Automation

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Buck Harmon
7 years ago
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1 Automation

2 Flexible Robotic Automation for Machining Centers and Pallet Management Systems Inteligent Production Systems from ALZMETALL offer flexible, tailored, customer specific robotic automation with inteligent engineering. ALZMETALL Robotic Solutions are your competitive advantage Global competition continues to demand more productivity to reduce labor cost per part. Only optimised production processes offer economic competiveness. Example: Robotic link for 3 ALZMETALL machining centers 24/ / - 7 Productivity Escape the vast cost increases for 24-7 prodution by increasing the effective production time of your machine. Higher Productivity by adding unattended machining time. Batch oriented loading to reduce the overall need for attended load/unlad periods. Direct operator support is minimized and thus provides an exceptional high savings potential. Improved operator safety and higher operating ergonomics offer better operator protection and even lower health risks. Machine run-times and loading/unloading or part change over times are sperated and easier optimized. Time blocks and flexible load/unlaod areas are created with space optimized pallet buffers Highly specialized operator and programming functions are easier accomplished by flexible robotic machine linkage Multi Shift Model Examples Model A Day shift: Attended machine operation with highly specialized operator-/ programing-/ and set-up personnel. Other shifts: Fully automatic, secure machining cycles from workpiece buffer during a low labor operation, or even lights out mode, to dry run the cell. Model B Day shift: Attended machine operation with highly specialized operator-/ programming-/ and set up personnel. Time Parallel loading of the ready set workpieces via pallet buffer by the robot Other shifts: Fully automatic, secure machining cycles from workpiece buffer in late shifts, or weekend and holiday shifts. Buffer optimized for long unattended machining periods. Freely customizable for multi shift models

3 Flexibility without limits Your overall workpiece variations demand: Serial-type workpiece production (Identical or simlar parts) Parts with short program cycle times (High rate of workpiece exchanges) Parts with complex part cycles, or long part run times, high demand for operater attention during fully attended shifts and low manned shifts for simple parts, or simple part cycles. Setup and changeover operation during the day-shift. Completion of long part cycles in late or night shifts Direct loading of machines for rush orders Robot in switched off idle position. Direct access to the work piece Direct access to the work piece Easy access without hurdles Operating personnel has access to the machine Ideal floor level acces, completely unobstructed in manual mode; Robot is in idle-position and switched off. Operating Personal has full access to the machine and part. Safe and Simple Access for inspection and interuption. Operating personal has access to the machine in manual mode. Parallel robot operation with load/unload functions from pallet buffer system by safety zone speration for work areas, with safety intergrated doors or functions. Machine access with parallel robot operation

4 PowerCell BASIC Single Machine-Robot-Cell with Palett Management System The Components ALZMETALL CNC machining center Robot, (Fanuc or Kuka) with Load capacity ranges 1) from 50kg (110 lbs) up to [1000kg (2200 lbs)] Multi Level Pallet Buffer System, Buffer stations to customer order Number of buffer stands Total number of pallet positions Load/unload station ALZMETALL CNC Machining Center GS 1000/ 5-T with Robot Pallet management system Safety fence with safety controlls PowerCell TWIN Basic units as per PowerCell BASIC plus Robot and pallet management system, to integrierte 2 CNC machining centers Palet buffer system Pallet buffer system - Status display PowerCell TRIPLET Basic units as per PowerCell BASIC plus Robot and pallet management system, to integrate 3 CNC machining centers 1) Load capacity is total weigth for part, fixture, pallet and robot gripper unit [] Option, 700 kg (1540lbs) standard Load/Unload Station

5 Interface Machine Work Piece Direct part transfer in the part specific fixture on the machine table/reciever, or Pallet change system with o-system clamping. High workpiece accuracy and short change over times. Standardized system to handle a large varity of parts Adapted O-clamp system (EROWA, SCHUNK, STARK, System 3 R, Vischer & Bolli) added to the machine table Or O-point clamping system integrated into machine table Direct part tansfer Pallet Management System Module HFG-20 Manual mode Load/Unload of the pallet buffer is controlled by the controller of the robot Automatic mode Pallet-Workpiece exchange between CNC machining centers and buffer storage positions Adapted O-point clamping system Pallet-Workpiece exchange is pocket coded in programmed sequence with the CNC-control of the machining center. Pallet pockets are freely selectable. Pallet and pocket status information display via Robot programming unit Integrated O-point clamping system as the machine reciever PowerCell TWIN

6 Pallet Management System Module SKA-24 Load/Unload of the pallets in automatic mode, fixed pallet location, first in / first out or via programable sequence. The pallet-part transfer to the machining center is performed during automatic mode Alternative Modified activated table mode (grouping mode). The handling, of the pallet-part exchange to the machining center and is handled automatically in a closed loop cycle. Palet Management integraged into the CNC-Control Fanuc Operating Module The pallet management is controlled by the CNC control Siemens 840 D of the machining center Part changer with twin robot-gripper When using a double gripper unit (twin gripper) at the robot for the pallet/part change cycle die unproductive time of the machining center is further reduced by up to 40% Robot with twin gripper Flexible, Automated Machining Center With Linear-Gantry-Robot Automated solutions for machining centers with gantry robot from ALZMETALL deliver highly productive custom solutions The part exchange is accomodated via direct part interchange, or parts are fixtured on a pallet loaded into the machining center Flexible Individual Machining Center Loading by one portal robot VLarge Volume Manufacturing Integration of three of more machinng centers with one linear gantry robot for large production volumes Linear-Portal-Roboter Advantages in ergonimics and operator safety 24/-7 Productivity Escape the never ending cycle of increasing labor cost, with effective production time increase, utilizing the machine idle times. Gain machine utilization time by low man power or lights out operation. Great savings potential with automatic part exchange (load/unload) when compared to manual loading. Separation of productive machine run time and part load times Separation of laod area, buffer storage and machine in terms of time and location Optimize operation and programming for multi machine cells for operators and programmersl Freely programmable models for shift operation

7 Pallet Change System PW-Flex A low cost, highly flexible automated solution is the pallet change system PW-FLEX from ALZMETALL: The pallet changer is released and moved aside with a few simple operating steps, performed in the operating area of the machining center Easy, unobstructed floor level access for manual set up functions is gained. When locked into operating position at the machining center automaitc palletized operation is activated Different configurations to customer specific needs. As standard soluttion the pallets are loaded on a turnable loading station parallel to the machine cycle. Upgrade Level I Preparing of a number of pallets exchanged using the single load station shuttle PW-FLEX Upgrade Level II For multi-pallet systems the pallet exchange is handled direct to the table and is combined with pallet buffer configurations. The pallet change system PW FLEX from ALZMETALL is esay to retrofit anytime to the GS 1000 machining centers Easy access for the operator Pallet change mode

8 T How profitable is more automation for CNC machining centers YThe total time potential per year is 8760 hours 8760 Std. For one-shift operation: The effective operating time is about 20% of the time available The operator is utilized only 1/5 of his time potential Return on Invetment By automation of the machine the effective spindle time of your machining center is increased by 50 % with dry-run cycle model after shift end with additional 4 hours. 100 % for an lights out 2-shift model up to 200 % for an effective 3-shift model without increase in labor cost Effective spindle run time Maschine idle times shift-model YYYMaximize your return on investment by increasing the effective spindle run time with flexible productive automation Machning Center GS 650 Machining Centers CS 600/ CS 1200/ CS 1200 P ALZMETALL Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH & Co. KG Representation in North America by: Metal Cutting Solutions, Inc W. Kemper Rd. Cincinntati, Ohio Phone: info@mcsshop.com Technical Ddetails and Vvolume are subject to change without notice. All rights are reserved. Copyright 2010, for details and information contact Metal Cutting Soltuions, Inc.

CIM Computer Integrated Manufacturing

CIM Computer Integrated Manufacturing INDEX CIM IN BASIC CONFIGURATION CIM IN ADVANCED CONFIGURATION CIM IN COMPLETE CONFIGURATION DL CIM A DL CIM B DL CIM C DL CIM C DL CIM B DL CIM A Computer Integrated Manufacturing (CIM) is a method of