Tru-Trac Die Accelerator System

For Roll Formers and Tube Mills

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WHAT IS A TRU-TRAC SYSTEM?

An AMS Tru-Trac is a closed loop die accelerator that greatly enhances the performance of a post cut roll former or tube mill. It replaces the gauge bar as the length control device. The Tru-Trac System consists of a linear actuator, servomotor, operator's console, and length controller. The linear actuator is rigidly mounted to the base of the machine and the output shaft is connected to the cutoff die. The Tru-Trac System controls the position of the die and replaces any existing die positioning device such as springs or air cylinders.

Read about Die Acceleration Methods!

HOW DOES IT WORK?

An optical shaft encoder or length transducer with a precision measuring wheel rides on the material and tells the controller how much material is past the cutoff press. When the desired cut point enters the cutoff press, the controller turns on the servo motor and accelerates the die up to line speed. The Tru-Trac System matches the die speed to that of the material and positions the die directly over the target point. When the match is made, the press is cycled. The Tru-Trac System continues to match speed and position until the press returns to its top position. The die is then returned back to its home position to await the next target.

WHAT ARE THE BENEFITS OF A TRU-TRAC SYSTEM?

The Tru-Trac System eliminates the gauge bar, which is a major source of problems for a manufacturer. Although the gauge bar can give accurate lengths, it is difficult to set up, it distorts the part at higher speeds, and is a frequent cause of jam ups. With the gauge bar, the material is being compressed during the cut. This leads to distorted parts and unnecessary die wear.

With the Tru-Trac System, the leading edge of the part is free. Since the cutoff die is moving at the same speed as the material, there is no strain on the part and no strain on the die. The results are a clean cut and longer die life.

Since the collision between the part and the die has been eliminated, the line speed can be greatly increased in many applications. This leads to higher productivity and a quick payback.

With a Tru-Trac System, virtually any length part may be run, from very short to very long. The Tru-Trac System is also much safer than a gauge bar. A potential pinch point is eliminated and the parts fall easily into a bin since the leading edge is free.

WHAT'S SO SPECIAL ABOUT A TRU-TRAC SYSTEM?

AMS offers a complete turnkey system with Tru-Trac. All you need to provide are the mechanical connections and the power feed with the proper disconnect. It can normally be installed in less than three days with the third day devoted to operator training while running full production.

The Tru-Trac System is very easy to use. All the operator has to do is answer two simple questions: How long are the parts and how many should be made. Lengths are entered in finished part dimensions and Tru-Trac makes any necessary compensation to achieve that length. Its unique program automatically adjusts for changing conditions.

The Tru-Trac System is easy to maintain. Built-in diagnostic programs help to quickly isolate a problem and restore production. A special die test mode allows a complete system checkout without wasting material.

WHAT ACCURACY CAN WE EXPECT WITH A TRU-TRAC SYSTEM?

Typically, accuracies better than +/-1/32 inches are achieved at moderate line speeds. Tolerance as close as +/-.005 inches can be achieved under the right conditions. Line speed, die weight, part stiffness, and cutoff die pattern can all effect accuracy. The tighter the required tolerance, the more expensive the system becomes and the slower the machine's speed is limited. Carefully specify a tolerance required for the application and not an arbitrary value.

 In order to guarantee a tolerance, AMS looks at each application individually. In some cases, it may be necessary to increase motor size or add special equipment. In many cases, AMS can provide cost versus tolerance and line speed versus tolerance tradeoffs.

WHY AMS?

AMS is the leading producer of length control systems for roll formers and tube mills in the USA. With over 25 years experience and over 4000 controllers in service, we can provide a system that will control any machine.

 We offer expert installation and continual telephone support with a toll-free number. Our service department offers same-day repair to minimize your downtime. We know the roll forming industry and know how important it is to keep your machine running.

HOW DO WE GET STARTED?

Simply fill out the Survey Form and our application engineers will specify the right system to meet your needs. The information on the form tells us about your machine and how you use it. The following is a step-by-step explanation of each question on the form. If you need further help, call our toll-free number at 1-800-334-5213 and ask to speak to a sales engineer.

Click Here to download the survey.

HOW TO FILL OUT THE SURVEY

Customer Information

Fill in your company name, address, telephone numbers, and person to contact for any technical questions. If you have more than one line, fill in the name you normally use for the specific line in question.

Present Method of Length Control

Indicate the present method of length control used on this line. If your machine does not fit into any of these categories, describe the measuring system in the space provided. If you have electronic length control presently, indicate the manufacturer and model number, if possible.

Type of Cutoff Press

The type of cutoff press is an important factor when sizing a Tru-Trac System. The most common types are listed. If you know the manufacturer and model number of the press, please indicate in the boxes provided.

An important factor in designing a Tru-Trac System is the time the cutoff device is in contact with the material. This determines the length of stroke required and the minimum part length that can be run at a given speed. Typically, this is the most difficult parameter to specify. If you have a mechanical press, AMS can derive this time from the RPM of the flywheel. In other cases, the cycle time can be derived from the present length of die travel at a known line speed. AMS engineers can offer other suggestions to approximate this value.

Die Travel and Weight

Die weight and die travel are the last important factors in sizing a Tru-Trac System. Die weight should include the weight of all moving parts. If it is not practical to actually weigh the die, it may be necessary to estimate the weight by measuring the pieces that make up the die, calculating the volume of metal, and calculating the weight using the density of the metal.

The length of travel can normally be easily measured. While checking this, you may want to look into the feasibility of lengthening the die travel if this becomes necessary to achieve the desired performance.

For stationary presses, die travel needs to be broken down into two values. The travel from the retracted position to the point where the die is in the center of the press needs to be determined along with the total travel of the die.

Line Speed

What is your present line speed? How fast could you run if cutoff restraints are removed?

Tolerance

What tolerance are you able to hold now? What tolerance would you like to have? Remember that very tight tolerance requirements may greatly increase the cost of the equipment and may limit line speed.

How often do you change lengths? If seldom, a single batch controller would be adequate. If you have short runs of varying lengths, a multiple batch controller or, possibly, a system with download capability would be cost effective.

A Tru-Trac System can cut virtually any length part. However, the shorter the part, the slower the line can be run. Enter your shortest part length and what speed you need to run that part.

Are there any characteristics of this machine aside from a straightforward feed and cut material to length? Some examples of other requirements would be progressive dies or pre-punched holes that the cut must register to. These require additional considerations. Use this space to mention any other condition that may seem important.