s hands are free from the work area and potential risk of injury. PLC actuated systems utilize sensors and physical/light curtain guarding to insure operator safety.
Direct double acting pneumatic presses are the most widely used type in industrial applications. These types of presses use air to advance and retract the cylinder, which is beneficial for applications with heavy tooling attachments, and applications that require quick response and cycle times.
DIFFERENCES BETWEEN HYDRAULIC (MECHANICAL) & PNEUMATIC PRESSES
There are several key differences between the pneumatic press and hydraulic presses.
Method of Operation
Hydraulic presses function similarly to the principles of the pneumatic press. However, instead of compressed air, the driver for their movement is a fluid base.
Maintenance`
Pneumatic presses do not require much in terms of maintenance.
If there is a leak, then only air escapes, which can be easily replaced once the leak has been repaired.
Conversely, if a hydraulic machine leaks, it loses fluids, which creates a mess that requires time to clean up.
Capabilities
Pneumatic presses operate at very high speeds, whereas hydraulic presses operate at much slower speeds.
A GUIDE TO PNEUMATIC PRESS SAFETY
Employee safety is the most crucial component of every industrial setting. Therefore, it’s important that you properly train your employees and operate each piece of equipment with care.
Below are some pneumatic press safety tips that any shop using a pneumatic press should follow.
Release all compressed air.
Whether the pneumatic press is shut down, undergoing maintenance, or merely inactive, it’s critical that the compressed air in the machine is released correctly.
Every pneumatic press should have a release valve (labeled “lockout/tagout”). This valve will safely and effectively release all compressed air back into the environment.
Failure to release air properly can result in serious injury to employees.
Restrain all tubing.
Tubing is overlooked in shop settings. However, pneumatic press tubing has the potential to cause injury if snapped or broken.
To mitigate this risk, group bundle/bond all tubing.
Proper training
Like any shop machine, adequate training is critical towards reducing potential injuries. It’s crucial that all employees are trained to industry standards on any new or old machine the shop.
Risk assessments
Again, like all other machines in the shop, performing regular risk assessments on your press can lower potential safety hazards.
BASIC TROUBLESHOOTING FOR YOUR PNEUMATIC BENCH PRESS
If you own a pneumatic bench press, troubleshooting potential problems is typically quick and strait forward. Referring to schematics, pneumatic have three basic components: The air cylinder, the power valve, and the signal source(actuator).
To obtain an accurate diagnostics, the best course would be to contact your pneumatic bench press manufacturer to diagnose and assist with fixing the problem.
In the meantime, here are a few steps you should take to diagnose and troubleshoot common problems associated with your pneumatic presses.
Do you hear any leaks in the system? First and foremost you want a have an air leak free setup. When the air supply is turned on be sure your hands are away from the pressing area.
When you operate the actuator, does the press cycle? If not, remove the signal out from the actuator and try to cycle to see if signal is present. IF not, the actuator may need repair/replacement. If the press is going down but not generating full force, check you air supply line to confirm adequate pressure is supplied to the press. If the press is not properly maintained and lubricated, it is possible you need to replace the seals and o-rings in the cylinder.
What do you use your press for?
If you work in clean room environments, such as medical device manufacturing and aerospace, pneumatic presses can be configured to be compliant to Class 100 Clean room particulate compliance. Utilizing stainless steel construction and air particulate filtration systems, clean room pneumatic presses have many advantages in these types of applications. Clean, efficient, quiet, ease of use, and trouble free; pneumatic presses have flexibility and functionality to meet your needs.
If you have an application running small production runs, but need accuracy, repeatability and ease of operation, the pneumatic press is well suited to offer a quick, flexible and cost-efficient solution configured for manual operations.
For applications with higher volumes, longer run times, or secondary processes, a pneumatic press solution that includes PLC controls is easily configurable. Pneumatic presses can be setup with end of stroke sensors to provide feedback to the PLC to insure the press reaches bottom of stroke to perform the work, and top of stroke to know when the press has completed the operation. PLC working with other inputs can provide for an effective automated solution while maintaining cost-effective, low maintenance production.
Your press should have come with a handbook or other form of documentation regarding troubleshooting.
They will often come with diagrams, showing the correct placement of certain valves, grippers, and pressure settings.
If any of these seem as if they are out of place, try adjusting them before trying other troubleshooting options.
Inspect while you use the machine
If there are no apparent problems when your machine is not in operation, perform a visual inspection while the machine is operating.
You should look for signs of air leakage, drastic changes in system pressures, and any faults when the system moves.
You might have to get the help of a colleague or a friend to stay safe while the machine is in operation.
With a pneumatic bench press, one issue may be causing smaller issues elsewhere.
Repairs
While some pneumatic hand press machines or other types of press may require simple lubrication or part replacement, it is essential to consult a professional when you make any major changes to your machine.
If a malfunction in your pneumatic press has been resolved, be sure to record where and when the incident took place to ensure you’re keeping an accurate log. This will be useful in the future if any other problems may occur.
Standard Pneumatic Presses at AIM Joraco
At Joraco, we have a number of different press models;
Since the start of the TOGGLE-AIRE® press line in 1961, our goal has been to build reliable, user-serviceable production equipment designed to provide the buyer many years of duty. Options for this press include:
The DIRECT-AIRE® press series features a straight pneumatic cylinder for applications requiring full force over the entire stroke, such as assembling bushings, posts, inserts, fasteners, and related products.
It is suitable for a wide range of manual and semi-automatic assembly operations, our Direct-Aire® Presses offer a standard 4.5” stroke, providing from 314 to 7,800 lbs; giving you the most efficient and accurate results possible.
AIM JORACO’SHydro-Pneumatic (HP) PressSeries offers clean, reliable, and accurate results.
This series is a much cleaner alternative to the hydraulic press and offers the same advantages.
It is fully contained with no fluid reservoirs or hydraulic lines and features rapid advance with an automatic power stroke.
Suitable for a wide range of manual and semi-automatic assembly operations, this press is offered with a standard 4” stroke with 1/2″ power stroke, providing from 2 to 16-tons of force, in both C-Frame and H-Frame configurations and is manufactured in the US from steel plate.
and HYDRO-AIRE line of precision pneumatic & manual toggle presses, semi-automatic rotary indexing machines, and assembly and fabrication tooling.
Our compact, bench air presses are available with forces from 1/2 to over 16 tons.
Whether you are staking, swaging, stamping, crimping, forming, riveting, punching, piercing, blanking, assembling, laminating, or marking… our c-frame and H-frame presses offer you a low cost, field-proven, time tested alternative to costly and complicated power presses and hydraulic presses.
