2017 | 2. Issue

Hot topicsAutomation and digitalization of production

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Equipped by SCHUNKMAGNOS magnetic chucks for efficient XXL tube machining

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SCHUNK NEWSInside: News from the family-owned company

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WorldwideTraining and high tech international

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DatesInternational shows 2017/2018

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Jens LehmannLocker room conversations – the new online campaign

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Product innovationOur innovations for highly efficientproduction processes

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Production of the Future – Equipped by SCHUNKIndustrial production is undergoing a fundamental change. The increasing digitalization of production processes, the high dynamics of start-up companies, e-mobility, and the increasing variety of consumer and capital goods are the main drivers of this change.

In the years to come, digitalization, mecha-tronization and automation of production processes, collaboration between humans and robots, and the intelligent interconnec-tion of all process-relevant components will inspire the emergence of a new mindset in industrial production. The focus here is on three aspects: communication between all the components involved, maximum trans-parency on the system, component, control and company levels, and finally, flexible responses to external and internal events.

The kinds of gripping systems and clamping devices used are critical in all three of these fields. SCHUNK’s aim is to use the exposed position of the SCHUNK modules as “closestto the part” to monitor each individual process step in detail and to permanently provide the system control, the superordi-nate ERP system, and the cloud solutions with process data, enabling flexible reac-tions to corresponding events. ■

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Dear Customers, Partners, and Friends,

Our industry and the global markets have always been met with constant change. Widespread digitalization, however, will cause a radical upheaval that will not only generate new poten-tial for greater competitiveness but also bring about immense changes to the way we work. Humans will have to meet completely new requirements in the realm of production. New technologies will transform those who were once machine operators into managers of multiple machines and processes.

Robots will take over new tasks and be-come more similar to humans. Big data is part of everyday life. Our knowledge and the possibilities for simulating pro-cesses and results in advance is grow-ing. Experts from all over the world are discussing the technical challenges that we will encounter in the coming years. SCHUNK is right in the middle of it all. We are visionaries at the cutting edge of the trends as well as “closest to the part” in the handling process.

When it comes to efficient production and automation processes, we are the sought-after experts with our Industry 4.0 portfolio and grippers for human/robot collaboration.

Find out more in this EMO edition of our customer journal, blue»!I hope you enjoy reading this inspiring edition!

Henrik A. SchunkManaging Partner | CEO

Equipped by SCHUNKOur Pick & Place units for intelligent high speed assembly

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EGL 90 2-finger parallel gripper with PROFINETThe first gripper with a certified PROFINET inter-face and integrated control electronics.

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Efficient Production and Automation Processes

1. a gripper never causes injuries when gripping

2. a gripper always detects human contact 3. a gripper never loses the workpiece For this purpose, SCHUNK uses a combination of various technologies and components, depending on the application. In the basic version and so-called inherently safe grip-pers for collaborative operation, a gripping force limitation is activated in hazardous situations, limiting the gripping force to 140 N. In addition, an HRC-compliant design with rounded corners and edges minimizes the risk of injury. SCHUNK Co-act Grippers will also be equipped with additional features in the future, such as safer drives that ensure that even heavy parts will be reliably held during an emergency stop. An environmental sensor system will perma-nently monitor the environment of the gripper. Intelligent software will evaluate and process sensor signals. The world’s

first collaborative gripper, SCHUNK Co-act Gripper JL1, which interacts and communi-cates directly with humans, demonstrates what will be possible at the top levels of technology in the future. The gripper was awarded the coveted Hermes Award for the collaborative operation in April 2017 due to its high degree of innovation.

Easy to use, easy to integrate, easy to maintain – modern gripping systems and clamping devices are the key to efficient and flexible production processes. SCHUNK as a competence leader, equips its robots and machine tools with high-performance, future-proof components for smart manufacturing.

SCHUNK already provides a large number of clamping force blocks that are capable of communication, as well as fully auto-mated palletizing systems and quick-change solutions for flexible production. SCHUNK is systematically expanding its Industry 4.0 portfolio. This means that technologies are emerging such as functional manufacturing cells, in which intelligent SCHUNK grippersEGL PROFINET with variable power and positioning enable autonomous handling scenarios and ensure fully automated quality assurance. Without the need for additional external sensors, the gripper autonomously detects faulty components and decides for itself whether the part should be ejected from the process. The information recorded can be continuously transferred to the machine control system, to higher-level internal and external systems, as well as to cloud solutions for statistical process analyses. All process steps are monitored in real time and superordinate levels such as ERP systems or cloud-based monitoring platforms are provided. In addition, SCHUNK is accelerating the trend toward fluid-free, highly inter-connected machine tools with the VERO-S NSE-E mini - the world’s first electrically controlled 24 V quick-change pallet module.

System program for workpiece direct clamping

The new trends are even reducing idle times, increasing productivity of machine tools and enabling flexible processes for mechanical clamping systems. Among SCHUNK’s objectives is the aim to further extend its modular system for workpiece direct clamping, to expand its portfolio of lightweight chucks and, after many successful customer tests, to get the ball rolling with the slim, vibration damping TENDO Slim 4ax hydraulic expansion tool-holder.

SCHUNK grippers for collabora-tive operations in machine tool environments

In cases where full automation proves difficult to implement economically, it will become common practice to single out individual processes and delegate them between humans and robots. Experts believe that monotonous and ergo-nomically demanding activities in particular will be gradually replaced by collaborative systems. This will increase productivity, enable high flexibility and will reduce the employees’ workload. In addition, it will reduce the risk of injuries and ensure consistent quality regardless of any fluc-tuation in the operator’s performance in reproducible processes. Based on underlying standards and guide-lines, SCHUNK has identified three central principles for grippers that define human/robot collaboration:

Please contact us with your individual requirements. Your SCHUNK specialist consultant can be found at:schunk.com/ansprechpartner

With the SCHUNK VERO-S NSR robotic coupling,

clamping pallets can be handled in a process-reliable

fashion. The SCHUNK quick-change pallet system

ensures a secure hold on the machine table with

maximum repeat accuracy.

Statistical process and condition monitoring:

The recorded process and gripper data can be

statistically evaluated and visualized over extended

periods of time, for example in order to analyze a

single contract or week of production.

The SCHUNK Co-act Gripper JL1 is the world‘s first intelligent gripper for human/robot collaboration to directly

interact and communicate with humans.

VERO-S NSE-E 24 V mini

quick-change pallet module

Equipped by SCHUNK

The new efficiency provider!

Hot Topic

2

Digitalization in the

OrderComplex workpiece geometries require customized gripper fingers. SCHUNK is offering the world’s first fully automatic 3D design tool for additively manufac-tured gripper fingers in polymide and metal with its SCHUNK finger designer eGRIP. The license-free browser-based web tool drastically reduces the design and ordering time for customized gripper fingers to just 15 minutes. Users receive a

detailed quotation in a few short steps, which show the 3D contour, delivery time, and price.

CommissioningOnline assistance tools for smart commissioning are already available today for top products in the SCHUNK 24 V program. There is an online commis-sioning assistant with interactive, web-based user guidance for quick commissioning of the SCHUNK gripper EGL PROFINET. To make the commissioning of the pneumatically driven high-perfor-mance SCHUNK PPU-P and SCHUNK DRL

assembly units even more convenient, a neutral PLC functional module for simplified control has now been developed, with which the sequential program can be integrated into every standard PLC software. With minimal effort, the sequence that has been pre-configured in the preset can be expanded or adjusted flexibly based on the individual application. This eliminates the need for basic modeling of the process. SCHUNK goes one step further with the linear module ELP. The easiest way to set up the electric linear module on the market is to use an auto-learn function for automatic speed adjustment.

Smart Gripping via Real-Time-Process and Part MonitoringSmart SCHUNK grippers enable au -tonomous scenarios and can transfer statistical process analyses to high-er-level systems as well as to cloud solutions. The process data for each gripping process, such as gripper finger position and gripping force, are recorded and visualized. Using data analytics, the system analyzes the data and specifies procedural actions if necessary. In addition, the causes of errors can be evaluated at an early stage.

Maintenance In order to increase machine availa-bility and avoid downtimes, sensors detect even the slightest deviations, providing the conditions for plan-nable and effective intervention in the context of predictive maintenance - even before any failures occur.

DesignSCHUNK offers a number of engineering tools to make the planning and design of smart handling solutions as easy as pos-sible. The new SCHUNK Online Configura-tor for assembly automation enables fast and error-free design of high-perfor-mance assembly systems. With the tool based on the eCATALOG solutions technol-ogy from CADENAS, complete Pick & Place structures can be configured comfortably

and intuitively downloaded in all standard CAD formats (either 2D or 3D) with just one click. SCHUNK is also integrating the world’s largest gripper program into the EPLAN Data Portal. This portal allows SCHUNK to achieve significant efficiency gains when designing assembly and handling systems. In the first stage, SCHUNK offers macros of 16 series with a total of 843 individual components on the web-based data platform. In the next stage, SCHUNK will digitize its electrically controlled gripping system components as Digital Twins using Siemens PLM software. With the aid of digital images, users and system integrators will be able to display their conceptual engineering process using mechanics, electrics and software right up to virtual commissioning in parallel and also to realistically validate the plausibility of highly integrated handling scenarios in virtual simulation environments.

OperationIntelligent SCHUNK modules with networking capabilities are the basis for flexible production automa-tion. The components offer a variety of interfaces for networking and communication using all the common bus systems, e.g. EtherNet TCP/IP or PROFINET. For monitoring, they deliver precise information for quality assurance and for monitoring system

parameters and process data. In order to create more dynamic and flexible processes, the SCHUNK intelligent components enable decentralized control at the component level. SCHUNK is pushing ahead with topics of the future such as IO-Link and NFC.

Smart Product Life Cycle

Product Life CycleSCHUNK products, tools, and services play a crucial role in the digitization of production, from design to commissioning, and operation to maintenance. SCHUNK already offers a wide range of products that are able to communicate, enabling the development and realization of a smart production line. The Industry 4.0 portfolio is being systematically expanded with intelligent and network-capable components.

Smart Product Life CycleSCHUNK products, tools, and services for smart production

System IntegratorIn our video, Karl explains the development process for smart production lines

schunk.com/karl

Design

Operation

Maintenance

Order

Commissioning

Digitalization

Hot Topic

3

NSE3 138 Quick-change Pallet Module

KSC-D Double Clamping Vise

Chuck jaw with oil chamber system for low-deformation workpiece clamping.

The new SCHUNK hydraulic compensation jaw is equipped with an oil chamber system for low-deformation clamping of thin-walled or sensitive workpieces. Even at high speeds, the integrated centrifugal force reduction ensures low loss of clamping force and safer clamping. For maximum machining accuracy, concentricity can be adjusted precisely with the new SCHUNK chuck jaw type. The hydraulic system excellently damps vibrations, ensuring improved workpiece surfaces. ■

Product information:schunk.com/hydraulic-compensation-jaw

Power Lathe Chuck

Hydraulic Compensation Jaw

The high-performance pneumatic Quick-change Pallet System for universal Milling Operations.

The new premium quick-change pallet module SCHUNK VERO-S NSE3 138 is the all-rounder for manual and automatic machine loading. The design of the SCHUNK VERO-S NSE3 138 was optimized for an even higher system rigidity under the effects of the pull-down force.At the same time, it has increased pull-down forces due to optimized modular kinematics for maximum rigidity in any clamping position. The new premium quick-change pallet module SCHUNK VERO-S NSE plus 138 is 100% compatible with the quick-change pallet module and can be exchanged 1:1. ■

Product information:schunk.com/vero-s-nse3

Extremely flat designfor maximum use of the machine room and maximum rigidity of the system.

Compensating 6-point clampingfor deformation-low clampingof thin-walled workpieces.

High-low clampingSuitable for machining of workpieces with different clamping forces.

Low height for maximum use of the machineroom and maximum rigidity of the system.

Third hand function Easy and safe loading ofseveral workpieces ontombstones.

VERO-S interfacefor direct clamping onto theVERO-S quick-change pallet systems without intermediate plate.

Manual Double Clamping Vise with Third HandFunction for clamping of two Workpieces.

The new manual double clamping vise SCHUNK KONTEC KSC-D is suitable for clamping two workpieces. Its perfected dirt seal is optimal for protecting against chip penetration. The third-hand function allows several workpieces to be loaded easily and safely - the first work piece is already held securely in position as the second work piece is clamped. Its extremely flat design ensures maximum utilization of machine space and maximum system rigidity. The KONTEC KSC-D has a VERO-S interface and can be used directly on VERO-S quick-change pallet systems without the need for an intermediate plate. Due to the large range of clamping jaws, the double clamping vise can be quickly and easily adjusted to new clamping tasks. ■

Product information:schunk.com/kontec-ksc-d

Sealed 6-Jaw Power Lathe Chuckfor significantly longer Maintenance Intervals.

With the new ROTA NCR-A, SCHUNK offers a sealed 6-jaw power chuck for significantly longer maintenance intervals. The 6-jaw compensation chuck is based on the principle of chuck jaws that oscillate in pairs. This ensures workpiece centering between six contact points, which can be adjusted in pairs. That makes for ideal low-deformation clamping of thin-walled workpieces. The low height of the chuck allows for the optimum use of the machine room and leads to maximum system rigidity. Due to dual pressure clamping, SCHUNK ROTA NCR-A is suitable for workpieces that require different clamping forces during the machining process. ■

Product information:schunk.com/rota-ncr-a

Adjustable run-out accuracyfor maximum accuracy during machining.

Deformation-low clampingof thin-walled orsensitive workpieces.

Vibration damping for better surface quality of the workpiece.

Centrifugal forcecompensationThe minimum loss of clamping force ensures safe clamping.

Vast chuck jaw programfor vast adaption to new clamping tasks.

Clamping Technology

New Products

Optimized designfor an even higher rigidityof the system.

100% compatible with the NSE plus 138 for easy exchange of the modules.

Increased pull-down forces through optimized module kinematics in every clamping position.

Optional cone seal for a fully protected clamping pin interface.

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ElectricLinear Module ELP

The first Gripper with certified PROFINET Interfaceand integrated Control Electronics.

The SCHUNK EGL 90 has a variable gripping force between 50 and 600 N, making it one of the most flexible mechatronic grippers with the most compact performance on the market. Finger position and closing speed can be freely programmed within a maximum stroke of 42.5 mm per finger. All of the control and power electronics are integrated into the housing. It is also suitable for decentralized and mobile use due to the 24 V-DC operating voltage. PROFIBUS, CAN or PROFINET provides maximum interface flexibility for swift and easy integration into superior plant controllers. The PROFINET-certification ensures compatibility with industry standards. ■

Product information:schunk.com/parallel-gripper-egl

2-Finger Parallel Gripper EGL 90 with PROFINET

Compact gripper The complete control and power electronics are integrated in the housing. Suitable for the use indecentralized systems.

Maximum interface flexibilityvia PROFIBUS (up to 12 Mbits/s)and CAN (up to 1 Mbit/s).PROFINET certification for ensured compatibility with industry standard.

Flexibly programmableFinger position, closing speed, and gripping force (50 to 600 N) can be freely programmed within the maximum stroke of 42.5 mm.

Comfortable commissioningInteractive online commissioning assistant for easy parameterization of the gripper hardware.

No other electric linear module on the market is as user-friendly to adjust.Now NEW with electric holding brake.

The linear module ELP is the new technological benchmark for use in modular assemblies. The module is ready to use in just two steps. The end positions are easily configured mechanically with a screw and the speed of extension and retraction is configured using the lateral rotary switches. The SCHUNK ELP features an auto-learn function that allows the speed to be configured automatically according to the add-on weight. This enables compensation for incorrect configurations. The low-maintenance 24 V linear motor drive automatically regulates the braking process, meaning a shock absorber is not required. ■

Product information:schunk.com/linear-module-elp

Integrated control and power electronicsControlled via digital I/O.

Low-maintenance 24 V linear direct driveProcess-reliable and long-lasting. Fully compatible with the SCHUNK 24 V modular system.

Unique auto-learn functionOptimum speed adjustment during the first 2-5 strokes. No shock absorbers are installed.

As a senior development engineer, Dr. Markus Glück is responsible for heading new product development. In the interview, he described how SCHUNK recognizes potential ideas and trends and drives innovations forward. The detailed interview was published in the VDMA news in July 2017.

Dr. Glück, you are Managing Director of Research and Technology at SCHUNK. What key topics are you dealing with at the moment?With our innovation management system, we have developed a process that creates inno-vation-friendly framework conditions that shape a culture of innovation and help us focus on market requirements and technological trends. Digitalization has had a special impact on industrial automation. It requires a radically new way of thinking. We have always been a classic component manufacturer for industrial automation. With the help of mechatron-ics, we are now developing into a smart company that actively takes on the challenges and achieves solutions for Industry 4.0. In the future, we will also offer intelligent, primarily software-based services. Customers will be able to select, customize, test and purchase the solutions on an online platform.

Is a change necessary in corporate culture? The corporate culture of innovation and the basic conditions available are crucial prerequi-sites for companies to be able to effectively implement innovative activities. Innovation can only succeed in a space free of fear, a space that allows for mistakes. In addition to a tolerance for mistakes, it is necessary to have calm and focus. However, all parties involved have to be allowed to stray from day-to-day business.

“Innovation can only succeed in a Space free of Fear”Dr. Markus Glück, Chief Innovation Officer at SCHUNK during a discussion with VDMA

What is the role of the management?The challenges of digitization are extensive and have an impact on almost all areas of the company. That’s why innovation is the key issue. Our Managing Partner and CEO, Henrik A. Schunk, takes a personal interest here and is actively participating in the steering meetings for the innovation management system. He was also the one that appointed me as Chief Innovation Officer with executive responsibilities.

SCHUNK was honored with the Hermes Award this year. What does this award mean for SCHUNK?The impact on motivation is amazing. The interest in our development work and in our company has grown so intensely that we are extremely busy trying to keep up with the current demand for our first new products. And this is a great thing, because innovations are most successful when market success is achieved quickly. That is most important in the end.

The detailed interview in the VDMA news can be found here: schunk.com/interview-vdma. ■

Dr. Markus GlückChief Innovation Off icer SCHUNK GmbH & Co. KG, Lauff en/Neckar, Germany

NEW: Electric holding brakeSecures against lowering of attachments in the event of energy loss in vertical applications.

Gripping Systems

New Products

5

The processing of long steel parts often entails significant outlay, starting with fitting the tensioning bars, through repeated reclamping, right up to lengthy manual flame straightening. The logistics and handling specialist BLEICHERT Auto-mation from Osterburken has chosen a significantly more efficient path: SCHUNK MAGNOS magnetic chucks mounted verti-cally on DEMMELER clamping brackets allow flexible and low-deformation set-up of three to eight meter-long pipes on a SORA-LUCE rigid bed milling and drilling center as well as highly efficient complete processing on five sides.

Make or buy? – particularly for basic compo-nents that are used regularly and that are significant for on-time delivery, machine and equipment manufacturers as well as systems suppliers are increasingly choosing the former. This primarily applies if with an enlarged production depth not only the flexibility can be increased but also the costs can be reduced. A good example of how such in-sourcing can be successful is provided by BLEICHERT Automation from Osterburken in Neckar-Odenwald district: with the investment into a SORALUCE rigid bed milling and drilling center SL-10000, the experienced automation, conveying and storage systems manufacturer brought the production of gantry bearers back in-house whilst at the same time optimizing the manufacturing process. In so doing, a clamping solution with SCHUNK MAGNOS quadratic pole plates proved a decisive key when it comes to productivity, flexibility and efficiency.

Diverse clamping solution for a wide range of parts

“With the clamping system, we have low outlay, we attain a high utilization factor, are extremely flexible and very fast”, reports Michael Diemer, production manager in prefabrication at BLEICHERT. A total of eight vertically assembled SCHUNK MAGNOS MFR-01-050 square pole plates in 800 mm x 300 mm format facilitate flexible and distortion-free suspended clamping of ST52 pipes with a length between 3,000 and 8,000 mm and pipe diameters of 200 mm, 250 mm and 300 mm. In order to facilitate a complete machining in a single clamping process, the magnetic chucks are mounted elevated on stable DEMMELER clamping brackets, meaning free accessibility to five sides is ensured. By means of standard

system holes in the doubled 100-channel grid, the magnetic chucks can be flexibly positioned at height and pinned using pins. In addition, the clamping brackets can be continuously moved in the X-direction along the machine table and fixed using pins or if necessary disassembled completely in just a few steps. Due to the lateral arrangement of the clamping modules, the machine table can also be used at all times in the full length and in a width of around 1,000 mm for other set-ups, without the magnetic modules having to be removed. This way, the machine can also be used at short notice for rush orders if required, without the need for costly retrofitting.

The MAGNOS magnetic chucks also offer a high degree of flexibility: “The big advan-tage of the SCHUNK system is that we are able to set clamping modules using the pin quickly and at different pipe cross-sec-tions”, Michael Diemer explains “You simply unscrew a row of pins and can immediately clamp a different cross-section. This way, we use three rows of pins for the 200 pipe and four for the 300.” If wider parts are to be processed, the entire magnetic chucks can be rotated by 90° and fixed upright. Regardless of the alignment of the module, the movably mounted SCHUNK EASYTURN pole extensions can be individually adjusted to the respective workpiece contour and ensure a gentle, low-deformation set-up. Specific damages or warping usual when processing long pipes are completely eliminated. Users benefit from maximum clamping precision and workpiece smoothness, without the parts having to be laboriously underlaid or clamped several times. Furthermore, clamping over a large surface area minimizes vibration, protecting both the machine spindle as well as the cutting edges.

Savings in set-up times, pre-paratory work, and reworking

“Unlike a classic set-up, we no longer have any preparatory work or reworking at all”, machine operator Armin Rieth confirms. “The pipes are clamped in the outer four corners on fixed poles and automatically underlaid over the entire length with movable magnets free of voltage. There-fore, we are making optimum use of the flexibility of the clamping system.” The four fixing points in turn ensure that all pipes exhibit identical end faces and can be connected with one another modularly without an offset. While with a conventional

set-up with welded strips and hydraulic clamps, the pipes are prepared, clamped and often reworked for several hours during flame straightening at great expense, they can be clamped using SCHUNK MAGNOS by a single operator in no time at all without any preparatory work and processed entirely in just one set-up without the need for reworking. “The clamping system brings about enormous time and cost saving”, Rieth highlights. And it works extraordi-narily reliably, as Michael Diemer confirms: “We partly make adjustments of 5 millim-eters in depth and 75 millimeters wide. On the face, we introduce bores and fittings. Milling takes place on five sides, with the full force of the machining, without the part moving”, Diemer highlights. This all takes place without additional clamping devices or stops.

For each MAGNOS clamping module, up to 32 fields are at work each with a theoretical clamping force of 380 kg at BLEICHERT. If all eight modules are completely covered, a theoretical clamping force of over 97 tons is produced – far and away enough to ensure the greatest possible process reliability, especially seeing as the magnetic clamping with SCHUNK MAGNOS electropermanent magnetic chucks is completely independent of the power supply. An electrical impulse is only required to activate and deactivate. To do this, Armin Rieth connects the modules connected in series for a short period to the MAGNOS control system. Within seconds, the electrically activatable permanent magnets ensure a continuous firm grip. After acti-vation, no additional energy supply is required, meaning the control system can be completely decoupled for the time of the processing.

One-man loading

Loading is solved just as conveniently. It can be completed even for long parts by a single operator. In just a few steps, the worker folds special auxiliary support consoles on each clamping bracket horizontally upwards, fixes the consoles using a bolt and places the pipe on top using a crane. He then initially tightens the pipes using a vise on

the fixed workpiece stops, compensates for a delay of the component using shims on the fixed poles, and finally actuates the SCHUNK magnetic clamping solution at the press of a button. In just a few seconds, all dialed magnetic modules are activated one after the other via two SCHUNK MAGNOS control units KEH. The respective clamping status can be read off using a visual display. If all dialed modules are clamped, the oper-ator removes the cable from the magnetic chucks and closes the spray guard of the SORALUCE rigid bed milling and boring center for processing. As two MAGNOS control units are used, two smaller supporting elements can also be clamped independently of one another. “The system works flawlessly and is significantly superior to classic clamping solutions for roughing,” emphasizes Armin Rieth. No malfunctions have arisen since commissioning. On the contrary: all in all, BLEICHERT saves a great deal of time and costs thanks to highly efficient in-house production. For the set-up times alone, the saving compared to processing with classic clamping equipment in two set-ups is up to three hours. Added to this are savings of four to five hours for preparatory work and reworking, particularly for welding strips and subsequently flame straightening parts. The investment into the clamping system is thereby amortized in no time at all. ■

Efficient XXL Tube MachiningWorkpiece Clamping on Five Sides

The highest precision even with enlongated workpieces

Equipped by SCHUNK

6

AERNE ENGINEERING AG, winner of the SCHUNK Competence Award 2017, proves that versatile factories are within easy reach with SCHUNK.

Dr. Markus Klaiber Dipl.-Ing. (TH) Technical Director/CTOSCHUNK GmbH & Co. KG, Lauffen/Neckar, Germany

Flexible High Speed Assembly

Pick & Place – Modern high-performance assembly systems must be capable of far more than short cycle times. The trend is towards intelligent high-speed solu-tions that cover a wide range of parts with process stability that enable an uncompromising zero-error strategy in 24/7 operation. The Swiss company AERNE ENGINEERING AG has taken the lead and in cooperation with SCHUNK, the competence leader for gripping systems and clamping technology, developed an assembly cell for injection molded parts that can produce thirteen different assemblies with a cycle time of 1.2 seconds. Pneumatic and mecha-tronic modules were skillfully combined for this purpose.

The main aim of the project is to provide each with three components that are equipped with a total of 19 variants, installed with a cycle time of less than 1.3 s and have a reject percentage of less than 1% to thirteen, and with the possibility of adding additional assemblies in the future. All this with a 100% check including differ-entiated error ejection, very high system availability and more autonomous opera-tions with an operating range of less than 10%. AERNE ENGINEERING specializes in such demanding and complex projects. “Our strength is in daring to take an active part in shaping the process to efficiently maxi-mize value for the customer”, explains CFO Raphael Schärer.

100% check

Instead of simply checking for the presence and position of the correct components, the system monitors the corresponding force pressure and ejects faulty parts and calibration parts in defined cycles in order to continuously verify the test process.

Defective parts are automatically separated into four categories based on the defined error type. This ensures that deviations in the upstream processes can be accurately detected, assigned and eliminated. If components or subcomponents change, or if the range of parts is enlarged, the system can be adjusted within a very short time with minimum effort.In order to achieve this high degree of effi-ciency and flexibility, AERNE established a close relationship with the customer and its suppliers. “We strive to be involved in projects as early as possible and to under-stand our customers’ requirements in order to develop tailor-made, intelligent solutions together with effective partners such as SCHUNK,” says Raphael Schärer. Over-en-gineering is strictly avoided. Instead, they follow the motto: high-tech only where necessary. With more than 4,000 standard components, the world’s largest stand-ardized gripping technology program from SCHUNK offers optimal conditions exactly for this.

Optimum results from two drive worlds

A total of six linear direct-driven Pick & Place units from the SCHUNK PPU-E 30 series ensure the shortest cycle times of 1.2 s and a high degree of variability. The fastest Pick & Place units currently on the market are powered by a wear-free direct drive instead of a tolerance and wear-prone movement transmission system. This minimizes maintenance costs, increases permanent repeatability, and simplifies the programming. Equipped with two stationary motors, the slender SCHUNK PPU-E 30 comes without moving and failure-prone motor cables. With its rapid cycle times and excellent repeat accuracy of 0.01 mm

per axis, it sets standards in the electronics, consumer goods, and pharmaceutical industries.Intelligent controllers can control both the cantilever arm as well as the actuators without a supe-rior control unit. The software required for this purpose is already integrated. Depending on the component, different positions can be achieved with changes “on the fly”. According to Richard Gross, Project Manager at AERNE, this is an important prerequisite for assembling the individual assemblies efficiently and for being prepared for any future modifications. “In order to achieve such versatility with a pneumatic system, additional intermediate stations and considerably more handling maneuvers would have been necessary”, explains the project manager.

AERNE combines the direct drive Pick & Place units with proven SCHUNK miniature parallel grippers MPG-plus and, in some cases, dynamic, high-performance damped SCHUNK mini speed swivel units SRU. The pneumatic actuators are directly supplied with compressed air via SCHUNK micro-valves, which are integrated directly into the Pick & Place units. On the one hand, this minimizes compressed air and energy consumption, while on the other hand the microvalves allow for the shortest closing times. Meanwhile the gripper fingers have been designed in such a way that they can grasp various components without the need for manual intervention and without damaging sensitive parts of the compo-nents. The grippers are queried via the analog SCHUNK magnetic switch MMS-A, a teachable displacement transducer, which can be directly integrated into the SCHUNK MPG-plus. The sensor is capable of accu-rately detecting the size of the gripped parts and outputting it as an analog voltage value. For Richard Gross, this is not yet the end of the story. “If components with larger geometric deviations have to be handled in the future, we could even integrate an automatic gripper change longitudinally along the Pick & Place units.”

Customized solution

The paths, strokes, velocities, and acceler-ations were accurately matched to within the range of milliseconds in some cases, in close cooperation with the specialists of SCHUNK and in intense detail. For example, with a particularly time-critical station, the time for a complete pick & place cycle was reduced to below 700 ms using a vacuum suction nozzle, including pick-up and storage of the component. “Some of the significant advantages in working with SCHUNK are, firstly, the truly extensive selec-tion of high-performance components, as well as the possibility of changing catalog products individually depending on the respective application”, emphasized Richard Gross. It is exactly this flexibility that makes it possible to tailor solutions such as the assembly line precisely to the needs of the customer. ■

Raphael Schärer (CFO AERNE ENGINEERING) and SCHUNK

consultant Martin Kluge and Richard Gross (Project Manager

AERNE ENGINEERING) (left to right) are well aware that the

complexity of assembly systems will continue to increase.

SCHUNK Pick & Place Gripping Systems

Flexible high-speed assembly wins SCHUNK Competence Award

Equipped by SCHUNK

7

SCHUNK is celebrating a very special anni-versary this year: 70 years of training! April 8, 1947, the company founder Friedrich Schunk introduced the first two appren-tices for the mechanics profession. The lathe that they worked with is still located in the entrance of the SCHUNK training center. Since then, training development has never ceased. In Germany alone, SCHUNK trains 190 young people in successful career development.

The fact that SCHUNK’s education is extremely attractive for young people is based on its first-class reputation within the mechanical engineering sector as well as the size of the company. Even as a global player with more than 2,800 employees, SCHUNK is still so agile that everyone has the opportu-nity to climb the career ladder as a result of excellent performance, even without a university degree. Many of the young people who begin their training at SCHUNK are well aware of this.

70 Years of TrainingHistory, Background and Developments

Attractive training opportunities

SCHUNK offers its own training centers as well as special “apprentice fitness programs” in the first year of training, in-house training programs, active participa-tion in educational and other events. Targeting support for apprentices and students according to their own skills and strengths is an important success factor. Numerous activities within the company are open to you.

Awards

Among others, SCHUNK has been awarded for their first-class training quality of the Chamber of Industry and Commerce, IHK Heilbronn-Franken with the “Dualis - Quality Label”, and with the training label “Top Training Company”. Crucial aspects included creativity, assertiveness, risk-taking and social responsibility. Henrik A. Schunk, CEO of SCHUNK GmbH & Co. in Lauffen/Germany, received a special award from

WirtschaftsWoche and Würth in 2016 for the company’s cooperation with Kaywaldschule, a school for children and teenagers with mental and physical disabilities in Lauffen on the Neckar.

Over the past 10 years, more than 20 apprentices from SCHUNK have been honored as first place winners by the Chamber of Trade or received best places from the IHK. In addition, SCHUNK apprentices have been selected as first and second place appren-tices in the nation five times, and one apprentice was selected as the nation’s best cutting machine operator in training (2011).

These are achievements that both these young people and the SCHUNK team are proud of.After training, there are excellent prospects for permanent employment. The hiring rate of up to 95% speaks for itself. ■

70 Years of SCHUNK Training in FiguresApprentices and students who have trained at SCHUNK to date

Mengen, Germany

Huglfing, Germany

Mataró, Spain

Bangalore, India

1.025

142*

9*

25*

7*

* since its affiliation to SCHUNK

Lauffen/Hausen, Germany

St. Georgen, Germany

Aadorf, Switzer-land

Caravaggio, Italy

Morrisville, USA

Santo André, Brazil

10*

2*

8*

5

3*

1991 -2000Starting point

1999 Start of electronic learning with the first apprentices studying mechatronics

2001 -2005Growth

2001 Opening of the first training center

2006 -2008New horizons

2006 The social com-petence project was initiated. Apprentices complete a two-week social internship start-ing immediately.

1945 -1970

1947 The first two apprentices started a training course to be-come mechanics at SCHUNK.

1945 Start-up workshop

2009 -2011Expansion

2011 Award for training company of the year from the Federal Association for Metal

2009 Relocation to the new training center in Lauffen am Neckar

2012 -the presentSuperior Clamping and Gripping

2012/2016 Dualisaward from the Heilbronn-Franken Chamber of Industry and Commerce

1971 -1990Setting the course

1980 The first commercial apprentice starts at SCHUNK

1990 The first two students began studying business economics.

2016 SCHUNK is now the top training company. Distinguished by the Chamber of Trade.

2016 Award for Entrepreneur with Heart. An initiative from WirtschaftsWoche and Adolf Würth GmbH & Co. KG.

Training

SCHUNK News

1.400 m2 of training area

600 students in school projects each year

200 internships each year

163 apprentices currently across all trainee years

80 people responsible for training in the departments

14 different professions or fields of study

9 Full-time trainers

Training in Lauffen/Hausen:

Founding years

8

2,0 m

1,6 m

XXL and Yet Precise

The training of highly qualified young people is as important to us as a company as it is for young people themselves. It is an excellent investment in the future.

Javier Garcia Gerpe General ManagerSCHUNK Intec S.L., Mataró, Spain

Lathe chucks from SCHUNK are incredibly versatile and offer our customers the highest possible precision.

Milton Guerry General Manager SCHUNK Intec Inc., Morrisville, USA

Large workpieces require even larger lathe chucks. The SCHUNK production facility in Mengen is well-equipped for this. On a V-Tech grinding machine, lathe chucks up to 2,000 mm in diameter can be produced.The optimized solution for set-ups with a focus on high-performance products for the aviation and automotive industry proves the performance of the specialists in Mengen.

For processing forged parts of up to 1,600 mm in diameter, a ready-to-set clamping solution was required, which SCHUNK was able to develop and produce within a short time. Here, the 1,600 kg ROTA Classic P with a diameter of 1,600 mm acts as a clamping station. It is equipped with 28 VERO-S NSE plus modules, on which the clamping device ROTA-S flex 1500 is clamped. The customer benefit: While one workpiece is machined, the other can be pre-machined outside the machine. The operator then swaps the device along with the workpiece using the VERO-S interface. This allows set-up time to be reduced from 2 hours to 2 minutes!

SCHUNK engineer Aaron Gottlieb at SCHUNK Intec Inc, in Morrisville, USA, showed a deep understanding to the customer’s require-ments for flexibility and set-up time optimization. He led planning, realization and the implementation at the cusstomer’s premises while this solution was manu-factured in cooperation with the SCHUNK Competence Center for lathe chuck technology in Mengen, Germany. ■

With the right performance, it is possible to complete part of the training at a SCHUNK subsidiary abroad. It was also possible to export the successful German dual training model to the USA: under the leadership of the SCHUNK Competence Center for lathe chuck technology and stationary work-holding in Mengen and in close cooperation with the Lake Constance Upper Swabia IHK and the German Chamber of Commerce in Atlanta, the dual vocational training program was transferred to the plant in Morrisville, USA.This intensifies cooperation between the individual locations, helping to synchronize processes and to ensure a consistent transfer of know-how between the individual loca-tions.

A successful example of an international university cooperation of SCHUNK Intec Spain. It has been an official training company of the AHK since 2015. There is also an intensive collaboration with many education facilities. Particularly worth mentioning are the EDU (Espana-Deutschland University Studies) and the

FEDA (German Business School). These are the only education facilities that implement the high-quality dual study courses of the AHK.

The dual training concept of SCHUNK Intec Spain stands for job-integrated studies in German, English and Spanish. The duration is a total of three years, in which the dual students pass through all departments and carry out their own projects under the lead-ership of the respective trainer. After the first two years, the students complete the

ROTA Classic XXL Chuck as Customized Solution

training examination of the AHK as indus-trial business management assistants. This is followed by the third year of the qualifica-tion for a Bachelor of Arts in Business Administration.

After this they are top employees for SCHUNK, who have mastered three languages, have vocational training and a completed qualification as well as a great deal of practical experience. Besides the training locations, the Intec Spain offers two apprenticeships in commercial fields and four apprenticeships for technical engineers on average each year. Due to the relocation into the Tecno Campis Mataró-Maresme company complex, they are even closer to the students. ■

Training International

USA | Asia | Europe

Worldwide

9

Editorial staff:Martin WerkmeisterSCHUNK GmbH & Co. KGSpann- und GreiftechnikBahnhofstr. 106 - 134D-74348 Lauffen/Neckar

The editorial staff reserves the right to select and shorten text submissions.

Publisher:SCHUNK GmbH & Co. KGSpann- und GreiftechnikBahnhofstr. 106 - 134D-74348 Lauffen/Neckar Tel. +49-7133-103-0Fax +49-7133-103-2399info@de.schunk.comschunk.com

Just in time for the start of Jens Lehmann’s appointment as co-trainer at Arsenal FC, a smart online format with the No. 1 goal-keeper and SCHUNK brand ambassador will start in August: the “Jens Lehmann Locker Room Conversations” are an entertain-ing mix of celebrity chat and professional knowledge involving top-class soccer and high-tech. Topics of the first episodes, which will run on different online channels by the end of the year, are the fascination with gripping, digitization, internationali-zation, careers, fans, and customers.

A variety of SCHUNK employees will now come to the locker room conversations as conversation partners for Lehmann.

The locker room conversations can be found online at schunk.com/kabinengespraeche. Just a click away! ■

September

EMO09/18 – 09/23/2017Hanover, Germany

CMTS09/25 – 09/28/2017Ontario, Canada

Northern Manufacturing & Electronics9/27 – 09/28/2017Manchester, UK

October

Maktek10/04 – 10/07/2017Izmir, Turkey

TOOLEX10/03 – 10/05/2017Sosnowiec, Poland

Robot Inv. Communication Forum and Exhibition10/04 – 10/06/2017Istanbul, Turkey

Motek10/09 – 10/12/2017Stuttgart, Germany

MSV10/09 – 10/13/2017Brno, Czechia

SEPEM industries Angers10/10 – 10/12/2017Angers, France

SIANE10/24 – 10/26/2017Toulouse, France

Fakuma10/17 – 10/21/2017Friedrichshafen, Germany

MECT 201710/18 – 10/21/2017Nagoya, Japan

KOMAF10/24 – 10/27/2017Ilsan City, South Korea

ETMS10/25 – 10/27/2017Santiago de Querétaro, Mexico

November

Robotics Show11/07 – 11/11/2017Shanghai, China

FMB11/08 – 11/10/2017Bad Salzuflen, Germany

Productronica11/14 – 11/17/2017Munich, Germany

17

Metalmadrid11/15 – 11/16/2017Madrid, Spain

Metalex11/22 – 11/25/2017Bangkok, Thailand

SPS / IPC / DRIVES11/28 – 11/30/2017Nuremberg, Germany

IREX11/29 – 12/02/2017Tokyo, Japan

2018

January

NORTEC01/23 – 01/26/2018Hamburg, Germany

February

METAV02/20 – 02/24/2018Düsseldorf, Germany

March

GrindTec03/14 – 03/17/2018Augsburg, Germany

June

AUTOMATICA06/19 – 06/22/2018Munich, Germany

International Trade Shows and Events List of SCHUNK

Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for safe, precise gripping and holding.schunk.com/lehmann

Imprint

Throw-in

Jens Lehmann

Within one’s Reach: Locker Room Conversation with World-class Goalkeeper Jens Lehmann

SCHUNK begins Online Campaign

Layout and Text:TEAMDREI GmbHHerrengasse 15 – 1974366 Kirchheim am NeckarPrinting:WALTER Medien GmbHRaiffeisenstraße 49 – 5574336 Brackenheim

Trade shows and events

At a Glance