APPLIED TECHNOLOGY MOTION CONTROL KUKA ROBOT AUTOMATES LOADING OF CNC MILLING MACHINES
With a need to meet the growing demand for its products and to shorten lead times, linear motion expert HepcoMotion recently invested in a KUKA robot to automate the loading and unloading of one of its CNC milling machines. The move to automation was a natural step for Hepco’s manufacturing capabilities, following a successful year in 2016. Still in its first year at Hepco, the KUKA KR 10 R1100 sixx (KR AGILUS) is enabling Hepco to machine overnight, and subsequently increase production and shorten lead times on its standard products. Based at Hepco’s headquarters, in Tiverton, Devon, the RoboDrill T21i
CNC milling machine using the robot is producing carriage plates for Hepco’s portfolio of products. Hepco offers over 42 product lines, with thousands of individual components in various sizes. Each linear and rotary product requires a carriage plate and therefore, the robot needs to be able to work with differing sizes and materials. In this application, the machinist loads the sawn blanks into a carousel,
the robot then picks a sawn blank and loads it into the CNC machine. The machine carries out the drilling and milling work, and the robot then returns the finished carriage plate to the exact space it was taken from. The robot movement and carousel is controlled via Omron PLC control. Thanks to its robust design, the KR AGILUS sixx achieves optimum
repeatability and continuous precision. With its extreme speed, it reduces cycle times and increases production quality, without ever getting out of step. There is space for 84 plates to be loaded in the carousel – with six stacks on the carousel each containing 14 plates. The cycle time depends on the size of the carriage plates but can be between nine and 14 minutes per plate, including the robot changeover time. Depending on the product, the complete batch cycle time is between 13 and 21 h ours. Over a prolonged period of time, and working nights and weekends, this autonomous process offers increased efficiency. The robot has enabled Hepco to increase production to put more products in stock, ready to provide quick delivery times. The carousel holding the metal plates is made from Hepco’s PRT2 ring
guide, and this is indexed through the Omron HMI PLC control to turn as necessary in order to rotate the un-machined plates for the robot to pick up. This ring system has an integrated rack and pinion drive and offers complete 360°, or segmental motion, allowing the table to be indexed to the correct station with repeated accuracy. With a load range of up to 9,300N, PRT2 can cater for a range of applications.
The KR AGILUS sixx achieves optimum
repeatability and continuous precision. It reduces cycle times and increases production quality
more quickly and to keep pace with the growing demand of Hepco’s products. The ability to run overnight without a machinist present has certainly achieved this. With branches and distributors in 41 countries, Hepco continues to employ new technology to its experienced manufacturing capability.
HepcoMotion
www.hepcomotion.com,
HOW TO INSTALL SB SERIES POWER-OFF BRAKES
Thomson Industries, manufacturer of mechanical motion control solutions, has released an educational video for design engineers, illustrating how to properly install its SB Series power-off brake. Thomson’s SB Series is
The carousel and robot are situated next to the CNC machine behind a safety cage, made of Hepco’s MCS aluminium profiles, to ensure the safety of the workers. In implementing a robot cell, one of the major considerations is the safety of operators and people working in the area. Guard doors are interlocked with safety gate switches so that control power to all moving parts is isolated prior to opening the guard doors. The sliding safety doors, connecting the robo cell and the CNC
machine, are fitted with Hepco’s DAPDU2 dual action linear actuator - a double acting system that is suitable for driving automatic doors in a variety of manufacturing applications. The doors are constructed using MCS aluminium profiles, and the two carriages run symmetrically and open simultaneously, achieving speeds up to 6m/s. The double acting system allows two narrower doors to be used, therefore the physical space required is kept to a minimum. Access to the CNC machine is therefore available to use quicker. The need to automate was driven by the requirement to fulfil orders
6 FEBRUARY 2017 | DESIGN SOLUTIONS
designed as a servo brake with low backlash splines for high-performance applications, such as robotics, medical equipment and packaging. SB power-off brakes are typically mounted on the back end of a motor that requires the stopping and/or holding of a load in the absence of power. The video describes the installation of these brakes in simple and clear steps. Thomson’s SB Series includes a spline drive, which is constructed to
withstand high-impact stresses and minimise system backlash. The spring-set, electromagnetic power-off brakes provide a safe and efficient way of stopping, or holding load, in the absence of power. Low- inertia, and rotating components, enable higher acceleration rates for design engineers to consider using for their specified application. Thomson has authored a wide range of educational videos, webinars and technical white papers, to inform and guide design engineers, explain technology alternatives and simplify the linear motion component selection process. The video is available to watch at:
www.thomsonlinear.com/techtips.
Thomson Industries
www.thomsonlinear.com
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