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Modular Die Stamping Line for TV Back Panels

Modular Die Stamping Line for 55-inch TV Back Panels

Core Concept: Ditching Progressive Dies for Modular Flexibility

Traditional 12-station progressive dies offer high speed but come with drawbacks, complex maintenance, and inflexibility for custom designs. The modular die solution splits processes into independent dies + presses, cutting die , slashing changeover to 8 minutes, and excelling in:

Process Breakdown & Layout (55-inch Panel Example)

Process Split Principle: ≤30s per process, 40% simpler dies

 

Machine

Die Type

Key Parameters

Automation

1. Laser Blanking

6kW Fiber Laser Cutter

No-die (CAD-driven)

Cutting accuracy ±0.05mm, burr ≤0.03mm

AGV with vacuum suction

2. First Drawing

1600T Double-Acting Servo Press

Modular drawing die (with blank holder)

Depth 25mm, R8mm, blank holder force 50–150T adjustable

6-axis robot + vision alignment

3. Secondary Forming

1000T Single-Acting Servo Press

Flanging & shaping die

15mm flange, perpendicularity ≤0.8°

Robot arm + magnetic separator (anti-iron filings)

4. Piercing & Tapping

500T High-Speed Press (200spm)

Multi-hole modular die

φ5–φ12mm holes, positional accuracy ±0.1mm

Vibratory feeder + CCD inspection

5. Levelling & Inspection

300T Precision Leveller

Floating levelling die

Flatness ≤0.3mm/m

Laser thickness gauge + AI defect detection

Plaintext

Layout: U-shaped tandem + buffer islands (25% space saving)

Key Equipment & Die Innovations

Laser Blanking Replaces Traditional Dies

Machine:  Laser (4000×2000mm), AI path optimization

Advantages:

Double-Acting Press + Modular Drawing Die

Machine: APC(double-point, outer slide 0–300T blank holder force)

Die Design:

Process: Drawing speed 80mm/s (crack rate 0.2% vs. progressive die’s 0.8%)

Quick-Change Piercing Unit

Die: Drawer-style structure (one-click plug-and-play), 55→65-inch die change in 8 minutes

Anti-Error: Die ID chip auto-matches NC program, 0 misinstallation

Efficiency: 180pcs/hour (progressive die: 240pcs/hour, but changeover time 1/5)

Application Scenarios & Upgrades

Ideal for:

Small/medium TV manufacturers

Annual capacity <1M units

ODM/OEM factories

Multi-brand, multi-model production

New display R&D

E.g., OLED curved back panels

Technology Upgrades:

Die Cloud Platform

7-day new die development (vs. 21 days traditionally)

Process Integration

Laser welding integrated into forming press, reducing 3 handling steps

AI Cracking Prediction

30-minute advance warning via drawing pressure curves (92% accuracy)