Achieving World Class Vehicles with Agile Fabrication Systems for Achieving World Class Vehicles Table Top Hemmer August 22, 2001 by

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 2 GSEG Supplies Engineering & Components with Proprietary Technology We integrate our proprietary technology and independent resources through our Company to deliver world class products for our customers Proprietary Technology Suppliers Process Engineering / Design Long Term Service & Support

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 3 GSEG Global in Our Outlook Providing Best Practices in –Lean Processing –Virtual Factory design –Low Cost Sourcing –Functional Build Our Mission GSEG is committed to eliminating waste, costly duplication of efforts and production start-up problems for our customers. We accomplish this by providing proprietary technologies and the simultaneous development and delivery of world class equipment from a single source through integrated subcontracts. The Company

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 4 Hemmer Design Originally Designed for Cologne Tool & Die Operations Over 50 installations in Ford of Europe GSEG has exclusive world wide rights to sell the this hemmer design and technology (except to Ford)

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 5 Table Top Hemmer Combination Electrical / Pneumatic Drive Multiple Die Sets –Capable of 2 to 4 Models Auto Die Change –30 Second Model Change Aluminium & Laser Welded Blank Capable

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 6 Specifications Features –Hemmer & Fixture Operation Pneumatic / Pneumatic –Size (l/w/h)2600x2500x1630 mm –Cycle Time (hem only)14 sec. –Cycle Time (w/part transfer)24 sec. –Quick Change CapableYes –Cycle Time (w/tool transfer)30 sec. –Cycle Time (w/part & tool transfer)50 sec. –Part Loading / Transfer Method Robot or Shuttle –Full Periphery Hem Capable Yes – 2 Strokes/1 Station –Full Periphery w/Beltline CapableYes –Full Periphery w/I/S Window Capable Yes –Full Periphery w/beltline and I/S Window CapableYes –Optimum Open Flange Angle90º –Max. Flange Angle Allowed113º –Accessibility for MaintenanceYes –Hem Force (kg/mm)10kg – 20kg/mm Delivery –From P.O. to complete 24 Weeks

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 7 The History of Clinching / Hemming Starts with High Speed Lines using Hydraulic Clinch Presses with Tool Change –Disadvantages »Requires Batch Build Moves to Captive Lines with Table Top Hemmers (Electric or Hydraulic Drive) –Disadvantages »Model Specific »High Investment for Multiple Models

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 8 Manufacturing’s Requirements Model Flexibility Reusability Model Changeover with Zero Production Loss Maintainability Accessibility of Clinch Steel No Use of Hydraulics Global Solution

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 9 New System Design Goals Hemmer Family to suit the whole Range of Models Model Related Clinch Dies and Reusable Facility Quick Die Change Use of Production Die for Prototypes Modular Design / Construction –Easy Access for Maintenance –Simplify Drive System

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 10 Modular Design Pneumatic / Pneumatic Drive Die Set Air Drive Frame

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 11 Station UPPER FRAME PLATE POWER CONNECTION (STATION) GUIDE FOR DIE SET FRAME LOWER FRAME PLATE UNIT FOR DIE POSTIONING AND CLAMPING LIFT TABLE ELECTRIC DRIVE (WAY) AIR CUSHION (FORCE) FORCE TRANSMITTER

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 12 Die Set UPPER DIE PLATE POWER CONNECTION (DIE) LOWER DIE PLATE CAM CAM DRIVE 90° STEELS 45° STEELS

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 13 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 14 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 15 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 16 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 17 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 18 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 19 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Electric Lifter Down 6.Hem Steels Out 7.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 8.Hem Steels In 9.90º Hem (Force by Air Cushion Lift Table) 10.Hem Steels Out 11.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 20 Table Top Hemmer Load Condition –Lifter Down –Hem Steels Out Operations Sequence 1.Load Part 2.Hem Steels In 3.Electric Lifter Up to 45º Hem Steel (within 10mm of Steel) 4.45º Hem (Force by Air Cushion Lift Table) 5.Hem Steels Out 6.Electric Lifter Up to 90º Hem Steel (within 10mm of Steel) 7.Hem Steels In 8.90º Hem (Force by Air Cushion Lift Table) 9.Hem Steels Out 10.Unload

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 21 Die Exchange 1.Electric Lifter Up 2.Open Die Position Clamps 3.Clamp Die Bed 4.Electric Lifter Down 5.Engage Tool Change Drive 6.Transfer Model A Out 7.Transfer Model B In 8.Close Die Position Clamps / Electric Lifter Up 9.Un-Clamp Die Bed from Die Set 10.Clamp Die Bed to Electric Lifter Sequence of Events

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 22 Die Exchange 1.Electric Lifter Up 2.Open Die Position Clamps 3.Clamp Die Bed 4.Electric Lifter Down 5.Engage Tool Change Drive 6.Transfer Model A Out 7.Transfer Model B In 8.Close Die Position Clamps / Electric Lifter Up 9.Un-Clamp Die Bed from Die Set 10.Clamp Die Bed to Electric Lifter Die Unclamped Lifter Down

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 23 Die Exchange 1.Electric Lifter Up 2.Open Die Position Clamps 3.Clamp Die Bed 4.Electric Lifter Down 5.Engage Tool Change Drive 6.Transfer Model A Out 7.Transfer Model B In 8.Close Die Position Clamps / Electric Lifter Up 9.Un-Clamp Die Bed from Die Set 10.Clamp Die Bed to Electric Lifter

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 24 Die Exchange 1.Electric Lifter Up 2.Open Die Position Clamps 3.Clamp Die Bed 4.Electric Lifter Down 5.Engage Tool Change Drive 6.Transfer Model A Out 7.Transfer Model B In 8.Close Die Position Clamps / Electric Lifter Up 9.Un-Clamp Die Bed from Die Set 10.Clamp Die Bed to Electric Lifter

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 25 Die Exchange 1.Electric Lifter Up 2.Open Die Position Clamps 3.Clamp Die Bed 4.Electric Lifter Down 5.Engage Tool Change Drive 6.Transfer Model A Out 7.Transfer Model B In 8.Close Die Position Clamps / Electric Lifter Up 9.Un-Clamp Die Bed from Die Set 10.Clamp Die Bed to Electric Lifter

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 26 Maintenance Die Set Out of Frame down open Unclamp Die Lifter Down

Flexible Hemmer © 2004 Global Systems Engineering Group, LC 27 To Contact Us Joerg Hoefer CEO 667 Elmwood, Suite 100 Troy, Michigan P.O. Box 1496 Troy, Michigan F AX Internet Dave Fisher Vice President 777 Wimbleton Drive Birmingham, Michigan / F AX 248/ Internet