July, 2026- Tens of thousands of stamping presses populate U.S. production floors. Meanwhile, record numbers of experienced operators are retiring, contributing to a growing labor shortage. Demand for smart manufacturing data and safer workplaces is also contributing to industry pressures. To adapt, stampers are choosing equipment that eliminates manual programming, reduces setup times and minimizes human error.
Wintriss Controls Group developed and recently introduced the WPC Apex clutch/ brake control to forge a link between basic press controls and advanced automation systems. Its primary functions include press safety and die protection. The Apex is able to monitor part ejection, material feed, material buckle and end of stock.
“We also included features such as a pro- grammable limit switch and timed output,” says Wintriss Product Manager Jim Finnerty. “For example, if I set up spray lubricant for material as it is fed to the press and the press happens to stop at 270 degrees, the operator could have lubricant being dispensed in areas where it is not needed. The control’s timed output tells the system when to initiate lubrication and for how long, even if it’s half of a second, which is about how long it takes for material to be fed to the press.”
The new WPC Apex clutch/brake control allows metalformers to upgrade older mechanical power presses with a safe, reliable, user-friendly system.
CUSTOMER FEEDBACK
Finnerty likens the new control to that of a luxury car brand producing an economy car— built for simplicity and cost efficiencies, but backed by 80-plus years of engineering expertise. Wintriss designs and builds rugged, industrial-grade press automation, die protection and safety controls. Its products such as SmartPAC Pro help stampers maximize factory floor safety, efficiency and productivity.
While some consider automation, AI and the Internet of Things (IoT) to be the backbone of modern smart manufacturing, Finnerty says customer feedback revealed an underserved market for a simpler control specifically designed for mechanical power presses.
“If you go into a traditional stamping plant, you’ll likely see several flagship presses equipped with some advanced technology,” he says. “But surrounding those presses will be a larger number of legacy machines. They are the workhorses of the facility and just as important as their modern alternatives because the parts they make are still needed.”
Primary users for the Apex are contract manufacturers who in addition to their stamping operations, also perform assembly and other secondary operations. “We performed extensive testing using failure mode effects analysis,” says Finnerty. “We also conducted beta testing to validate Apex under real-world operating conditions because we wanted to identify a wide variety of different applications for the control.”
In addition to its core functions, the Apex has a touchscreen interface that replaces legacy button setups. Easy to use, the touchscreen significantly lowers an operator’s learning curve while making setup times faster. Specific self-diagnostic information helps operators quickly resolve faults and reduce press downtime. Integrated guarding provides plug-and-play inputs for up to four operator stations and four Wintriss Shadow light curtains. It allows the system to instantly halt the machine’s ram if a person or object enters the safety field and disrupts the beam of light without the need for an external light-curtain control box.
The Apex uses dual, independent microprocessors to ensure the clutch and brake operate safely and reliably. It also uses a brake monitor that continuously performs stop-time tests. In addition to ensuring that safety distance calculations are correct, it also triggers preventive maintenance before safety limits are breached.
The tool setup screen allows operators to load settings for a specific die in one place.
Operators can store, recall and manage critical setup parameters and automation settings.
The Apex gives operators a secure programming interface to configure press parameters.
Operators can manage press operations and die protection functions from one screen.
“Everything is checked and cross-checked multiple times to ensure that the press is safe to run,” says Finnerty.
Upgrades include enhanced memory and expanded I/O. The Apex can also connect directly to SmartPAC Pro using a dedicated digital communications cable and hardwired stop circuits. This link pairs Apex’s press safety controls with the SmartPAC’s automation, which allows it to act as the master HMI. The integration eliminates the need for standalone systems and allows the operator to manage die protection, programmable cams and safety devices from the main touchscreen.
“Giving customers the ability to access SmartPAC Pro and combine it with Apex gives the operator flexibility to [for example] move from processing on a legacy machine to one of their flagship stamping presses,” Finnerty says. “There are a lot of new features with this control and because of the technology available today we were able to include them without increasing the cost.”
For stampers with operations that require upgrading or retrofitting, Apex cuts compliance costs and labor downtime. It also extends the lifespan of older machines compared to making the investment in new capital equipment. Perhaps most importantly, the clutch/ brake control simplifies operation and spans the skills gap with its intuitive features and built-in self-diagnostics, reducing the need for specialized training.
“It’s the easiest thing in the world to listen to your customers and make what they want,” says Finnerty.
Wintriss Controls Group LLC, 978/268-2700, wintriss.com.
