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In Focus - Archive May 2012
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The multi-tooth guided universal gripper PGN plus from SCHUNK is a robust and proven all-rounder.
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05-05-2012 -
In many industries, the increasingly wide range of product variants, the ever-shorter cycle of innovation, and the increasing comparability among products are leading to an enormous pressure on costs. Experts believe that production automation will be one of the keys to business success in the coming years. These issues also apply to gripping systems: the precision, flexibility, speed and reliability of a gripping system has a significant impact on the profit margin which they can achieve. Although pneumatic gripping systems were long considered the state of the art, mechatronic solutions have since made significant strides. As a result, users and system planners are increasingly faced with the question of which drive concept is more advantageous to handling and assembly processes: pneumatics or mechatronics?
Adaptable drives, versatile controller concepts, and the large selection of standard interfaces have made it increasingly easy to integrate mechatronic modules into higher-level system controllers. At the same time, the rapid progress in electrical servo drives are making mechatronic components increasingly attractive from a price and efficiency perspective. As a result, comparing the advantages of the two drive concepts has become an increasingly important step in the process of selecting the optimal gripping system.
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PGN-plus linear direct drive
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The compact PPU-P pneumatic unit from SCHUNK is particularly designed for high-speed applications.
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Pneumatic solutions are robust, have a compact performance, and are easy to operate.
Pneumatic gripping systems have been continuously optimized over the past decades. They are generally fully developed from both a construction and mechanical point of view. Systems such as the multi-tooth guided PGN plus universal gripper, the MPG plus is a roller guided gripper for handling small components, and the most powerful SRU plus swivel unit from SCHUNK, the compentence leader for clamping technology and gripping systems, are powerful, robust and reliable performers for even the most demanding tasks. Pneumatic systems are very easy to operate and maintain, making them well-suited to users who do not have a high level of technical knowledge. Finely graduated, standardized series and a comprehensive range of accessories make it possible to achieve a customized design at an attractive price. On average, pneumatic modules require an investment that is one-third to one-half that of comparable mechatronic modules. Users who assemble only identical parts, who require high cycle times, and who have little mechatronic knowledge are thus well-served by pneumatic solutions. As a rule, only the sealing components of these systems require ongoing maintenance, which also helps users maintain an overview in their maintenance costs. Because of the need for compressed air, their operating costs are comparatively high; however, this can be significantly reduced by the use of micro valves. Nowadays, highly efficient valve solutions are available for many pneumatic modules, from grippers to complete pneumatic pick&place units; these solutions can reduce compressed air consumption by up to 90% while also increasing the cycle time by up to 100%. By these means, pneumatic pick&place units can achieve up to 95 picks per minute with a repeat accuracy of 0.01 mm and high energy efficiency. However, air-operated rotary and linear modules are still poorly suited to particularly large translational movements over approximately 1500 mm, or to high loads over approximately 50 kg. Pneumatic systems remain poorly suited to such conditions. By contrast, electrically driven linear modules (spindle/belt drives) can achieve linear movements up to 8000 mm, and electrical rotary modules can handle loads up to 800 kg.
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The EGA long-stroke gripper can be equipped with many of the conventional servo motors
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Mechatronic solutions are energy-efficient and versatile in their application
Applications that require versatile and adjustable handling are well-suited to the use of electrically driven modules. They offer particularly high versatility: they allow mechatronic grippers, rotary and linear modules to approach non-standardized sequences of intermediate positions with a high level of precision and dynamics. During these processes, the position, stroke, speed, acceleration, force, and torque can all be individually adjusted. This makes it possible to handle a variety of parts during a process. In addition, mechatronic systems can quickly be adapted to handle new part designs. This increases the versatility of handling and assembly processes, and also provides a great deal of flexibility in the introduction of new products, sizes, and equipment specifications. The increasing wide range of product variants also make these systems increasingly attractive. This is particularly the case for applications with a high number of cycles and many gripping processes. In such processes, electrically driven grippers operate with greater energy and cost efficiency than their pneumatic counterparts. Even though the initial investment is usually significantly higher than in pneumatic modules, decreases in the cost of acquisition and operation have led to significant decreases in the amortization time of mechatronic modules. Their performance is now also on a par with pneumatic solutions. Like its pneumatic counterpart, for example, SCHUNK's mechatronic EPG gripper for small components is now equipped with a high-performance junction roller guide, which offers unusually high efficiency and speed while maintaining consistently high gripping force. Even very simple mechatronic modules are equipped with maintenance-free servo motors, which help make the modules extremely compact and reliable. In some cases, mechatronic modules can even be started up or maintained via the internet or a data line.
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The electrically driven EGP gripper for small components can directly replace the pneumatic MPG-plus.
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Switching systems is getting easier all the time
The start-up and integration of mechatronic modules has become much simpler due to factors such as adaptive drives. However, users continue to require significantly greater know-how for mechatronic solutions than for pneumatic ones. While intuitive plug & work concepts will at some point become available for complex systems and high-speed applications, this is not yet the case. However, the compatibility and handling of simple mechatronic applications has improved significantly in recent years. Within its mechatronic series, SCHUNK has developed a group of modules that have made the switch from pneumatic to mechatronic systems easier than ever before. For example, the EGP gripper for small components is comparatively simple to control via a digital sensor distributor. In many cases, users can transfer the sensor systems used in the MPG plus to the EGP, and easily convert existing systems from pneumatic to electrical operation. Similar to its pneumatic counterpart, the EGP can be screwed through and fixed either laterally or at the base, which also simplifies the conversion to a mechatronic solution.
With these rapid advances in mechatronic modules, users and system planners can benefit from a careful assessment of the advantages and disadvantages of different types of drives. SCHUNK offers both pneumatic and mechatronic solutions within what is the world's most comprehensive module selection for gripping systems, which in turn provides users with significant synergy benefits.
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2012-12
New application possibilities for square pole technology
The electro-permanent square pole technology is a part of the magnetic clamping technology, and represents an ideal clamping solution for machining centers. It offers numerous advantages: Workpieces are easily accessible, and can be machined in one set-up from five different sides. It is no longer necessary to spend time on the fine adjustment of clamping elements. Multiple clamping operations of workpieces during the machining process are no longer necessary as well. In addition to milling applications, square pole technology also covers flat grinding applications. Moreover, special display modules increase process reliability and create optimum preconditions for automated loading.
 more...
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2012-11
High-performance automation from the modular system
Those who plan high-performance assembly plants for electronics, medical technology, automotive, or consumer goods industry, know of the challenges, if individual modules and assembly groups need to be linked to an entire system. Missing mechanical joining elements, incompatible controller concepts, or insufficient planning tools influence the planning and implementation processes as well as during the process itself. The variety of combinable system programs can be an efficient alternative - provided they are well thought out in terms of performance, volume, compatibility, and configuration.
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2012-10
Applying strengths in a targeted way
Stationary clamping systems have enormous hidden efficiency and quality potentials for production. Those who want to utilize them, should question, where the strengths of the individual clamping technologies are. If they are selected and combined in a targeted manner, their investment costs can be amortized very quickly.
more...
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2012-09
The underestimated collaborators
In view of sophisticated lathe chucks, clamping blocks with compact performance, and highly engineered devices, the technological possibilities of chuck jaws may seem at the first glance rather limited. In reality, however, these direct interfaces to the workpiece open up enormous potentials: Beside conventionally hard and soft top jaws, a broad range of established chuck jaws ensure that even tricky clamping tasks can be economically solved. An overview shows what is potentially possible.
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2012-08
Efficient concepts for automated machine loading
In the past, automated loading and unloading was restricted to large series, today though, small batches and individual pieces are now standard. The ultimate aim is to reduce set-up involved downtimes and to have as few workers possible manning production around the clock. What is needed, is the sophisticated interaction of innovative clamping equipment and automated components which lead to utmost precision and ensures reliable processes all at the same time.
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2012-07
Consistent maintenance increases precision, process reliability,
and safety of the clamping vises in the long run
Vises used for workpiece clamping in today’s production environments are exposed to extreme conditions. This significantly influences the precision of the workpiece, process stability, and safety for both operator and machine. In order to ensure optimum clamping force, users normally follow the manufacturer’s information on lubrication intervals. Moreover, many more companies are choosing preventive maintenance programs, where the clamping vise is thoroughly tested in defined cycles. This ensures longtime accuracy, minimum wear, and high process reliability.
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2012-06
High performance without chatter
The times when brachial roughing was normal are over. Those who want to produce a lot of chips in a short space of time now take advantage of high-quality cutting and intelligent toolholding systems that transmit high torques and, at the same time, reliably absorb any occurring vibrations. Modern toolholders protect the cutting edges, the machine spindle, and the workpiece surface and allow you to work with high metal removal rates even when using challenging materials.
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2012-05
Pneumatic or mechatronic gripping?
In many industries, the increasingly wide range of product variants, the ever-shorter cycle of innovation, and the increasing comparability among products are leading to an enormous pressure on costs. Experts believe that production automation will be one of the keys to business success in the coming years. These issues also apply to gripping systems: the precision, flexibility, speed and reliability of a gripping system has a significant impact on the profit margin which they can achieve. Although pneumatic gripping systems were long considered the state of the art, mechatronic solutions have since made significant strides. As a result, users and system planners are increasingly faced with the question of which drive concept is more advantageous to handling and assembly processes: pneumatics or mechatronics?
more...
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2012-04
Vacuum clamping technology: an ideal addition to the standard clamping devices
In comparison to clamping brackets, clamping blocks, jaw chucks, quick-change pallet systems, or magnetic clamping technology, vacuum clamping technology is mostly unknown in the metal cutting industry. Nevertheless, vacuum clamping technology can perform a valuable service here, especially when machining thin parts that are susceptible to deformation, or workpieces made of aluminum and other non-ferromagnetic materials. Particularly when they are in the form of versatile matrix plates, they are a useful and easy to handle addition to clamping devices already in use.
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2012-03
Gripping Systems of the future
Mechatronic handling systems offer distinct advantages: They are very flexible, offer numerous intelligent functions, and despite higher acquisition prices, they quickly pay off. Therefore, it is no surprise that the handling issue is becoming increasingly important in the pneumatics dominating world. This particularly applies, since more and more mechatronic components can be easily operated by average users.
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2012-02
Tool extensions with minimal interfering contours
Due to the success of modern 5-axis machines, tool mountings with slim interfering contours have experienced a real boom. With sufficient torque, and high run-out accuracy they allow a deep, collision-free tool path into the workpiece, and thus ensure precision machining, even in areas which are difficult to access. These slim tool extensions are economic, flexible, and can be assembled between tool and toolholder on request. They can be combined with various machine tapers.
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2012-01
Up-to-date support for all gripping tasks
Gripping systems in handling and assembly are often in operation around the clock, seven days a week. Many components have to withstand external influences such as chips, dust, aggressive media or heat. In addition, tight margins and deadlines due to just-in-time production often result in enormous scheduling and planning pressure, usually starting well before the initial commissioning. In view of these challenges, many purchasing decisions are increasingly made based not only on the quality and performance of the modules, but also on the range of services offered. Services increase planning reliability, facilitate commissioning and ensure maximum cost effectiveness during operation.
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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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