Atlas self-powered die change systems are used in hundreds of installations for fast, accurate and safe die or mold changeover. They provide controlled movement and positioning of dies in stamping presses or press lines, via pendant or line controls.

1. Die Change
Solutions

2. Our History….
At Atlas, our entire 46 year history has been
centered around the goal of optimizing the
movement of sheet metal and dies during
stamping processes—in short, solving pressroom
production problems and taking advantage of
automation opportunities to help our customers
excel.
Atlas is a full service facility with the tools, talent
and experience to provide objective based
engineering studies that examine alternatives
and find the most productive and cost effective
mixture of manual and automated operations,
specifically tailored to suit each individual
customer and their requirements.
Atlas has complete in-house capability for total
system responsibility, mechanical and controls
design, fabrication, machining, assembly, test
and installation. We then back our equipment
with a full one year warranty and support our
customers with 24-7-365 emergency service.
You can trust Atlas with your die handling
needs...after all, we have more installations
around the world then all of our competitors
combined.

3. The World’s Best Die Change Automation
Atlas designs and builds the most
comprehensive range of accelerated die
change solutions in the industry. Systems
utilizing powered die carts and integrated
die racks are used in applications ranging
from a single press or multiple independ-
ent presses, to sister tandem lines.
With these systems, handling of dies
becomes highly predictable, manageable
and very fast. Die change is reduced from
hours to minutes. Scheduling for reduced
inventory becomes practical...Just-in-Time
becomes possible. Stock piles disappear
and response time quickens. You no
longer need to live with potential
compromises to product quality due to
the down time required to pull dies for
checking.

4. Reasons to Establish a Die Change Program
Atlas Die Change Systems give you complete con-
trol of the changeover process for:
• Faster Response to changing production
schedules or sudden demands, since dies can be
changed over in mere minutes
• Reduced Inventory
Reduce batch size costs effectively, minimize
work-in-progress and meet Just-In-Time
requirements
• Greater Press Uptime and Utilization
Reducing die change from hours to minutes can
add hours of stamping productivity per day
without added presses
• Quality Control
Dies can be pulled and checked quickly without
destroying your production schedule. Controlled
handling means less chance for damage to the
dies

5. The Principles of Atlas Die Change
Many of the steps within a die change are
larger time wasters than you might realize. Some
of the largest culprits are organizing tools and
people, removing of the old die and
locating the new die within the press. With Atlas
Die Change Systems, we strongly recommend
three basic areas of consideration to best utilize
time and personnel:
1. Dies mounted to subplates for
commonality
2. Rolling rather than skidding
3. Pre-staging of the in-coming dies

6. Subplates
Fundamental to Atlas die change systems is a
common interface between the die, the press and
the die change equipment. The use of subplates
provides a common surface for all of your existing
dies, allowing them to roll into and out of the press.
A subplate is normally the same size as the bed of
the press and approximately 2 1/2” thick. Most
subplates have a pattern of tapped holes to
mount a number of different dies. Die locator pins
mounted on the left to right centerline of the
subplates are used to locate the various dies
accurately on the plate. The subplate is designed
to be bolted or clamped in position on the press
bolster.
The common surface is also the key to fast,
consistent die clamping. The consistent location
achieved by pre-staging dies on subplates is
maintained through the use of a keyway or side
guides, which guide the die subplate into the
press. The common height provided by the sub-
plate makes either powered or manual clamping
easier.

7. Rolling Dies
Rolling a die out of the press reduces frictional forces
so that the die is moved smoothly and efficiently. To
accomplish this rolling feature, Atlas recommends the
use of hydraulic lifters (Lif-T-Rols or Max-Rols). These
lifters raise the die off of the press bolster and place it
on wheels. This reduces the force required to move
the die to approximately 1% of its total weight.
When Atlas designs die change equipment employing
Lif-T-Rols the rolling concept we use a 10 times safety factor
and figure on 10% of the weight to be moved. In
contrast, when the skidding technique is used, the
equipment must be designed for 70% of the weight.
These higher forces mean heavier equipment with
higher potential failure.
Atlas die lifters are designed to fit in T-slots or milled
pockets in a press bolster and will raise the die’s
subplate just enough to allow it to roll off the bolster
with only minimal effort.
Max-Rols

8. Pre-Staging
The third ingredient of an Atlas die change
system is the pre-staging of dies on Atlas Die
Racks. Without this feature quick die change
would be impossible. When the in-coming
die is pre-staged, all of the positioning work of
the next die on the subplate is accomplished
prior to going into the press and more
importantly, while the press is in operation.
Pre-staging removes the crane or other forms
of die moving equipment from the die
change process, thus greatly reducing the
time required to change dies.
Shown left, subplate mounted dies are
pre-staged on Atlas Die Racks fully prepared
for the next die change at a major appliance
manufacturer.

9. Die Change Configurations

10. Die T-Table
Atlas Die T-Tables are based on our die cart technology and our racks combined. The long
rack portion contains a conveyance device and is divided by a center die table section
complete with a push/pull module. Atlas T-Tables provide a very cost effective die change
capability in situations where floor space and/or economic constraints prohibit the use of die
carts.
Die Exchange is as follows:
1.) The incoming die is delivered to Station 1
and conveyed to station 3 for pre-staging
and/or waiting for changeover.
2.) The out-going die is pulled to Station 2
3.) The conveyor indexes both dies to the left
to move the outgoing die to Station 1 for
pick up and moves the incoming die to
Station 2, and then into the press
3
2
1

11. Die Tables
Atlas die tables utilize a combination of push/pull modules and powered conveyors to
automatically unload and load dies to and from a press. They are often mated with
elevating die carts for automatic die storage and retrieval. Die tables provide complete,
cost effective die change capability in situations where floor space and/or economic
constraints prohibit the use of die carts. Adjustable height tables can service two adjacent
presses of varying heights. The table itself is moved by fork truck or crane.

12. Die Tables & T-Tables

13. Die Carts
Atlas Die Carts have become the industry
benchmark with over 1000 installations
around the world. Self-powered and
controlled either by pendant or remotely,
Atlas carts move on floor rails at speeds up to
30 feet per minute, transporting dies of almost
any size to and from presses and die racks.
Precision ballscrew driven push/pull modules
engage die subplates on either end, indexing
one or more dies on or off the cart and into
or out of the press. For safety and long life,
carts are built to handle much more weight
than your highest load requirements.
Die racks become a “close to the press”
staging area. Equipped with rollers, they are
ruggedly built like Atlas die carts. In many
configurations, added racks extend the
usefulness of each cart, maximizing the
benefit of your investment.

14. Single Cart with Two Racks
An Atlas die cart with two racks in the perfect way to increase the versatility and output rates of a
stand alone press. Dies are exchanged in minutes allowing for rapid changes in production and
increasing JIT capabilities. The next in-coming die is pre-staged on one rack while the press is in
operation. When die exchange is required, the die cart moves into position in front of the press, pulls
the old die from the press and places it onto the empty die rack. The cart then moves into position in
front of the rack holding the incoming die and pulls it onto the cart. The cart moves back into position
and pushes the new die into the press, then returns to the home position. The die is clamped into
position and production begins.

15. Single Cart with Two Racks

16. Dual Position Cart (single press)
The Atlas dual station (position) die cart eliminates
the requirement for racks that would typically be
used for pre-staging of the incoming die. In this
scenario, the pre-staging is done on one position
of the cart while the press is in operation. The
benefit of this configuration is that the area
surrounding the press is left clear.
Die exchange would occur as follows:
• The die cart moves in front of the press
• The die cart pulls “old die out of the press
• The die cart is advanced to the second die
position
• The “new” die is loaded onto the press
• The die cart is moved to the home position
• The crane removes the old die and pre-stages
the next die to be run
Racks may be used in conjunction with the dual
station die cart if additional pre-staging of dies is
desired.

17. Dual Position Cart
(single press)

18. One Die Cart with Three Racks (two presses)
One Atlas die cart used in conjunction with three die racks to service two presses has two benefits. First, the
dies may be fully prepared to enter the press by pre-staging the in-coming dies on the racks while the press
is in operation, thereby increasing production time. Secondly, the cost to implement a die change system is
dramatically reduced by sharing the automation between the presses.
Die exchange is as follows:
1.) New dies are pre-staged on the racks beside each
press (one rack will be empty)
2.) The die cart pulls the first old die onto the cart
3.) The old die is deposited on the open rack
4.) The die cart picks up the pre-staged new die
5.) The die cart pushes new the die into the press
6.) The die cart removes the old die in the adjacent
press
7.) The die cart deposits the old die on the empty rack
and picks up the new die
8.) The cart then moves into position in front of the
receiving press and pushes the new die into position
Once the dies are clamped into position, press
operation may start and the old dies may be
exchanged with the next set of in-coming dies.

19. Die Carts with Racks

20. Dual Position Die Carts
Atlas Technologies dual position die cart utilizes one cart
with a double push/pull module and four racks (2 pre-staged
with the in coming dies and 2 empty) to service two presses.
This method of die change is accomplished in approxi-
mately 12 minutes due to the die exchange process, yet
greatly reduces the costs to automate.
Die exchange is accomplished as follows:
1.) The cart moves in position and pulls the old die from the
press
2.) The cart travels to the empty racks and unloads the old
dies
3.) The cart then moves to the pre-staged racks and picks
up both incoming dies
4.) The cart moves to the press and pushes the new dies into
position.
5.) The cart moves back to the clear position

21. Dual Position Die Carts

22. Die Change Configurations - Domino (single line)
Domino die change consists of utilizing one additional cart to the number of presses in the
line. All but the last cart would be pre-staged with the incoming die while the presses are in
operation. The carts would then move into position (to include the empty cart). The push/
pull module would then latch onto the subplate of the old die and push it out of the press,
onto the next cart while pulling the new die into the press. The carts then travel back to the
home position. The new dies are clamped into position and the old dies are removed from
the carts while the presses are in operation. Die change may occur in either upstream or
downstream directions.

23. Domino Lines

24. Die Change Configurations - Domino (sister lines)
Sister line domino die change is identical to single line domino die change except two lines of
presses share the carts used by one line in the first example (7 carts service 12 presses). The
presses must share common alignment with each other to implement this configuration. Die
racks may be utilized beside the presses to assist in the pre-staging efforts to ensure the carts are
continuously available for die exchange.

25. Domino Sister Lines

26. Transfer Press Die Change
Atlas transfer press die change utilizes two die
carts, one cart on either side of the press. One
cart is pre-staged with the in-coming die and
another cart is empty. The use of two carts
allows pre-staging of the in-coming die and
simultaneous exchange with the old die.
Die exchange is accomplished as follows:
1.) The empty cart travels into position in front
of the press via pendant controls
2.) Once in position, pins are lowered into floor
bushings to positively locate the cart and
lock it into position
3.) The die lifting devices are actuated to raise
the die off of the bolster
4.) The push/pull module then pulls the old die
onto the cart
5.) As the old die exits, the pre-staged die on
the opposing cart is pushed into place

27. Automatic Storage & Retrieval Systems
Atlas automatic storage and retrieval systems
(AS/RS) are a high speed, proven, fully
programmable method of efficiently storing
and handling dies, parts, coils and other items
weighing up to 50 tons. Our customers gain
valuable floor space by utilizing vertical,
otherwise unused space. The average lead
time to complete retrieval is less than 5 minutes,
which eliminates the time associated with
personnel searching for lost items. A touch
screen user interface is used to facilitate ease of
part storage.
Automatic operation allows items to be
presented at a common location at the
prescribed time. The Atlas AS/RS can span from
one crane bay or building to another,
eliminating the need for die trucks. The
controlled handling of items, reduces the
potential of costly damage to dies, coils and
parts. Our AS/RS systems are available in wire
rope or ballscrew lift designs and feature lift and
carry capability.

28. Automatic Storage & Retrieval Systems

29. Die Transfer Carts
Atlas Transfer Carts have been used in hundreds
of installations for fast, smooth and safe
movement of materials and/or product through
manufacturing facilities. Based on our world
renowned die cart technology, Atlas transfer
carts provide consistently controlled movement
of oversized and heavy loads.
Transfer carts increase production by eliminating
lost time waiting for material or dies to be
delivered to the appropriate location. They also
eliminate the need for overhead cranes and
fork trucks to move heavy loads through
manufacturing areas, thereby greatly improving
plant safety and ergonomics and potential
damage to dies or material.
Atlas Transfer Carts are capable of carrying
loads from 10,000 to 180,000 pounds and have
available options such as accurate shot pin floor
locators, self loading/unloading, automatic
operation and safety features such as horns,
lights, E-stop, bumpers and lasers.

30. Die Transfer Carts

31. Why Atlas?
All automation companies talk a good game. At Atlas we back it up… with results.
We understand that excellent technical skills aren’t the goal, they’re the price of entry.
We will design, build and integrate a solution that will achieve your goals.
Our engineering documents will be accurate and complete.
Our designs will function as promised.
Our manufacturing will be precise and durable.
Your project will be spearheaded by a contract manager that is intimately familiar with your industry.
Our finished product will exceed your expectations.
Every customer. Every project. PERIOD.
Contact Information
3100 Copper Avenue
Fenton, MI 48430 USA
Phone: +1 810.629.6663
Fax: +1 810.629.8145
www.atlastechnologies.com
www.pressroomautomation.com