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In Focus - Archive November 2011
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By using modular systems, more than ten thousand application variants can be implemented.
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11-01-2011 -
When designing gripping systems for handling and assembly applications, standardized modular systems will play an increasingly important role in the future. They reduce the necessary time for project planning and commissioning, and lower the investment costs. Due to the standardization, they offer optimum preconditions for stable processes. Since modular designed units can be flexibly modified and enlarged, they can be re-configurated for any changes that come up in the future.
Modular systems are based on standardized individual components, which can be combined in different ways to form a whole. A basic precondition are standardized interfaces, which ensure that the modules are compatible. If the systems are consistently modular in design, they can offer numerous advantages: They lower the machine’s complexity, shorten the project planning time, lower the development and manufacturing costs, simplify assembly, commissioning, maintenance and repair, and can be quickly adjusted to the changing conditions and tasks.
What are the details a user should pay attention to?
Over the past few years in the field of gripping systems, a trend to modular systems can be observed. Some manufacturers are limiting the idea of a modular system by offering a limited number of actuators, which can be flange-mounted via a unique interface to gantries or robots. Often modularity won’t work, if components have to be mechanically connected. Therefore it is appropriate to consider several aspects if a modular system is chosen:
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Volume of the program, accessories, energy-efficiency: When choosing a modular system, it is worth paying attention to important aspects.
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Scope of the module program:
How big is the selection of modules for gripping, rotating, and translational movements? Which sizes, weights and movement ranges are covered? Which drive types does the program comprise? What kind of performance does the modules allow? Is the systematic of the program easily understandable? Is it easy to choose the right module? Does the program also include connecting and add-on elements?
Compatibility of the module program:
Do the modules have uniform interfaces?
Control of the modules:
How are the modules controlled? How difficult is the integration into subordinated machines/plants?
Project planning:
Does the manufacturer offer CAD data for every module? Are there planning-/design tools available which will facilitate the selection of the right module?
Pre-configured assembly groups:
Does the manufacturer already pre-configure the components to assembly groups?
Energy-efficiency:
How high is the energy consumption of the modules? Are all the offered possibilities consistently used for saving energy, such as lightweight solutions or valve technology?
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Everything should match each other within the modular systems.
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Ideal for simple applications: modularly structured, pneumatic Pick&Place units.
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Adapter plates, pillar systems and software tools are useful accessories
Basically, modular systems should be designed in a way that system integrators, plant designers, and users have minimum planning, design and commissioning efforts, along with the utmost flexibility and variety in configuration, cost-efficiency, flexibility and safety. In addition to the actual modules for gripping, rotating and linear motion, a modular system should also dispose of a continuous system of adapter plates and stable pillar profiles, which allow a free, precisely fitting, safe and stable combination of each component. It would be ideal, if intermediate designs could be directly downloaded as a useable CAD model.
Additional software tools can be a valuable help for facilitating the design work and selection of the components. They show which modules can be combined with each other, and which adapter plates, centering, and standard parts are required for assembly. In the ideal case, the tools automatically calculate the position co-ordinates of the modules, and simplify their design. Meanwhile solutions are now available which calculate the guide loading, cycle times, and for pneumatic modules the degree of utilization of the hydraulic end positions. This will lead to the full use of the individual component’s performance, and costly overdimensioning is avoided.
Complete gantries from the modular system
A very young variant of the modular system’s principle is the modularization of complete assembly groups. With the modular system for line and room gantries, project planning, assembly, and commissioning times are cut in half without having to lower your sights in functionality, performance, durability or precision. The "efficiency lever" occurs in laborious small steps, which are necessary for a complete configuration of the assembly groups: project planning, engineering, warehousing, logistics and assembly. Instead of taking care for connecting elements, plug connectors and cable feed-throughs, the plant designers and system integrators can focus on the actual process with the help of such a modular system. Special systems are only needed for challenging applications. The other 80% of applications can be covered with standard solutions, which are pre-configured from high-quality single modules to complete assembly groups. Every unit, no matter if pneumatically or electrically driven, are already assembled prior to delivery. In case of pneumatically driven gantries, the chief concern is the energy chain, the sensor system and all the necessary mechanical connecting elements. In case of the electrically driven gantries, the servo drives, energy chains, and the sensor system are integrated, and all the necessary mechanic connecting elements as well.
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Modular linear direct drive
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In the modular gantry system from SCHUNK complete assembly groups are supplied.
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Complete modularity
SCHUNK, the competence leader for clamping technology and gripping systems is a pioneer when it comes to complete modularity. The world’s largest modular system for high-performance assembly comprises of more than 7,000 combination possibilities for designing innumerable applications for handling small components and assembly automation. Via an adapter plate, most of the gripping modules from SCHUNK can be connected to the modular system. In this way, tens of thousands application variants can be obtained, ensuring highly-accurate reproducibility every time.
But the innovative family-owned company goes one step further with its modular system for line- and room gantries. Five standard assembly groups form the basis: a pneumatically driven line gantry, two electrically driven line gantries and two electrically driven room gantries. The stroke lengths are graduated in practice-orientated steps, and can be individually adjusted to the particular application. The pneumatic gantries are designed for a payload of up to 5 kg. Electrically driven gantries are available for payloads up to 10 kg or 20 kg respectively.
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2011-12
Clamping solutions for automated mass production
Efficient manufacturing means automated manufacturing. This particularly applies if large series are machined. This is when the clamping vises, which are the direct interface to the workpiece, playing an important role. In only a few seconds, they have to mount the components, safely and precisely align them, clamp them with-out deformation, and after machining they have to be reliably released. In view of the several million clamping cycles, which have to be carried out by many clamping vises being exposed to chips and coolant, process reliability is one of the decisive factors of success.
 more...
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2011-11
Modularity the factor of success
When designing gripping systems for handling and assembly applications, standardized modular systems will play an increasingly important role in the future. They reduce the necessary time for project planning and commissioning, and lower the investment costs. Due to the standardization, they offer optimum preconditions for stable processes. Since modular designed units can be flexibly modified and enlarged, they can be re-configurated for any changes that come up in the future.
more...
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2011-10
Producing more efficient
For a number of years, everybody was talking about the energy efficiency issue. Increasing energy costs, a growing environmental awareness, and the political guidance were all triggers for many companies to highlight the energy consumption of machines and components in their communication with the public. Efficiency is much more than simple energy efficiency now, especially when considering the
time- and cost aspects in regards to efficiency. When all these factors have been considered in a holistic way, the full potentials for modern machining and production become visible. The modern clamping devices and gripping systems make it clear how complex the possibilities are.
more...
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2011-09
Welding demanding materials crack- and pore-free
Laser welding technology is second-to-none, regardless of whether you are dealing with gears and injection molds or delicate and challenging welding works. When conventional cw lasers and many Nd:YAG-lasers reach their limits, modern process strategies can help to machine demanding welding metallurgies, different types of materials, or micro components process reliably and efficiently. Laser welding is particularly used if components have to be joined at a high welding speed, because slim welding seams, and a low thermal distortion are required. Compared with other welding techniques, the energy during laser welding fully penetrates into the material.
more...
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2011-08
More than a "Stopgap":
Intermediate sleeves ensure safe clamping and precision
They appear to be unimposing - but they are located at a decisive interface in the chain of the metal cutting process. Between toolholder and workpiece, the intermediate sleeves influence reliability and precision of the clamping operation. The thin-walled, mostly slotted precision sleeves cover the difference between the clamping diameter of the toolholder, and the workpiece which has to be clamped. Functioning like reduction inserts, they multiply the fields of application of the toolholders or arbors, compensate tolerances, and ensure safe and gentle clamping of gear wheels. The newest sleeve design can do even more. Intermediate sleeves with nozzle effect extend the tool service life and increase the volume machining.
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2011-07
Changing, machining, compensating -
current trends in robot accessories
In dealing with industrial robot efficiency cycle rate and process reliabilty largely depend on their front ends, the grippers and other tools, but also from the effectors’ interfaces to the robot arm. Robot accessories have a great influence on the robot’s performance, flexibility and fields of application. Latest developments of quick-change systems, driven tools, compensation units, and power sensors show that the potentials of modern accessory components are enormous. Experts assume that their importance for handling, assembly and manufacturing will continuously increase.
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2011-06
Deformation-free clamping:
From the plastic chuck jaw to the hybrid chuck
In case of rings, housings and other workpieces which are highly deformable dur-ing processing, conventional 3-jaw chucks quickly reach their limits. If the clamping forces are too low, there is no secure hold. If they are increased, workpieces de-form, and precision is reduced. A comparison shows the alternatives, the differ-ence between them, and how users can achieve an optimum result.
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2011-05
Service robotics is the future key market
Insiders are convinced that golden times lie ahead for service robotics. Around the world companies and institutes have recognized the potential of robots as helpers for humans, and are working on everyday solutions. All different kinds of businesses are interested in service robotics, from large companies, to innovative startups, and also conventional manufacturers of industrial robots, electronic and automation components.
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2011-04
Having set-up times under control
You cannot earn money with a turned off machine. However, in many companies the workpieces are still set-up in a complicated and time-consuming way on a grooved table while the plant is turned off. But solutions exist, which optimize the machine tool load. Modern quick-change pallet systems demonstrably accelerate the machining process, and at the same time, ramp up the precision and process reliability score. This leads to a reduction of set-up costs of up to 90%.
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2011-03
Toolholders for micro cutting
Clamping tools used for micro cutting have their own rules. The subtle tools, the high spindle speeds, and the extreme precision requirements are a challenge for every tool manufacturer and user. Those who want to achieve continuously precise results, need mountings with a high run-out accuracy and balancing grade. Moreover, they should be as slim as possible and resistant to dirt. Furthermore, they have to assure that even small tools can be precisely adjusted and exchanged.
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2011-02
Leight-weight design increases efficiency of Gripping Systems
Light-weight modules are now playing an increasing role in the area of gripping systems. Integrated into the system, they are saving energy at the same efficiency, or achieve a considerably higher efficiency at the indentical energy consumption. In both cases, the efficiency of the whole system is increasing. This is why the lightweights are so interesting for plant manufacturers, system integrators, and users. Since light-weight solutions had the reputation of being overly expensive in the past, recent developments now show that efficiency and cost control can go hand-in-hand. Modern designs, materials and techniques are paving the way to lighter solutions, which are rigid and robust, too. This also offer many more advantages.
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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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