is configured for an abb irb 6640 robot, with cables and · pdf fileis configured for an abb...

June 2014 | ManufacturingEngineeringMedia.com 71

Automation systems are much more

than just using robots to weld, cut or

finish components. Today’s part-han-

dling automation choices are expand-

ing, with new or enhanced robotic and

non-robotic material-handling solutions

that can improve cycle times, optimize factory floor space

and help lower overall manufacturing costs.

Linear motion automation systems greatly expand the

robotic work envelope and help manufacturers maximize

factory-floor layouts. Using track-mounted or overhead

gantry robots offers manufacturers better options to cre-

ate production lines best suited to their manufacturing

operations. Among non-robotic material handling, newer

spindle pick-up automation and linear pallet-handling

systems offer manufacturers more choices in small-parts

manufacturing for high-volume applications like automo-

tive gears and engine components.

The third-generation Trackmotion TMF-4 from Güdel Inc.

is configured for an ABB IRB 6640 robot, with cables

and center mount cable track.

Keeping Automated Manufacturing on TrackLinear axis-mounted robots, spindle pick-up automation and robotic hybrid palletizer systems help boost production efficiencies

Patrick WaurzyniakSenior Editor

Automation

Photo courtesy Güdel Inc.

“Machine tending and machine loading are about 42% of

the robot market. It’s significant, and it’s for everything from

die-cast machines, to injection molding, to machine tools and

all manner of machines,” said Joe Campbell, vice president,

sales and marketing, Güdel Inc. (Ann Arbor, MI, and Lan-

genthal, Switzerland). “Right now, because of linear motion

technology you have an unprecedented array of choices for

how to load and unload your machine tools.”

Those choices include using a robot at each machine tool,

putting the robot on a floor track to serve multiple machine

tools, or employing overhead gantry-mounted robots to service

multiple machines. “The cost-effectiveness and reliability of

linear motion robotic automation makes all of these choices

viable,” Campbell said.

Expanding the Robot’s Reach

Automation specialist Güdel builds linear-motion automa-

tion systems for mounting multiaxis robots on track systems

using universal plates that can fit any OEM robot brand. In

January 2014, the company announced that it had transi-

Renishaw’s laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD.

From tooling inserts featuring conformal cooling, to lightweight structures for aerospace and high technology applications, laser melting gives designers more freedom, resulting in structures and shapes that would otherwise be constrained by conventional processes or the tooling requirements of volume production. It is also complementary to conventional machining

technologies, and directly contributes to reduced lead times, tooling costs and material waste.

� Shorten development time—be � rst to market

� Reduce waste and cost—build only what you need

� Increase design freedom—create complex structures and hidden features

Unlock the potential of Additive Manufacturing

…build tomorrow

Renishaw Inc Hoffman Estates, IL www.renishaw.com/additive

cmyk

design today…

SEE US AT BOOTH #1404

AdditiveAdME6-14.indd 1 4/30/14 9:11 AM

72 ManufacturingEngineeringMedia.com | June 2014

Automation

The Güdel BDS-1 Press De-Stacker/Loader for press automa-

tion applications features carbon-fiber master boom con-

struction and is capable of handling 18-20 parts per minute.

Pho

to c

ourt

esy

Güd

el In

c.

tioned all manufacturing of its third-generation robot tracks

from Switzerland to its US headquarters in Ann Arbor, MI.

The Güdel next-generation robotic track systems include

a newly launched overhead rail, the Trackmotion Overhead

(TMO) system, that mounts robots on

overhead gantries in either an inverted

orientation, on the side of the rail or on

top of the rail. The overhead tracks are

somewhat unusual for the market, said

Campbell, with FANUC offering its own

gantry robot tracks while other robotic

OEMs do not. “A lot of people use floor

tracks rather than overhead gantries

based on outdated perceptions of what is

easier,” he added.

Rail-mounted six-axis robot models

are popular because of their flexibility

for multiple applications. “The operative

word is multiaxis. The robot controller

can manage the linear track motion as

a seventh axis, making the robot and

track operate as an integrated, highly

flexible device,” Campbell said. “Fur-

thermore, these systems can be reap-

plied and used in other applications.”

Using highly reprogrammable robots

makes them an ideal flexible manufac-

turing choice for automating factories.

“We configure linear motion tracks for

an application, but we’re configuring

them with the same building blocks that

we may use for a completely different

industry or a different segment, and

they can be redeployed,” Campbell

said. “We’re doing a number of jobs

right now in automotive powertrain parts

manufacturing where we’re relocat-

ing, reconfiguring, reprogramming and

adding onto old gantry robots that we’ve

installed over the years.”

More Robust Construction

In high-speed sheetmetal press au-

tomation, powertrain machine load and

unload, and tire manufacturing, Güdel

acts as an integrator. “We use our standard modules config-

ured specifically for an application such as powertrain. In both

tire and sheetmetal, we have standard products designed for

those applications,” Campbell said.

® COM

Are we proud of how it all started? Just a little bit.And it started in a garage and attic in 1964 with LittleBit®, our first line of tools for turning applications. Now, 50 years later, we’ve grown into an industry leader manufacturing the world’s finest precision cutting tools for grooving, threading, parting, boring, turning and more.

Kaiser Tool Company, Inc. | 888-THINBIT | 888-THINFAX

Shipment from 24 hours

™

TH11-I4C-ME2014 December 10, 2013 5:10 PMJune 2014 | ManufacturingEngineeringMedia.com 73

The traditional approach has been to build very light,

open-truss-designed gantry robots, he added. “You’ve got two

X tracks in parallel, then the beam that goes across them is

an open truss, like the truss you’d find in a steel building,”

he said. “From that design standpoint, the way you get speed

and performance is to keep taking weight out—you want as

light a weight as possible. We think we’ve got a better alterna-

tive for the increased demands for higher throughput in the

packing area.”

Güdel takes a different design ap-

proach, he said. “We built our gantry

mechanisms with welded box-beam

construction and steel tube, not an

aluminum truss. Our philosophy is to

build the mechanism as stiff as possible,

with a rack-and-pinion drive instead of

the belt drive, and take that stiff mecha-

nism and push a tremendous amount of

power into it through the motors and the

gearboxes—that’s how we get speed.”

“The robot guys want the best ratio of usable work

envelope to footprint—the smallest dead space around

the base of the robot, and the biggest work envelope.”

The new generation of Trackmotion

adds improved performance and reli-

ability. The frame is now a closed, gus-

seted weldment that delivers increased

stiffness with a smaller footprint. The

enclosed frame design also prevents

debris buildup in the center of the track.

The track’s improved stiffness means

less deflection over the travel length, with

repeatability of ±0.02 mm, the ability to

operate at higher speeds and accelera-

tion of up to 180 m/min, while requiring

less floor space.

“The previous generation was kind

of brute force, they would lay down two

C channels and weld a bunch of cross

beams, like railroad ties, across them,”

Campbell said. “You still see people

offering this, which is big and heavy. If

Tool Holder �t is critical to all millingapplications. Just because a toolholderis engaged with the spindle does notmean it is making full taper contact. When the toolholder is not properly seated with the spindle, the toolholderis susceptible to variable cutting forcevariations, misalignment, and harmonics.

When a retention knob is installed intothe toolholder the small end of the toolholder taper can become expanded.

When the taper is expanded it makes contact with the spindle before becomingfully engaged with the spindle. This creates a gap at the gage line and allowsthe toolholder to move duringengagement. Toolholder expansion also e�ects the position of the cuttingtool.

The deformation of the taper is in theelastic zone of the material and cannot be seen by the eye, but can be checkedusing a taper inspection gage.

ExpandedTool Holder

Non Deformed Tool Holder

The High Torque Retention Knob is theonly retention knob designed to preventtoolholder expansion. With High TorqueRetention Knobs you can expect:

Increase In Tool LifeBetter Finishes

Reduced HarmonicsIncrease In Rigidity

Improved Tool Holder & Spindle Life

1.800.322.7750www.jmperformanceproducts.com

Fairport Harbor, OHPRODUCTS, INC.

discover innovate solve

Do Your Tool Holders Fit Your Spindle?

Reduced Harmonics - Enhanced Tool Performance Tool Holder Rigidity - Increased Pro�ts

A Must For All Dual Contact Applications


Automation

you look at the new Trackmotion systems we’re doing, it has a

welded, closed-profile design with gussets—it’s like a unibody

in a car.” The welded frames give the system much more

stiffness with less mass while taking up much less space.

“The robot guys want the best ratio of usable work envelope to

footprint—they want the smallest dead space around the base

of the robot, and the biggest work envelope.”

Testing for a worst-case scenario is critical to ensure reliabil-

ity. Where many buyers make a mistake is to just add the weight

of the robot and the payload together, Campbell noted. “If the

robot weighs 1000 pounds, with a payload capacity of 100

pounds, and I build my track and the bearing structure to sup-

port 1100 pounds, that’s guaranteed to fail,” he said. “The worst

case is the robot with a full payload, and the full payload is at a

certain distance from the toolplate on the robot, then you put the

robot at full extension and at 90° to the track so it’s stretched out

over the side, move it at full speed and then hit the emergency

stop. That is when you need your track to perform.”

Adding Robotic Flexibility to Palletizers

For more flexible palletizing systems, automation and

robotics integrator Intelligrated (Mason, OH) has been adding

High Precision Surface Finish?

COMPREHENSIVE SYSTEM SOLUTIONS FOR MOST APPLICATIONSAs a worldwide technology and innovation leader in surface fi nishing we supply manufacturers with best-in-class lapping, grinding, polishing, fl at honing and deburring systems for the micron-range high precision surface machining of metal, glass, ceramics, plastics, and semiconductor materials. With our renown brands PETER WOLTERS, MICRON and VOUMARD we offer advanced technologies for most precision surface machining applications, including solutions for internal / external diameter grinding, creep feed-grinding, profi le grinding and HEDG grinding – from a single source. As your partner, our mission is to provide you with the systems, people, process expertise and support you need to achieve your goals.

PETER WOLTERS of America Inc.509 N. Third AvenueDes Plaines, IL 60016 - 1196

Phone: (847) 803 - 3200Fax: (847) 803 - [email protected]


Automation

Robotic hybrid palletizers for material handling from Intel-

ligrated combine robotics with traditional palletizing for

increased flexibility and to optimize factory floor space.

Pho

to c

ourt

esy

Inte

lligr

ated

Come see us at North Hall Booth #7333

robots to its traditional palletizing systems used in process

industries, packaging systems and warehouse applications.

“We’re seeing an increased need for flexibility in our solu-

tions,” said Matt Wicks, Intelligrated vice president, product

development, manufacturing. “Many of

the demands placed on our customers

require them to be agile with their solu-

tions. Robotic applications are at the

forefront of this trend.”

Intelligrated’s solutions for manu-

facturers include case packing, pallet-

izing, warehousing and order-fulfillment.

“Many manufacturers’ automation

solutions focus on the process of manu-

facturing the product, but when it comes

to packing, palletizing and warehousing,

this is where their automation systems

stop,” Wicks said. “We offer automation

solutions to streamline manufacturers’

processes downstream of their manufac-

turing.” The company’s automation sys-

tems include robotic case packing and

palletizing, conveyance and sortation,

automated storage and retrieval systems

(AS/RS) and shuttle technology, inventory

management, warehouse management

systems software capabilities and order-

picking solutions.

Many requirements should be con-

sidered when investing in an automation

system, Wicks said, including system ca-

pacity, return on investment and reliability.

“When considering solutions to automate

manufacturing order fulfillment, integra-

tion with the manufacturing systems is

critical,” he said. “The tight relationship

between what is being manufactured,

what is in inventory and what is required

to fulfill orders must be balanced to main-

tain efficiency of all the systems.”

Several new products recently

launched that lend support to order ful-

fillment needs of manufacturers, Wicks

said, including the Alvey 750 robotic

hybrid palletizers, several new product

offerings from Intelligrated’s Knighted subsidiary and the OLS

(one-level shuttle) system for case storage and retrieval.

“Integration of robotics into our automation solutions have

been increasing over time. A good example of this is how we

Machine Tool Gage & Fixtures Makers Automotive Aerospace Glass Energy Medical Electronics

Earning the maximum ROI from your In-process Gaging investment starts withmatching exactly the right gage to yourmachine application and production requirements. That’swhy Marposs developed the mostcomprehensive lineof in-process gages.From versatile single-finger OD and ID heads forhigh productiongrinding, to flexible, wide-range absolutegages for grinding families of shafts up to 1,500mm diameter while eliminating parasitic downtime for changeovers.Helping you choose the best gaging solution and backing it up with total global support are some of the things we do to help keep your uptime up.

MARPOSS MAKES SENSE.Visit us at www.marposs.com/MakesSense

RELIABLE CHOICES

Marposs Reliable ad island 1/2 ME


See us at AMERIMOLD Booth #623

have been integrating robotics into our conventional palletizers,”

Wicks added. “Traditionally, automated palletizing has been done

with a custom machine suited to the needs of the manufacturer

that are unique to the manufacturer’s products. If those products

change over time, physical changes may be required to support

the new product types. By integrating robotics into a conventional

machine, this provides more flexibility into the palletizing patterns

being formed and reduces the need for physical changes when

packaging changes. As robotics become more advanced, the

opportunities for their integration have followed suit.”

Spindle Pick-Up Automation

For smaller parts manufacturing, the VL-Series turning

machines from EMAG LLC (Farmington Hills, MI) use the

machine working spindle not only to machine workpieces, but

also to load and unload them from automation. The VL-Series

vertical pick-up turning machine models include the VL 2, VL

4, VL 6 and VL 8 lathes aimed at small-part manufacturing

applications in automotive and nonautomotive medium-to-

large-scale part production.

With EMAG’s patented spindle pick-up technology, the

workpiece is transported into the machine using a lateral

conveyor system in an “O” design included as standard

equipment. The “O”-automation is a workpiece transport

system which is fitted to the left side of the machines. “The

parts travel on the conveyor to a pick-up station,” said Marius

Mazur, product manager for the VL of turning machines.

“In the pick-up station, the parts on the conveyor belt are

positioned exactly in the center using the NC program. A

gimbal-mounted pressure plate pushes the part safely to the

clamping jaws and workpiece clamping system, irrespective

of burrs or casting projections. For us, this automation is an

integral part of the machine, where one operator can operate

up multiple machines at a time.”

The VL-Series vertical turning machine’s advantages in-

clude a small footprint and the automation’s ability to lower cy-

cle times and optimize machine uptime. The pick-up spindle

takes the raw parts from the universal workpiece prism and

after machining places finished parts back on the prism.

Workpieces handled by the VL-Series lathes are mostly cy-

lindrical; however, asymmetrical or position-oriented workpieces

can be put on specially designed pallets and simply inserted in

the drag frames, Mazur said. Workpiece sizes range from 100-

mm diam and 150-mm length for the VL 2 lathe, ranging up to

400-mm diam by 300-mm lengths on the largest VL 8 ma-

chine. The systems offer users attractive Overall Equipment Ef-

fectiveness (OEE) levels with high machine uptime. Cycle times

are improved dramatically with the system, Mazur said. “Pick-

up working spindle moves in the X and Y axes with minimum

response times and the tool turret guarantees short swiveling

times,” Mazur said. “The machine is working constantly.”

High-Efficiency Pallet Changers

Another non-robotic solution, the Rotary Loading System

(RLS) comes from automation developer Liebherr Automation

(Saline, MI), a subsidiary of Liebherr-Versahntechnik GmbH

(Kempten, Germany). The RLS offers a smaller footprint and it’s

aimed more at job-shop-type applications, noted Kevin Heise,

vice president, Automation Systems, Liebherr Automation.

The RLS is ideal for smaller operations that don’t need and

cannot afford larger linear automation systems like Liebherr’s

PHS pallet-changing linear automation systems. The RLS is a

cost-effective way to automate high-efficiency production on

one or two machine tools, Heise said.

“The linear gantry is the backbone of our portfolio,” Heise

said. “It was basically one of the whole enablers, once manu-

facturing switched from transfer lines.” The systems help

manufacturers maximize production, he said, for high-volume

lines in automotive that build crankshafts, cams, heads,

blocks, and transmission parts.

Medical components are another area targeted by Liebherr

with the RLS automation, which comes in two sizes, the RLS

800 and RLS 1500 systems capable of transporting workpiece

weights of 800 and 1500 kg, respectively. “The Rotary Loading

System is kind of like the little brother of the PHS,” Heise said.


Automation

The pick-up automation system in EMAG’s VL-Series turning

machines transports parts to the lathe where spindles load

and unload parts into the machine tool.

Pho

to c

ourt

esy

EMA

G L

LC

“For smaller footprint applications, it’s ideal and you might load

one or two machine tools with it.”

Liebherr’s RLS automation helps keep machines running

constantly, Heise said, with machine uptime averaging up to

90–95%. For a job-shop owner, this

allows the operation to free skilled opera-

tors for more advanced work in toolset-

ting, gaging or other areas, he added.

The RLS features rack columns that

are modular designs, with up to 24 stor-

age locations in a minimal footprint. The

optional Rotary Storage Tower (RST) can

be added later, with the tower offering

space for up to 18 additional storage

locations in a slightly larger minimum space requirement. The

systems include the Soflex Cell Controller for simple operation

with an intuitive user interface for the Soflex-PCS cell control

system software. ME

When we introduced our MV Series wire EDM machines,

we had a feeling they’d make waves. A year later, the

never-before-seen design improvements have reinforced

our leadership in the market—and sparked our customers’

success. No other machine on the market has our

non-contact cylindrical drive technology, improved power

supply and deeper submerged cutting capabilities—all

backed by the reliable, expert support our customers expect.

See what all the buzz is about at www.mcmachinery.com or call 866-994-7856.

DISCOVER THE #1-SELLING EDM IN NORTH AMERICA

LEADING THE CHARGE.

ONE SOURCE. ENDLESS EXPERTISE.

Cylindrical Drive Technology Revolutionary non-contact design

Auto-Threader Allows up to 14 inches of through-part

wire threading for tall parts

Compact Head Design Easy indexing during operation

For current open positions, please visit our website:

www.mcmachinery.com or email: [email protected]

EOE M/F/D/V

Visit Our New WEB SITE

www.mcmachinery.com


EMAG LLC Ph: 248-477-7440

Web site: www.emag.com

Güdel Inc. Ph: 734-214-0000

Web site: www.gudel.com

Intelligrated Inc.Ph: 866-936-7300

Web site: www.intelligrated.com

Liebherr Automation Ph: 734-429-7225

Web site: www.liebherr.us

Want More Information?

Pho

to c

ourt

esy

Lieb

herr

Aut

omat

ion

The Rotary Loading Systems (RLS)

palletized automation from Liebherr

features a reduced footprint and is

used in small-part manufacturing

loading and job-shop applications.

See us at Booth #N-6825

is configured for an abb irb 6640 robot, with cables and · pdf fileis configured for an abb...

Documents