A leading North American metal stamping facility has partnered with Align Production Systems to solve a common challenge in metal stamping environments, transporting heavy steel coils and large stamping dies using a single piece of equipment. The result is a custom-built Semi-Autonomous Vehicle (SAV) that navigates independently using magnetic pucks embedded in the floor but requires an operator to activate a controller switch.
The stamping facility needed to move coils of various sizes up to 72″ × 72″ and dies of various sizes up to 96″ × 190″—sometimes in the same shift. Traditionally, this would require two different machines, adding operational complexity and unnecessary cost. Align’s engineering team developed a dual-purpose flatbed SAV using a V-cradle for coil support with vertical poles for coil stabilization and rail inserts to support die transport, allowing fast reconfiguration between load types.
“This design gives the customer flexibility to switch between coil and die transport quickly, without needing multiple machines,” said Rachel Larson, Mechanical Engineer at Align Production Systems.
Built to handle up to 80,000 pounds, the SAV uses magnetic puck navigation embedded in the facility floor for semi-autonomous movement, guided by an operator using a handheld control switch. A lithium-ion battery powers the unit and includes Wi-Fi connectivity, onboard accessory storage for poles, and operator stairs, making it future-ready for full AGV upgrades.
With the SAV now in operation, plant personnel can:
- Transport both coils and dies using one machine
- Change the deck quickly with modular accessories
- Load and unload safely using integrated stairs
- Lay the foundation for long-term AGV automation
The project highlights Align Production Systems’ ability to engineer flexible, scalable equipment that evolves with manufacturers’ production needs.
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