> AUTOMATION Modular effi ciency
A super precision, high speed gantry loaded, twin spindle turning cell with a maximum turning capacity of 40mm and a gantry loading system that runs at 154m/ minute is able to achieve a load/unload time of under six seconds, most of which can be overlapped within the cutting cycle.
The modular designed Ocean Cincom GN-3200W cell, available through Citizen Machinery can also be specified with a single spindle, one or two saddles and with a choice of fully integrated multiple pallets for extended unmanned running operations. Further extending the
flexibility of the fixed head, twin spindle machine for automated production of single part types or ‘family’ ranges of components such as those required in high precision bearing or fuel injection production, the Ocean Cincom GN-3200W has a programmable double gripper
gantry integrated to form a self-contained, fully automated turning cell. With this arrangement, production can be set for optimum productivity by duplicating the same cycle at each independent spindle or perform first and, through an integrated turnaround unit, provide a second successive operational cycle to machine both ends and deliver a fully completed part. Each 2.2kW, 8,000rpm spindle is serviced from its own 2-axis platen-based tooling platform each able to accommodate up to five tools. Due to its non- turret indexing requirement, this platen arrangement is able to carry additional functions such
as ganged or combination tools and high speed driven tools that can be supplied by Citizen Machinery UK as an option. Two entry doors with adjacent removable hatches provide easy access to the machining zone and to the pre- and post-machined components held on pallets. Such is the configuration of the two double gripper component handling units that the high speed loading action, which typically takes just six seconds, can be effectively overlapped within the production cycle.
The compact design of the Ocean Cincom GN-3200W turning cell requires a floor area of just 1.4m by 1.48m with a focus on maintaining thermal stability and providing long- term production consistency. Its construction helps to eliminate any influence of vibration that could degrade the achievement of a fine surface finish especially when used for hard turning applications. Tool
Lay it on the line
Kuka Systems, in conjunction with Bombardier Aerospace, has devised an innovative robotic cell for laying up dry carbon fibre material as a result of a national R&D project.
The robotic automation solutions provider took part in the one year i-Composites programme run by the Technology Strategy Board. Kuka together with other project partners Loop Technology and Güdel, formed part of a wider consortium looking at ways of developing affordable composites manufacturing technologies.
The robotic cell developed during the project focused on its potential use in future wing production and is currently being trialled at Bombardier in Belfast. It aims to process dry carbon fibre material more quickly and efficiently than the existing method.
Depending on the size and profile of the wing structure, up to 200 plies may need to be put in place, which can be time consuming due to the material’s flexible nature and tricky application technique. The robotic cell features a 12m by 1.5m gripper matrix which comprises an array of vacuum suction cups. These pick up a flat ply and transport it in the gripper along a gantry system to the mould tool. The gripper array then reconfigures to a contoured form before placing the ply accurately into the mould. Furthermore, the number of suction cups activated can be altered to suit different ply sizes.
Once the laying up operation is complete, a Kuka KR30 robot with twice the reach capabilities of a standard model picks up an end effector equipped with a vision system and travels along a linear track to inspect multiple
pre-programmed locations on the preform. The camera checks the edges and weave angle to ensure the plies are positioned properly and within the correct tolerances. An alarm is triggered if an error is detected. The robot then returns to the workstation to replace the end effector with a similar tool containing an induction iron. It is used to tack the plies together in preparation for the preform to be processed further.
“The cell was completed within the year and we are extremely pleased with its performance during this early development phase,” comments Gavin Campbell, director, design engineering and technology department, Bombardier Aerospace, Belfast. “With further development and trialling we believe there is an opportunity for future application on aircraft wing programmes. The technology may also be attractive to others working in the field of composites such as the marine, automotive and sustainable energy sectors,” he adds.
Mark Schlanker, business manager at Kuka Systems says the cell has also been designed to deliver more efficiency to the laying up and tacking process with the option to add more robots at a later date.
> KUKA
www.kuka.co.uk
Production Engineering Solutions • January 2012 39
life, even on difficult to machine materials, will also benefit from the inbuilt rigidity and help to maintain cost-effective consistent production cycles when processing high tolerance precision parts.
Both spindles are able to accommodate diaphragm chucks or pull-back collet
chucks. Control of the machine and loading system is via a fully integrated Fanuc unit and all service items for the machine and automation are easy to access.
> CITIZEN
MACHINERY UK
www.citizen-miyano.co.uk
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60