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In Focus - Archive July 2008
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The gripper is connected to the machine like a toolholder.
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07-01-2008 -
Modern machining centers are used for machining of workpieces with maximum feed rates, minimum tool changing times and optimum cutting speeds. In comparison with these parameters, manual tool changing seems like a spare wheel on a Formula 1 racecar. It slows down the entire system.
A significant potential for increasing efficiency in modern machining processes is the automated loading and unloading of the machines. The spectrum of possibilities ranges from a convenient robot to an economical gripper with a spindle interface. In large batch production, it is worthwhile to use gantries, robots and horizontal conveyor systems for changing workpieces. For small quantities, however, such solutions are often inordinately expensive. Before deciding on a system, therefore, it is worthwhile to determine the actual requirements and then to adapt the automation solution accordingly.
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Efficient: Grippers with a spindle interface
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An attractive and efficient automation solution for the production of small batches and single parts with the use of machining centers is the gripper with a spindle interface from SCHUNK.
The gripper is connected to the machine spindle in the same way as a tool via the standard interface and allows fully automatic changing of the workpieces by means of the axial movements. This eliminates the need for expensive automation solutions and also reduces set-up times.
Industry Award 2008 for spindle gripper
In April 2008, the business organization "Initiative Mittelstand" distinguished the gripper with a spindle interface from SCHUNK with the Industry Award 2008. The jury was convinced by the product’s high utility value and innovative features.
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Innovative solution for mid-sized companies: the gripper with a spindle interface enables easy and cost-effective automation.
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Machine axes change workpieces
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The workpiece is changed within the machine room.
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The gripper with an interface for the tool spindle is placed in the tool magazine like any other toolholder. At the beginning of a cycle it is changed onto the machine spindle, after which the machining center moves on its own axes to a magazine on the machine table, where it grips a part and places it in the machine’s clamping device for machining. Then the gripper is placed in the tool magazine. After machining, the gripper is changed, the finished workpiece is transported back into the workpiece magazine and the cycle starts again. This process enables fully automatic workpiece changing.
Axial compressed air from the machine spindle or cooling lubricant up to 60 bar through the internal high-pressure cooling system can be used as actuating media for the gripper. The grippers are available both as PGN-plus two-finger parallel grippers and PZN-plus three-finger centric grippers. They are available with standard HSK, Capto and KM interfaces. Other interfaces are available on request.
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Wireless sensor ensures controlled production
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Monitoring of the gripper status provides for highly controlled production using the gripper with spindle interface. For this purpose, it is recommended to operate the gripper in combination with the RSS wireless sensor system from SCHUNK. Two sensors on the gripper are monitored by a wireless transmitter, which is also provided on the gripper. The information from the sensors is transmitted via a wireless link to the receiver in the control cabinet, from where the signals are sent to the SPC. The transmitter is equipped with a lifetime battery and is therefore maintenance-free. Distances of up to 30 meters can be covered with the RSS.
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Individual: Gantry solution with standard modules
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SCHUNK modules enable a multitude of solutions.
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Gantry solutions for automation of machining centers are based on the principle "as much standardization as possible, as much individuality as necessary".
Numerous SCHUNK standard components are mutually compatible. They can be combined to form diverse functional units or integrated as component solutions in automation systems. The result: customized, well thought-out and cost-attractive systems. At SCHUNK the individual interfaces are intelligently designed to work together. This ensures maximum precision, reduced set-up times and efficient production processes.
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Simple control via the machine
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The precise and robust linear axes from the System HSB can easily be controlled.
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High-efficiency linear axes from the SCHUNK System HSB provide for maximum positioning accuracy together with a high load capacity and a long service life. They enable gantry solutions in a wide range of sizes and variants.
Linear axes offer significant advantages in the automation of machining centers where
- only two to three degrees of freedom are required;
- the strokes are larger than 1.5 m;
- pick and place tasks are carried out with one pick or one place position.
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Only one of countless examples for a gantry solution from SCHUNK.
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In combination with the extensive line of gripping modules, rotary modules and robot accessories from SCHUNK, it is possible to create robust and extremely reliable automation solutions.
Generally, only two to three additional regulators are needed in the control cabinet for integration of a gantry solution in a machining center controller. A separate controller is not necessary. Also, the user needs no additional knowledge of robot controllers. Gantry solutions are therefore a cost-conscious alternative for convenient, customized automation.
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Perfect connection to the machine table
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The SCHUNK UNILOCK NSA SF quick change pallet system is a well thought-out versatile automation module.
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The SCHUNK UNILOCK NSA SF quick change pallet system provides a perfect connection between the machine table and the workpiece. Air purge, system control, maximum repeat accuracy, maximum absorption of tilting and turning moments, as well as ejection and media transfer are integrated in a single station.
Reference-precise centering is achieved by four variable short tapers, which can be adapted to different pallet sizes for optimum compensation of tilting and turning moments. Forced air flow cleans the short tapers during automated pallet changing, therefore ensuring an absolutely flat work surface.
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Convenient: Robot-assisted workpiece changing
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The pallet rack and robot are integral components in state-of-the-art machining centers.
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Robot-assisted machine automation is without a doubt the most convenient option. It enables maximum versatility and speed. The robot makes use of intelligent concatenation not only for the actual workpiece handling, but also for additional, parallel production time tasks, such as cleaning of parts, marking, measuring or chamfering.
In robot solutions, a pallet magazine generally provides for continuous feeding to enable highly efficient production around the clock with no manufacturing downtimes. The workpiece pallets are prepared at a set-up station outside of the machine, then placed in the pallet magazine, where they are automatically gripped by the robot. The pallets can be loaded with a wide range of workpieces and clamping devices. Robot solutions are suitable for small and mid-sized batches, but also for versatile one-off production.
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Maximum versatility
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The robot provides for reliable changing and performs additional tasks parallel to machining.
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Compared with the gantry solution, the robot offers maximum versatility and mobility. For example, the pallets can be turned after machining to remove swarf. The automation of additional tasks by the robot is convenient and efficient. Especially in the event of major deviations in the utilization of production capacities, unattended production allows maximum leeway in planning.
Restrictions associated with the robot solution are the relatively high price, the significantly higher space requirements and the additional skills required for operation of the robot.
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Conclusion: Use SCHUNK SYNERGY
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All three variants are valid in their own right. Which automation solution is the best depends on the individual application. It is necessary to carefully weigh the costs and advantages of the various solutions.
In any case, precise matching of the individual components is very important for reliable use of any automation system. As a complete provider of workholding/toolholding and automation technology SCHUNK optimizes the critical interface between the machine and the workpiece, to ensure optimum machining results and maximum controlled production.
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2008-12
Quick jaw change brings flexibility and substantial savings
Flexibility in production is a crucial competitive advantage. Only companies that can respond to demand with flexible yet absolutely precise production can supply their customers rapidly with a constantly increasing variety of products without needing to build up expensive and inefficient stocks.
 more...
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2008-11
Pneumatics or mechatronics? … It all depends!
To date, pneumatically driven gripper modules have been used primarily in gripper technology. Recently, however, more and more electric grippers have been coming onto the market. Both competing systems have powerful arguments in their favor.
more...
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2008-10
High-Performance-Cutting (HPC)
Hard on the outside, clever on the inside: Toolholder systems developed especially for HPC that have strong rigidity as well as good vibration dampening provide clear benefits for HPC.
more...
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2008-09
Cleanroom
The importance and the use of cleanrooms in assembly and handling are constantly increasing.
more...
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2008-08
Clamping Force / Torque
We are frequently confronted with torques on a daily basis, even though we do not recognize them as such.
more...
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2008-07
Convenient robot or attractively priced spindle gripper?
A significant potential for increasing efficiency in modern machining processes is the automated loading and unloading of the machines.
more...
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2008-06
Polygon clamping technology - round pegs in polygonal holes
The principle behind polygon clamping is surprisingly simple. The know-how that makes it work is however highly advanced.
more...
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2008-05
Packaging
A package for everything
Packaging is a universal function that is required in practically every industry and meanwhile is so important that it has become a separate industry itself.
more...
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2008-04
Magnetic clamping technology has strong attraction
Workpiece clamping with electroermanent magnets reduces set-up times by up to 50 percent and brings about significant advantages especially in the manufacture of large parts.
more...
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2008-03
Quick-change systems speed up production
Changing systems for components such as grippers and tools add a high degree of flexibility to production processes
more...
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2008-02
Vibration damping
Improves surface quality and reduces wear on the tool and spindle.
more...
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In Focus - 2013
In Focus - Archive 2012
In Focus - Archive 2011
In Focus - Archive 2010
In Focus - Archive 2009
In Focus - Archive 2008
In Focus - Archive 2007
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