the liebherr group & liebherr-verzahntechnik gmbh · 2 gantry robot lp 100 & liebherr...

The Liebherr Group &

Liebherr-Verzahntechnik GmbH

Martin Winterstein

Director Global Market Sales and Market Service


Kaufbeurer Straße 141

87437 Kempten

International Seminar on Machining Technologies

23 January 2019, Bangalore

Agenda

2

Gantry Robot LP 100 & Liebherr Manufacturing Software 4.02

Pallet Handling System PHS 1500 Allround3

Robot solution with vision system4

The Liebherr Group1

Multifaceted Product Range

3

Liebherr Group

Top left to bottom right: Plant Kempten, Plant Collegno, Plant Ettlingen, Plant Saline

Since 1952 production of gear cutting machines

in Kirchdorf

Founding year LVT GmbH in Kempten: 1969

Productions Sites:

Kempten – Ettlingen – Bangalore (India) – Saline

(USA) – Seoul (South Korea) – Turin (Italy)

Turnover LVT / Division*

2016: 212.5 Mio. € / 219.3 Mio. €

2017: 238 Mio. €

Prime Markets

Germany & Western Europe, South Korea, USA,

China, Brazil

Number of Employees (31.12.2016)

LVT: 1,145

Worldwide: 1,353


At a glance

* Konsolidated within the division

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Global Presence

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Sᾶo Paulo - Brazil

Saline - USA

Moscow - Russia

Bangalore – India

Tokyo –

Japan

Shanghai – China

Seoul –

South Korea

Paris - France

Ettlingen - Germany

KemptenCollegno - Italy

Chongqing – China

Assembly / Production

Sales & Service

Product portfolio Gear Technology Kempten

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DeburringHobbing

ShapingSkiving M/C Automation

Tools

Grinding

Gear inspection

machines and software

New business partner

for extending Liebherr

Product Portfolio

Agenda

7

The Liebherr Group1




Individually configurable software packages

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Production Schedule App

Management of production orders and processes

Part Tracking App

Guarantee of reliable process

long-term logged part tracking

Production Monitoring App

Recording of production and operating data

Info Board App

Display of machine status on

large screen or on mobile end devices

Liebherr Manufacturing System LMS 4.0

Software solution for monitoring and supporting production processes

9

Liebherr Manufacturing System LMS 4.0 (Video)Individually configurable software packages

Cylinder block manufacturing, Beijing China

Highlight-Projects

OEM Automotive, China Resource: MAG IAS GmbH

Benefits

Cylinder block line with gantry robot and friction

roller conveyor (FRB)-design Liebherr

Manufacturing of friction roller conveyor by

Chinese co-operation partner locally =>

maximum cost-efficiency

Automation of all production processes by

Liebherr

Rate of production/Year: 180.000 parts (step 1)

210.000 parts (step 2)

250.000 parts (step 3)

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Agenda

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The Liebherr Group1




Flexibility due to the modular concept

PHS Allround

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Compact20 % smaller footprint

compared to

PHS PRO

Both ends useable

for setting station,

machine interface

or shelf magazine

loading

Quantitiy of connected

machining centres, shelf

magazines and set-up

stations configurable

Front access for

manual loading of

the machine or

maintenance

assignments

- PHS 800 Allround (2019)

max. 800 kg / 630 x 630 mm

- PHS 1500 Allround (available)

max. 1500 kg / 800 x 800 mm

- PHS 3000 Allround (2020)

max. 3000 kg / 1250x1250 mm

Soflex PCS5 pr

PROCAM EMS

Allaround

Intelligent

Modular Dimensions

User friendly

Touch-operation, App based

Increase of the intuitive operation – short training time and period of covational adjustment

Extending of leading functions for the operator – autopilot for necessary operating steps

Visualization of processes and procedures

Modern cell controller

PHS Allround

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Large-sized diesel engine manufacturing, Switzerland

Highlight-Projects

Lift module 1 Lift module 2

Benefits

Expansion to the longest pallet

handling system in the world in several

stages by modular system

Integration of second carriage

Transport weight up to 13,000kg

possible

Rate of production/Year:

approx. 500 parts

Max. load 13,000kg

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Agenda

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The Liebherr Group1




1. Randomly arranged parts in

provided container

2. 3D image recognition system

to identify objects

3. Software identification and

selection of work piece

4. Collision detection with

possible offset

5. Intelligent gripper with

additional axes enables

collision-free removal of parts

6. Precisely positioning of work

piece at a defined location or

in a machine

Process descriptionBin Picking - Intelligent work piece handling

A complex interaction between image detection system, software and robot is

required

1. 2. 3.

4. 5. 6.

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Bin Picking - Intelligent work piece handling

Modular system

Handlingmodul (standard) Output module (customized)

Robot

Gripper Additional axis

Compensator Unit

3D–Vision system

Conveyor (optional)

Options (repacking station, …)

Basic system: 3 x 5m

Required hall hight: 4m

Supplying module (standard)

Bin size1.200x1.000x1.000mm

(LxWxHmm)

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Accurate: Laser run-time

Precise: Laser triangulation

Fast: Stereo vision triangulation

The new intuitive operator interface (HMI)

with graphically guided programming masks

Reach the target in 3 steps:

1) Simply teaching of work pieces, gripper and grip points

2) Fast parameter adjustment

3) Simple configuration of bins

Apply teaching of work pieces, grippers and grip points


Operator interface

Work piece Gripper Grip point

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Typical cycle times - Crankshaft

Crankshaft

(~15kg)

Scan & Calculation

11.0 sec Robot movement

16.0 secCycle time

24.5 sec

Scan and calculation time are partly parallel

Exemplary cycle time for crank shaft Bin

Picking: 24,5 sec

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Bin Picking – Crankshaft (Video)

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Fully automatic line entrance for crankshaft loading

Bin Picking – Crankshaft

Workpiece: Crankshaft

Weight: max. 20 kg

Highlights:

AGV interface

Rotary storage system for 8

different workpiece types

Vision System for part

detection

Liebherr/Fraunhofer Software

Cycle time: 37 sec

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Flexible Manufacturing System for Transmission Case Machining Line

Turnkey System

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Transmission Case Truck

12 & 16 gear shifts

Line cycle time: 120 sec/part

Work shifts: 17/Week

Workpiece: transmission case

Highlights:

Rough Part Gripping based on ENSENSO Vision system (depalletizing)

Marking Station for part identification and tracking, RFID Chip

Part Storage Robot 7th axis, Assembly Station for RFID Chip bases on Liebherr PHS

SCADA-IPC Packages - The system solution for optimizing production by SIEMENS

JIS - just in sequence (outgoing parts in batches)

Thank you for your attention!

the liebherr group & liebherr-verzahntechnik gmbh · 2 gantry robot lp 100 & liebherr...

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