35 Load

GENERAL MOTORS
DIE DESIGN STANDARDS
Title Valid for No. Page

LOAD AND UNLOAD 35.00.aa 01 of 01
Sub-title Link to
INDEX
35.05 SAFETY
35.05.00 Safety Items
35.10 BILL OF PROCESS

35.10.00 Bill of Process
35.15 GENERAL INFORMATION

35.15.00 Interference Curves
35.20 TIMING CHARTS

35.20.00 Design Procedures
35.25 INTERFERENCE CURVES

35.25.00 Iron Hands
35.25.05 Pick and Place
35.25.10 Crossbar Transfer
35.25.15 Tri-Axis Transfer
35.30 AUTOMATION TOOLING

35.30.00 General Information
35.35 PANEL LIFTER

35.35.05 Automation Style Tubular Component Lifter
35.35.10 Fabricated Lifter
35.35.15 Press Slide Driven
35.40 PANEL CONTROL

35.40.00 Lifter Gaging
35.40.05 Lifter Magnets
35.40.10 Weight Pins
35.50 MANUAL LOAD PROVISIONS

35.50.05 Operator Safety Zone
35.50.10 Load Assist
35.55 AUTOMATION WITH SUCTION CUPS

35.60 PICK AND PLACE PRESS

35.60.00 Swivel Unload Þ
Page: Implementation Timing: File Path:

1 gbl2edr12\35load\35_00_aap1.cvx 07 APR 09
GENERAL MOTORS

LOAD AND UNLOAD 35.05.00 01 of 01
Sub-title Link to
SAFETY ITEMS
• The following listed ‘SAFETY ITEMS’ are found in this section:
Page Item Bullet Subject

35.50.00 All Manual Load Provisions
35.50.05 All Operator Safety Zone
35.50.10 All Load Assists
• NOTE;
This section is general information for loading & unloading. Consult Press and Automation Þ
Standards for specific press information.

2 gbl2edr12\35load\35_05_00p1.cvx 07 APR 09
GENERAL MOTORS

Sub-title Link to
BILL OF PROCESS
LOAD AND UNLOAD

Normal Duty Heavy Duty Ultra Heavy ¨
Item Condition Die Die Duty Die
Construction Construction Construction
Iron Hands
Horizontal Flange Jaws 1st Choice 1st Choice 1st Choice
Vertical Flange Jaws 2nd Choice 2nd Choice 2nd Choice
See Regional Press Standards for 3rd Choice 3rd Choice 3rd Choice
additional jaw configurations.
Lifter Methods
No Lifter 1st Choice 1st Choice 1st Choice
Direct Lifter 2nd Choice 2nd Choice 2nd Choice
Press Slide Driven
Direct Lifter 3rd Choice 3rd Choice 3rd Choice
Process Control Air
Indirect Lifter 4th Choice 4th Choice 4th Choice
Lifter Cradle
Clearance
Cast Clearance 1st Choice 1st Choice 1st Choice
Machined Clearance 2nd Choice 2nd Choice 2nd Choice
Positive Return
for Lifter Cylinders
Upper Shoe 1st Choice 1st Choice 1st Choice
Upper Pad 2nd Choice 2nd Choice 2nd Choice
Nitrogen Gas Spring 3rd Choice 3rd Choice 3rd Choice
Panel Reorientation
Finger Dwell 1st Choice 1st Choice 1st Choice
Lifters 2nd Choice 2nd Choice 2nd Choice
Position Station 3rd Choice 3rd Choice 3rd Choice
Outer Panel
Lifter Construction
Fabricated Lifter (Welded) 1st Choice 1st Choice 1st Choice
Standard Automation Components 2nd Choice 2nd Choice 2nd Choice
Steel Blade Template No No No
Contoured Urethane Yes Yes Yes
Vacuum Cups Optional Optional Optional
Magnet Optional Optional Optional
Inner Panel
Lifter Construction
Fabricated (Welded) 1st Choice 1st Choice 1st Choice
Standard Automation Components 2nd Choice 2nd Choice 2nd Choice
Steel Blade Template Yes Yes Yes
Contoured Urethane No No No
Vacuum Cups Optional Optional Optional
Magnet Optional Optional Optional ¨
REQUIRES MANAGEMENT APPROVAL
NOTE:
• A “Direct Lifter” is a lifter assembly that has the energy source (air cylinder) mounted directly to the panel
nests. The cylinder rod moves in the same direction as the lifter nest.
• An “Indirect Lifter” is a lifter assembly that has the energy source (air cylinder) mounted indirectly to the
panel nests. An example of this would be a rack and pinion lifter. Another example would be a horizontal
mounted air cylinder driving a vertical moving lifter assembly. An Indirect Lifter would also have process
control air (see below).
• “Direct Lifter Press Slide Down” is a lifter assembly that has constant air to the lifter cylinder or spring driven
device and the upper die compresses the lifter when the press slide comes down. See 35.35.15
• “Direct Lifter Process Control Air” is a lifter assembly that has a condition where the air is not always on.
The air must be activated at a specific time in the press cycle to extend or retract the lifter.

3 gbl2edr14\35load\35_10_00p1.cvx 21 DEC 09
GENERAL MOTORS

Sub-title GENERAL INFORMATION Link to
INTERFERENCE CURVES
• All die designs shall include the interference curves for automation tooling.
• All automation tooling clearances shall be 30 mm minimum cast, 15 mm machined clearance is allowed i
with management approval.

4 gbl2edr16\35load\35_15_00p1.cvx 16 SEP 10
GENERAL MOTORS

Sub-title TIMING CHARTS Link to
DESIGN PROCEDURES
• A timing chart is required for all die designs except blank dies and position stations.
• The timing chart serves as a die checking aid.
• Chart items that affect panel relationship with incoming transfer tooling. Typical items include:
cam travels, pad travels, lifter travels, air control items, etc.
• Use press motion curves provided in press model. (Refer to press standards.)
• The complexity of the die functions will dictate the amount of timing information shown on the chart. Þ
• Provide timing chart in die design file.
Þ
TIMING CHART DESIGN PROCEDURE
• Use this information in conjunction with the sketch on the next page.
A. Left-hand columns of timing chart to indicate press ram upstroke in mm & degree of crank angle
when available.
B. Right-hand columns of timing chart to indicate press ram downstroke in mm & degree of crank
angle.
C. Timing chart to indicate appropriate press stroke information. (Refer to press standards.) Þ
D. Use leaders as shown to indicate sequence of die actions such as pad travels, cam travels & lifters.
Indicate ram controlled or processor controlled lifters on timing chart.
E. Designer to indicate all recommended valve activating settings.
F. Designer to note all air requirements for die operation.
G. Indicate press and production plant information.

GENERAL MOTORS

Sub-title TIMING CHARTS Link to
DESIGN PROCEDURES
D
TOP OF STROKE 1016 STRK. DEG. STRK. DEG.
990.6 340
EXTEND FILL SLIDE *
F
NOTE: DIE MEMBER FUNCTIONS MARKED (*)
ARE RECOMMENDED SETTINGS
FOR ACTIVATING AIR VALUES.
AIR REQUIREMENTS
LIFTER - CONSTANT AIR
FILL SLIDE - TIMING CHART G
WEDGE SLIDE - SEE TIMING CHART
E 670.4 40
VACUUM CUPS - SEE TIMING CHART
EXTEND INTERMEDIATE SLIDE*
B
FINGERS CLAMPED
603.2 264
F
552.5 56 TURN VACUUM CUPS ON (FINGERS *
TURN VACUUM CUPS OFF 10 FROM DOWN POSITION)
(FINGER 5 FROM
CLAMPED POSITION) 483 254 489.0 65
START UNCLAMPING
LIFTER MUST BE UP C
FINGER 100 FROM
350 242
CLAMP POSITION
LIFTER UP 330 241 330 87 NITRO CYL. CONTACTS LIFTER
(FINGERS OUT 120.7 mm)
LIFTER MUST BE UP INTERMEDIATE 230 231 230 104

DRIVER CONTACTS INTERMEDIATE SLIDE
IN 635 OF PRESS STROKE CAMXX BACK Þ
12 SPM - .35 SECONDS 166.6 223 166.6 117
8 SPM - .55 SECONDS FILL SLIDE BACK INTERMEDIATE SLIDE CONTACTS
FILL SLIDE (IF AIR DIDN’T POSITION)
LIFTER STARTS
127 217 127 126
UP (FILL SLIDE LIFTER DOWN
MOVED 17) 104.6
AERIAL CAMXX CONTACTS DRIVER Þ
FILL SLIDE INTERMEDIATE SLIDE UNDER
79.2 211 79.2 138
BEGINS TO RETRACT FILL SLIDE (SOLID)
70 209 70 141
MAIN PAD LEAVES PART MAIN PAD CONTACTS PART
63.5 143
MAIN PAD UNDER PRESSURE
46.2 148
PAD ON CAMXX BEGINS TO FORM Þ
38 202 38 153
PAD ON CAMXX RELEASES PAD ON CAMXX DOWN Þ
15 195 10 163
*RETRACT FILL CAM CYL.
AERIAL CAMXX CONTACTS PART Þ
(PRESSURE AGAINST .25 185
INTERMEDIATE CAMXX) 0 180
DIE CLOSED POSITION Þ
STRK. DEG. STRK. DEG.
*RETRACT INTERMEDIATE UP DOWN
CAM CYL. (PRESSURE STROKE STROKE
AGAINST DRIVER
TIMING CHART
H
PRESS - PUT PRESS IDENTIFICATION HERE
GENERAL MOTORS

Sub-title INTERFERENCE CURVES Link to
IRON HANDS
• For iron hand information refer to press standards. Þ

GENERAL MOTORS

PICK AND PLACE
• Consider interference with the pick and place unit incoming path and the slide when positioning the i
panel in the die and press.
• Consult Regional Press Standards for panel handling. i
SEE REGIONAL PRESS STANDARDS

FOR STANDARD TOOLING HEIGHT

GENERAL MOTORS

CROSSBAR TRANSFER
• Crossbar transfer presses have crossbars that span the rails to load, unload, and transfer panels from
die to die within the press system. Vacuum cups are attached to the crossbar to mechanically handle
the panel.
• The motion of the crossbar is:
1. Crossbar moves from rail rest position to previous die station. (Incoming curve) Þ
2. Panel is clamped (picked up) with suction cups and is transferred (indexed) to the next die station
and is unclamped (placed down) onto the die post. (Transfer curve)
3. Crossbar returns back to rail rest position. (Return curve) Þ
• All upper die details must be above the interference curve safety lines (1) with all pads and aerial cams
extended in die open position.
• All lower die details must be below the motion curve safety lines (2) with all pads and cams extended in
die open position.
DIRECTION OF FLOW
RETURNING CROSSBAR Þ
LIFT & TRANSFER MOTION
MOTION CURVE WITH
CURVE WITH SAFETY LINE
SAFETY LINE
INCOMING CROSSBAR MOTION NEXT DIE

CURVE WITH SAFETY LINE STATION
40 TYP.
2
1
3
PREVIOUS RAIL REST

DIE STATION POSITION
RAIL REST
POSITION
BOLSTER
RETURNING CROSSBAR
INCOMING CROSSBAR INTERFERENCE INTERFERENCE CURVE
CURVE WITH SAFETY LINE WITH SAFETY LINE
Þ
TYPICAL FRONT ELEVATION
OF CROSSBAR PRESS STATION

GENERAL MOTORS

TRI-AXIS TRANSFER
• The transfer press slide cycles continuously without delay for panel index to the next station.
• There are eight areas of potential interference in a transfer press:
Panel and the incoming shovel/gripper
Shovel/gripper and the upper die on return stroke
Shovel/gripper and the lower die on return stroke
Shovel/gripper and the upper die on clamp/unclamp stroke
Shovel/gripper and the upper die on feed stroke
Panel and the upper die on feed stroke
Shovel/gripper and the lower die on feed stroke
Panel and the lower die on feed stroke
• The panel must be timed to be in position before the shovels/grippers are in clamp position. i
• Refer to Tri-Axis Transfer Press Specifications for panel/shovel/gripper timing relationship information.
• All cams in the upper and lower are to be shown extended when checking for interference.
• Use the press simulation tool to also check for interference.

GENERAL MOTORS

TRI-AXIS TRANSFER
• For specific transfer press motion curve and motion diagram, see Press Standard Book. Þ
PRESS TOP POINT

Þ
PRESS BOTTOM POINT
POINT “D”
LIFT STROKE
2 FEED STROKE
3
CLAMP STROKE POINT “B”
1
DOWN STROKE
4
RETURN STROKE
6
UNCLAMP STROKE
5
TRI-AXIS RAIL MOTION DIAGRAM

GENERAL MOTORS

TRI-AXIS TRANSFER
RETURN STROKE INTERFERENCE CURVE - FINGER WITH UPPER DIE AND LOWER DIE
• These press curves check the interference of the fingers/grippers with the upper and lower die on the
return stroke.
30 MINIMUM CAST CLEARANCE,

15 FOR MACHINED CLEARANCE.
INTERFERENCE AREA
30 MINIMUM
CLEARANCE
TYPICAL
i
HALF PLAN
OF PUNCH
HALF PLAN
OF DIE
INTERFERENCE AREA

GENERAL MOTORS

TRI-AXIS TRANSFER
CLAMP / UNCLAMP STROKE INTERFERENCE CURVE - FINGER AND UPPER DIE

• These press curves check the interference of the fingers/grippers with the upper die on the clamp/unclamp Þ
stroke.
• Show moving parts (upper pad, cams, etc.) in open position.
30 MINIMUM CLEARANCE Þ
POINT "B"
RAIL AT CLAMP POSITION
A
INTERFERENCE AREA Þ
HALF PLAN OF PUNCH
POINT "A"
PAD AT OPEN POSITION
INTERFERENCE AREA
30 MINIMUM CLEARANCE TYPICAL Þ
SECTION A-A

GENERAL MOTORS

TRI-AXIS TRANSFER
FEED STROKE INTERFERENCE CURVE - FINGER AND UPPER DIE
• These press curves check the interference of the fingers/grippers with the upper die on the feed stroke. i
• Place curve in rail-up position.
• Multiple locations may be required to be checked.
Anywhere you have a high spot on finger tooling or panel that passes through low hanging upper
components in extended position.
POINT "B" RAIL AT CLAMP POSITION
INTERFERENCE AREA
A A
HALF PLAN
OF PUNCH
POINT "C"
30 MINIMUM
CLEARANCE
TYPICAL
INTERFERENCE AREA

SECTION A-A

GENERAL MOTORS

TRI-AXIS TRANSFER
FEED STROKE INTERFERENCE CURVE - FINGER AND UPPER DIE

• These press curves check the interference of the finger/gripper with the upper die on the feed stroke. Þ
A A
INTERFERENCE AREA
HALF PLAN
OF PUNCH HIGH POINT OF PANEL
30 MINIMUM
CLEARANCE
TYPICAL Þ
INTERFERENCE AREA
SECTION A-A

GENERAL MOTORS

TRI-AXIS TRANSFER
FEED STROKE INTERFERENCE CURVE - PANEL AND LOWER DIE
• These press curves check the interference of the panel with the lower die on the feed stroke.
• All lower die details must be below the interference curves, with all moving parts (lower pads, cams,
compressible storage blocks, etc.) in die open position.
INTERFERENCE
AREA
A A
HALF PLAN
OF DIE
INTERFERENCE AREA
30 MINIMUM
CLEARANCE
TYPICAL
i
LOW POINT
ON PANEL
SECTION A-A

GENERAL MOTORS

Sub-title AUTOMATION TOOLING Link to
GENERAL INFORMATION
• When shovels are used to unload the draw/form die station, place shovel at anticipated edge of draw
blank. Do not design finger assemblies and clearances to the punchline.
• Provide 30 mm cast clearances minimum, and 15 mm machined clearances, all around automation Þ
tooling.
• The clearance shown is for all types of automation (shovels, grippers, fingers, etc.).
30 MINIMUM
CAST CLEARANCE 10 x 30º LEAD - TYPICAL
Þ
5 CLEARANCE
50 MINIMUM
30 MINIMUM Þ
30 MINIMUM CAST CLEARANCE
CAST CLEARANCE Þ
50
MINIMUM
50 PRESS SPECIFIC
MINIMUM CLEARANCE
(REFER TO PRESS
STANDARDS)
30 MINIMUM
CAST CLEARANCE Þ

GENERAL MOTORS

Sub-title PANEL LIFTER Link to
GENERAL INFORMATION
FIRST CHOICE
• Loading or unloading the panel from the die with no lifter.
SECOND CHOICE
• Loading and unloading the panel from the die with lifter up, using a slide driven lifter.
THIRD CHOICE
• Loading and unloading the panel from the die with lifter up, using processed controlled air.
• Avoid the use of multiple lifters when using process control. !
• Keep lifter travels to a minimum. Direct lifter air cylinder stroke shall be total lifter travel plus 10 mm
minimum. (See 35.35.10 page 02.)
• Design lifter cradles to nest panel for positive control throughout the lift cycle.
• Lifter cradles shall be designed to minimize weight and to maintain structural integrity. Construct the
assembly from steel and steel tubing.
• See press standards for lifter sensor requirements and any other additional information.
• Design lifter assembly to avoid pinch points when retracted. Provide clearance, baffle, or allow for break
away in pinch point areas.
• Lifters should be a minimum of 5mm below the panel before work is performed.
• Keep enough clearance between lifter cradles and other die components to provide safety conditions for
Die Construction and Production
• Lifter bar cradles, in the lift up position, are to remain engaged in the lifter pocket 5mm minimum for lifter
alignment. If this is not possible, provide a Ø10 anti-rotation pin. (See 35.35.10 page 02)
SAFETY OPTIONS WHEN DESIGNING A PANEL LIFTER:
FIRST OPTION:
• Design lower casting with 40mm rough cast clearance for lifter pocket.
SECOND OPTION
• When rough clearance is not possible, machine the lifter pocket with 5mm clearance on each side
of lifter bar. Also provide a Ø10 anti-rotation pin. (See 35.35.10 page 02)
THIRD OPTION
• For safety reasons, in machined areas that are pinch points, provide a swivel feature at the tip of
the bar to allow this portion to rotate up.
THIRD OPTION
FIRST OPTION MACHINED
LIFTER
POCKET
(UP POSITION)
40 MIN. SECOND OPTION

ROUGH
CAST
CLEARANCE 5 MIN. PER SIDE
MACHINED POCKET
ROUGH-CAST
POCKET
SWIVEL FOR
SAFETY
LIFTER BAR TO REMAIN INSIDE

POCKET 5 MIN. WITH LIFTER UP ANTI-ROTATION PIN

18 gbl2edr15\35load\35_35_00p1.cvx 04 MAY 10
GENERAL MOTORS

LOAD AND UNLOAD “H” & MINI STYLE 35.35.00 02 of 02
Sub-title PANEL LIFTER DIRECT LIFTERS Link to
GENERAL INFORMATION
• Use self-guided “H” style lifter units for direct lifter applications.
• Self-guided direct air lifter unit selection is based upon panel weight, lifter cradle assembly weight, and
off-center overhang distance and load of lifter cradle. Refer to chart for specifications.
• Locate lifter cylinder as close to the center of the lifter cradle as possible. Q
MAXIMUM OFF-CENTER Q
MAXIMUM LIFTER
LIFTER OVERHANG CAST HOLE
CRADLE
TYPE DISTANCE (mm)
ASSEMBLY LOAD (kg)
A B D E
MINI 40 235 75 40 50 85
H-40 310 150 40 50 85
H-63 330 180 60 60 95
H-80 350 200 80 70 100 Q
RAISED MOUNTING BOSS
B
B A 5 TYP
A
D
CL OF
CYLINDER E
25 TYP Q
CAST CLEARANCE HOLE
• Slide controlled direct lifter is FIRST CHOICE. DIE PLAN VIEW

• Processor controlled lifters should be considered as a last choice.
• Processor controlled lifters can have a direct negative impact on the strokes per minute (spm) of a die.
• The approximate spm of a die with a press processor controlled lifter can be calculated with the
following formula:
spm = .1666 x degrees

seconds
Degree = The difference in degrees of press stroke when the fingers are
100 mm from the clamp and when the lifter can start to lift part.
(From press motion curves or timing chart)
Note: Lifter can‘t start lift until fill slides or rotors are retracted.
Seconds = The time required to lift part. A good average is 125 mm per second
or lift divided by 125.
• It is acceptable to process control multiple lifters.

• The operational sequence for press processor control is:
1. load panel with lifter up.
2. processor control lifter down prior to upper assembly contact with the panel.
3. processor control lifter up at bottom of press stroke, using the upper assembly to
control speed on upstroke. For outer panels restrict lifter return to keep panel 5 mm away
from upper pad on the up stroke. Refer to 35.35.15.

GENERAL MOTORS

LOAD AND UNLOAD GMNA
35.35.05 01 of 03 Þ
Sub-title PANEL LIFTER - AUTOMATION STYLE Link to
TUBULAR COMPONENT LIFTER
• Construct vacuum cup lifter cradle from standard automation tooling.

• Tack weld after final adjustment.
AUTOMATION STYLE TUBULAR COMPONENT LIFTER

2nd CHOICE
STEEL TUBING
Þ
BLOCK - Þ
PROXIMITY
SENSOR
MOUNT
MANIPULATOR
BLOCK
90° CENTER
BLOCK GUIDED AIR UNIT

90° CENTER
URETHANE
BLOCK BLOCK WITH
PROXIMITY MAGNET
SENSOR
BLOCK CLAMP
LONG
SEAMLESS HYDRAULIC TUBING

(SEE REGIONAL PRESS BOOK VACUUM CUPS Þ
FOR MATERIAL AND
ORDERING INFORMATION)
URETHANE BLOCK
WITH MAGNET
1.0 MINIMUM
BELOW PANEL
(MAGNET)
AUTOMATION
BLOCK
MAGNETS

GENERAL MOTORS

LOAD AND UNLOAD GMNA 35.35.05 02 of 03 Þ
VACUUM CUPS
• Use vacuum cups with standard automation components to utilize processed air.
• Add neoprene to standard block with a magnet epoxied in neoprene.
1.0 MINIMUM
BELOW PANEL
(MAGNET)
URETHANE BLOCK
WITH MAGNET
AUTOMATION
BLOCK
VIEW Z

GENERAL MOTORS

LOAD AND UNLOAD GMNA 35.35.05 03 of 03
• When casting is used opposite vacuum cups, provide 10 mm vent hole along centerline of vacuum
cups through the cast back-up so that when the die is cycled empty, no damage to lifters and suction
mechanism occurs.
10
TYPICAL SECTION
Þ
URETHANE BLOCK
WITH MAGNET
AUTOMATION
BLOCK
VIEW Z

GENERAL MOTORS

LOAD AND UNLOAD ALL REGIONS 35.35.10 01 of 03 Þ
FABRICATED LIFTER
• Construct welded lifter cradle from square tubing or bar stock.
• Use urethane block or steel blade templates to contact part.
• Add magnets to urethane blocks or blade templates, when required on flat conditions.
• Epoxy patch around and over magnet, or positively retain magnets with mechanical fasteners (screws). Þ
• Urethane blocks or templates must be located on lifter to balance part when lifted.
• Screw urethane block to lifter frame.
• Details that fit the panel should be FABRICATED LIFTER
adjustable if possible. 1st CHOICE
WELDED TO TUBING
FOR SENSOR
URETHANE
- BAR STOCK
MAGNET
MAGNET HOLDING
FASTENED TO
LIFTER CRADLE
SQUARE TUBING
WELDMENT BAR
STOCK OPTIONAL
1.0 MINIMUM
BELOW
EPOXY URETHANE
URETHANE
STEEL SPACER URETHANE BLOCK

IF REQUIRED
WELD
SQUARE TUBING
Z
SECTION
W
URETHANE
BLOCK WITH
MAGNET SQUARE TUBING
W
WELDMENT
RIB BAR STOCK OPTIONAL
FOR M6 SOCKET
HEAD SCREW
(OPTIONAL WELD TO LIFTER)
LIFTER
STEEL BLADE TEMPLATE
VIEW Z

GENERAL MOTORS

LOAD AND UNLOAD OVERSIZE ROD 35.35.10 02 of 03
Sub-title PANEL LIFTER LIFTER Link to
FABRICATED LIFTER
• Use 90.35.10 oversize rod lifter cylinder only for this application - DO NOT USE STANDARD AIR ¨
CYLINDERS.
• Use self-guided slide controlled lifter units for direct lifter applications.
• Self-guided direct air lifter unit selection is based upon panel weight, lifter cradle assembly weight, and
off-center overhang distance and load of lifter cradle. Refer to chart for specifications.
• Fit panel shape with zero clearance when depressing the lifter through the panel.
BORE MAXIMUM OFF-CENTER MAXIMUM OFF-CENTER MAXIMUM LIFTER CRADLE
OVERHANG DISTANCE (mm) LOAD (kg) ASSEMBLY LOAD (kg)
Ø50 200 10 85
Ø63 300 15 130
• Provide a Ø10 anti-rotation pin or engage lifter bars in a machined pocket lifter up to ensure lifter
alignment.
• Lifter travel to be a maximum travel - 10 mm to provide tryout with up to 10 mm of additional travel.
• Lifter travel to include 10 mm of additional travel for tryout adjustment.
W
W
W W
W W
A A
PLAN VIEW
ZERO CLEARANCE
PANEL
LIFTER BAR
M 12
W
W
35 MINIMUM
W
W
Ø30
W
W
W
W
ROD
DIAMETER
+1 mm
UP TO A 10 mm THICK
SHIM MAY BE ADDED AT
LIFT +10 TRYOUT FOR UP TO AN
ADDITIONAL 10 mm OF
LIFTER TRAVEL
CYLINDER TRAVEL =
LIFTER TRAVEL +10
15 MINIMUM
Ø10 MINIMUM
MINIMUM
SECTION A-A
OVERSIZED ROD AIR CYLINDER - DIRECT LIFTER CONSTRUCTION

24 gbl2edr14\35load\35_35_10p2.cvx 05 OCT 09
GENERAL MOTORS

FABRICATED LIFTER
• 5mm minimum engagement from bottom of lifter template to top surface on lower adapter. Þ
LIFTER TRAVEL
LIFTER BAR
(UP POSITION)
PART IN DIE 5 MINIMUM

5 MINIMUM ENGAGEMENT CLOSED POSITION CLEARANCE
20 MAXIMUM
LIFTER BAR
DOWN POSITION
10 MINIMUM Þ
SECTION A-A

GENERAL MOTORS

PRESS SLIDE DRIVEN
• Provide direct positive return for lifter with upper shoe casting and steel block as First Choice. The Þ
distance between the panel and the lifter bar in the die closed position should be pad travel plus 5 mm
minimum safety.
.• Provide direct positive return for lifter with upper pad and steel block as Second Choice. (See sht. 2) Þ
Consider pad balance when locating direct lifter unit in die.
• Provide direct positive return for lifter with 7.5 kN nitrogen gas springs on upper shoe as Third Choice. Þ
(See sht. 2) This method requires bottoming the lifter attaching plate on the lifter body to allow the
positive return nitrogen gas spring to collapse on the downstroke.
• Provide 5 mm minimum safety between the panel and lifter bar at die closed position with nitrogen gas Þ
spring positive return.
• Nitrogen gas spring travel shall be pad travel plus 5 mm minimum. Nitrogen gas spring stroke shall be
5 mm minimum greater than the required positive return travel.
• Upper casting and block for positive return should be located directly above the air cylinder. Þ
• To ensure panel stays on lower die after operation, provide upper stripper pins when required.
• Upper stripper pins must be opposite to lower lifter assembly to ensure the positive location of the
panel.
UPPER PAD PANEL AT LIFTER UP POSITION Þ
PANEL LIFT PANEL AT DIE CLOSED POSITION
UPPER SHOE CASTING
LIFTER TRAVEL
PAD TRAVEL +5 POSITIVE RETURN

MINIMUM SAFETY FOR LIFTER
LIFTER CRADLE AT DIE CLOSED POSITION

Þ
AIR CYLINDER TRAVEL = LIFT + PAD TRAVEL + 5
AIR CYLINDER STROKE = TRAVEL + 5 MINIMUM SAFETY
+ 10 MINIMUM
TRYOUT ADJUSTMENT
FIRST CHOICE: Þ
DIRECT LIFTER POSITIVE RETURN WITH UPPER SHOE

GENERAL MOTORS

PRESS SLIDE DRIVEN
PANEL AT LIFTER UP POSITION Þ

PANEL LIFT
LIFTER TRAVEL
UPPER PAD
STEEL BLOCK
5 CLEARANCE
PANEL AT DIE CLOSED POSITION
LIFTER CRADLE AT DIE CLOSED POSITION Þ
AIR CYLINDER TRAVEL = LIFT + 5

SECOND CHOICE:
DIRECT LIFTER POSITIVE RETURN WITH UPPER PAD Þ
UPPER PAD Þ
PANEL AT LIFTER UP POSITION UPPER
SHOE
PANEL LIFT
LIFTER TRAVEL
NITROGEN
GAS SPRING
5 CLEARANCE
PANEL AT DIE CLOSED POSITION
LIFTER CRADLE AT DIE CLOSED POSITION NITROGEN

SPRING STROKE=
PAD TRAVEL + 5 Þ
AIR CYLINDER TRAVEL = LIFT + 5
+ 10 MINIMUM
TRYOUT ADJUSTMENT
THIRD CHOICE:
DIRECT LIFTER POSITIVE RETURN WITH 7.5 kN NITROGEN GAS SPRING IN UPPER SHOE Þ

GENERAL MOTORS

Sub-title PANEL CONTROL Link to
LIFTER GAGING
• Panel must be positively located on lifter when disengaged from panel locators and gaging on lower die.
1ST CHOICE SHAPE Þ

2ND CHOICE SHAPE WITH MAGNETS Þ
3RD CHOICE PIN GAGES

GENERAL MOTORS

LIFTER MAGNETS
MAGNETS MOUNTED INTO LIFTER BAR

• Machine lifter frame for magnet block.
• Screw urethane block into lifter frame. (Weld to lifter frame optional)
• Set magnet into urethane block with epoxy or directly into lifter cradle, with adhesive. Þ
• Do not install magnet before welding, high heat damages magnets.
• If set into urethane block, epoxy patch around and over magnet.
• Magnet may be bonded directly to structural members with loctite #392, when used with loctite #3780 Þ
or 3787 activator.
MAGNET
URETHANE BLOCK
WITH MAGNET
EPOXY INTO Þ
URETHANE
BLOCK
FOR M6 SOCKET HEAD SCREW
(OPTIONAL WELD TO LIFTER)
USE LOCTITE #392 ADHESIVE

TO MOUNT MAGNET DIRECTLY Þ
INTO LIFTER CRADLE* LIFTER
VIEW “Z”
LIFTER
NOTE: LOCTITE 392 IS DESIGNED TO BE USED Þ
WITH ACTIVATOR 7380 OR 7387.
VIEW “Y”

GENERAL MOTORS

WEIGHT PINS (SHOE MOUNTED)
WEIGHT PINS 90.50.501,502 E

• Used to hold panel on lifter when press is opening.
• Mount to upper shoe and extend through upper pad.
• Mount to upper pad only when pins don’t interfere with load and unload. (See 35.40.10, page 02)
• Weight pins are available in self-weight and spring loaded.
• Distribute pins evenly over panel.
• See chart (page 02) for usage.
• Provide a minimum of (2) STABILIZER PINS for panel control when die opens. E
NOTE:
IF USED IN TRANSFER PRESS, CHECK WEIGHT PINS WITH INTERFERENCE CURVE.

30 gbl2edr18\35load\35_40_10p1.cvx 06 MAY 11
GENERAL MOTORS

WEIGHT PINS (PAD MOUNTED) Þ
• Weight pins mounted to pad.

• Use vacuum cups on lifter and weight pin. (See chart.)
NOTE:
IF USED IN TRANSFER PRESS, CHECK WEIGHT PINS WITH INTERFERENCE CURVE.
Use of Weight Pins

Structure Type of Pressure Panel size Panel Type
Spring + Urethane Medium to Heavy Large Inner
Spring + Vacuum Cups Medium to Heavy Small Outer
Weight + Urethane Light Large Inner
Weight + Vacuum Cups Light Small Outer

GENERAL MOTORS

Sub-title MANUAL LOAD PROVISIONS Link to
GENERAL INFORMATION
• Refer to press standards for specific requirements.

• Every cycle of the press is a potential hazard for the operator. The policy of “No Hands in the Dies”
must be considered as part of the design process. Every effort shall be made to insure the operator‘s
body does not have to enter into the danger area.
• Do not overhang the press bolster or ram with the die except with management approval.
• Clearance must be incorporated on die designs that require manual loading.
• Refer to sketch below for minimum clearance envelope.
100
200
40 MIN.
100
50

32 gbl2ed\35load\35_50_00p1.cvx 17 OCT 05
GENERAL MOTORS

OPERATOR SAFETY ZONE

• Follow the specifications in the following sketch for the Operator Safety Zone design.
• No portion of this safety zone shall be infringed upon by upper or lower die members.
• Design cam drivers, heels, guide pins and any other pinch points with fully engaged safety guards.
• If die conditions do not permit a safety zone design as shown below, shield the heels, guide pins and
any other pinch points with fully engaged safety guards.
• Add note to die drawing, “Production Plant to Furnish and Install All Safety Guards.”
X
50
X 75
305
75
105
MIN.
635 R
CLEARANCE AREA
EDGE OF RAM

GENERAL MOTORS

LOAD ASSIST

• Provide (2) load assist rails on all dies running in manually loaded column presses.
• Load assist rails must be long enough to support a panel and extend past ram 650 mm minimum.
• Mount load assist rails parallel to bolster as far apart as possible without encroaching on operator
safety zone.
• Construct load assist rails from 19 mm diameter cold-rolled steel.
• Fasten load assist rails with mounting bracket to rough casting.
• Provide 25 mm minimum vertical adjustment in each direction.
• Side guides on load assist rails are not required.
• Designer to provide note in the Special Note Section of the BOM (Bill Of Material) document sheet, Þ
“PRODUCTION PLANT TO MARK HEIGHT OF SHAFT WITH RED PAINT AFTER FINAL
ADJUSTMENT.”
• Designer to provide note in the Special Note Section of the BOM (Bill Of Material), “PRODUCTION
PLANT TO ROTATE LOAD ASSIST RAILS INTO DIE FOR PROTECTION WHEN DIE IS NOT IN
PRESS.” Þ
• Always provide a stock support or chute feed for gap dies.
650 RAM
MIN.
FLOW
19 DIA. ADJUSTMENT
CRS SCREW
MOUNTING BRACKET
BOLSTER
LOAD ASSIST RAILS

GENERAL MOTORS

Sub-title AUTOMATION WITH SUCTION CUPS Link to
GENERAL INFORMATION
• Provide cast back-up opposite vacuum cups on all crossbar or conventional automation.
• Provide 10 mm vent hole along centerline of vacuum cups through the cast back-up so that when the
die is cycled empty, no damage to automation and suction mechanism occurs.
• Consider panel shape when locating vent hole.

GENERAL MOTORS

LOAD AND UNLOAD 35.60.00 01 of 01 Þ
Sub-title PICK AND PLACE PRESS Link to
SWIVEL UNLOAD
• Swivel unload is used on last operations for pick and place presses, substituting iron hand.
• It can also be used on intermediary operations, since the part can be thrown on the belt conveyor.
PREFERRED METHOD
PROVIDE 40 MIN. CLEARANCE

TO THE UPPER DIE
SECOND CHOICE - WHEN PANEL CANNOT SLIDE ON UNLOAD BAR
PROVIDE 40 MIN. CLEARANCE

TO THE UPPER DIE


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GENERAL MOTORS

DIE DESIGN STANDARDS

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35.10 BILL OF PROCESS

35.15 GENERAL INFORMATION

35.20 TIMING CHARTS

35.25 INTERFERENCE CURVES

35.30 AUTOMATION TOOLING

35.35 PANEL LIFTER

35.40 PANEL CONTROL

35.50 MANUAL LOAD PROVISIONS

35.55 AUTOMATION WITH SUCTION CUPS

35.60 PICK AND PLACE PRESS

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• The following listed ‘SAFETY ITEMS’ are found in this section:

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LOAD AND UNLOAD

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EXTEND INTERMEDIATE SLIDE*

LIFTER MUST BE UP INTERMEDIATE 230 231 230 104

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• For iron hand information refer to press standards. Þ

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SEE REGIONAL PRESS STANDARDS

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INCOMING CROSSBAR MOTION NEXT DIE

PREVIOUS RAIL REST

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Panel and the incoming shovel/gripper

Shovel/gripper and the upper die on return stroke

Shovel/gripper and the lower die on return stroke

Shovel/gripper and the upper die on clamp/unclamp stroke

Shovel/gripper and the upper die on feed stroke

Panel and the upper die on feed stroke

Shovel/gripper and the lower die on feed stroke

Panel and the lower die on feed stroke

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PRESS TOP POINT

TRI-AXIS RAIL MOTION DIAGRAM

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30 MINIMUM CAST CLEARANCE,

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CLAMP / UNCLAMP STROKE INTERFERENCE CURVE - FINGER AND UPPER DIE

HALF PLAN OF PUNCH

PAD AT OPEN POSITION

30 MINIMUM CLEARANCE TYPICAL Þ

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FEED STROKE INTERFERENCE CURVE - FINGER AND UPPER DIE