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Automate or DieTaken from American Machinist, February 2007
Shops in high-mix, low-volume production environments no longer can expect to compete simply by running lines of stand alone machining centers with an operator at each one. Labor costs are too high, and, more importantly, operating in such a fashion typically translates to only a 40-percent machineutilization rate because so much time is wasted loading and unloading workpieces and cleaning off workholding fixtures between parts. However, shops can boost machine-utilization rates to 50 percent, 80 percent, or as high as 95 percent by incorporating automation and horizontal machining centers. The simplest forms of automation are automatic tool changing and automatic pallet changing. Combined, these two functions can increase a horizontal machining center's utilization 50 percent to 80 percent, given the right application. But, to catapult machine utilization into the 90-percent and above range, shops must take the next step in automation — multiple-pallet systems. While usually associated with high-volume premium shops, multiple-pallet, pallet-pool, or pallet-magazine systems let shops that produce a high mix of low-volume jobs run machines unmanned and in lights out operations. For example, an 8-pallet system could accommodate eight or more different jobs or as many different operations on the same part. Essentially, these systems ramp up machine utilization without requiring a shop to increase its labor resources. Along with multiple-pallets, many machine tool builders recommend that shops also use modular fixturing and some type of pallet-management system within a cell controller. Modular fixturing allows shops to quickly build workholding for virtually any workpiece from a kit of components in about four hours. The alternative is to make customdesigned fixtures that would take a lot more time and labor. After running a job that uses modular fixturing, shops can take a digital photo of the fixture, or use the software that typically is included with modular-fixturing systems to document the specific fixtures it used. That lets the shop easily re-configure the fixtures for repeat orders and eliminates having to keep shelves full of fixtures for repeat orders. A cell controller connects one or more machining centers to a pallet-changing system and keeps track of the parts that are loaded on the array of pallets. All part programs and any type of fixture-management software typically reside in the cell controller to provide "one-point" operation. Some cell controllers even accept videos or photographs of various part setups for future referencing. As a pallet loads, the cell controller automatically delivers the appropriate part program to the machine it is destined for. By handling the whole cell on its own, the cell controller increases a shop's output without having to add more operators. Robots Need Apply Makino's system consists of a robot that feeds subpallets of work into a horizontal machining center — typically a five-axis type machine. Locators that match up to the machining center's pallet ensure that each loaded sub-pallet is qualified to the machine tool, so the machine knows the sub-pallet's location. Because sub-pallets are qualified to the machine tool, shops also can qualify the workpieces on those pallets to the machine tool. This eliminates the extra step of having to determine the workpiece location on the machine or qualifying the workpieces to the machine. "When using conventional pallet-changing systems, shops still must qualify new fixtures to machine tools and make sure the parts on those fixtures are properly positioned," said Tim Jones, product line manager for horizontal machining centers at Makino. Unlike conventional pallet systems that stack pallets horizontally, Makino's system stores its sub-pallets vertically. This allows the system to fit into a small space and eliminates the need for long lines of pallet-storage units. Only the work-setting stations in Makino's system are horizontal, so operators do not have to fight gravity when loading parts. According to Jones, sub-pallets and the fact they are stored vertically have been instrumental in Makino being able to apply robots to high-mix, low-volume work. Automated Concepts takes a different approach to automation for high-mix, low-volume work. Its system, called the LM-8D, is a self-contained, off-the-shelf automation package that matches up to a shop's existing machine tool. The system includes a Fanuc M 16i six-axis robot, a bidirectional five-drawer part feeder and a Fanuc "B" style controller. By using standard pre-engineered components such as these, Automated Concepts can offer the LM-8D for less than $100,000, a price that is about 25 percent to 40 percent less than a custom-designed system, Brian Turner, special services manager at Automated Concepts, said. "A lot of shops tell us they need to automate, but they are often dissuaded by cost and a belief that the system won't be flexible enough. The LM-8D addresses these two constraints," he said. Shops load various jobs into the system's feeder drawers. The feeder drawers adjust in height from 5 in. to 8 in. and accommodate workpiece diameters ranging from 2.5 in. to 4.5 in. The robot then opens an individual drawer shelf, removes a raw part and loads it into a waiting machine tool. Once the part is complete, the robot unloads it from the machine, places it back into the drawer from which it was taken or onto an outbound conveyor or into a bin, and loads another workpiece. The robot handles various part shapes using a three-finger gripper system that includes six other aluminum finger blanks that can be used for different families of parts. Automated Concepts integrates its robots to machine tools via the machine tool's interface, so machine tools that are to be automated must be robot-ready. That means the machine tool must have the ability to interface a robot into its controller. In addition to its other benefits, the LM-8D is portable because its robot and drawer unit are bolted to the same base/platform that is enclosed by steel wire safety fencing. After a run of jobs on one type of machine, a shop can simply fork truck the whole system to a different machine. The LM8D applies to any type of machining operation — milling, turning, grinding and others, and plans are in the works for an LM-8D system that will feed two machines. The current model is designed to tend only one machine at a time. Also, because the robot and drawer feeder rest on the same platform, the robot always knows the feeder's position. Shops do not have to re-teach the robot where the feeder is after moving the system to a different location. Once the system is positioned, it is simply a matter of touching the robot to the machine's workholding to teach it where the machine is, running air and power to the system and connecting it to the machine's I/O block. |
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Making sure that it’s all systems goTaken from ‘The Age’ newspaper, October 4, 2003 Robert Duncan is completing Swinburne University's engineering degree in robotics and mechatronics. He speaks to robotics and automation manager Stuart Simmons from robotics company John Hart about the industry. ROBERT: In year 10, I became pretty keen on the idea of building things and started dabbling in electronics. By the time it came to applying for a university course, I wasn't sure what field to pursue. I was also interested in aeronautical engineering but ended up getting into the Swinburne degree in 1998. After a few years I added a computer science and engineering degree to my robotics and mechatronics degree to make it a double degree. The six-year course includes one year of industry-based learning, which I spent at Bosch. My final year project was to design and develop soccer-playing robots and their control systems, which we presented at the Swinburne Expo at the Royal Exhibition Building at the end of August. I'm interested in the technical side of things.
Robert Duncan with Stuart Simmons at John Hart in Clayton
STUART: I've been a toolmaker by trade for 17 years and have worked in the machine tool industry for 15years; nine of which have been here at John Hart where I've been heavily involved in large project work. After I finished my apprenticeship, I became involved in programming CNC (computer numeric control) machinery and did additional courses in that area. I became the manager of a programming area in an Adelaide company, where I looked after and programmed 35 CNC machines. Also, working as an application engineer, I learned how to make a robot depending on what the customer wants. The kinds of tasks a robot can do means this is a very broad area. ROBERT: What are your typical processes for robot construction? STUART: It starts with project management and design, which are the keys to what we do. If we get a design wrong, we kiss a lot of money goodbye. Rework costs this industry huge amounts, so it's imperative your designs are absolutely correct before you start manufacturing. A robot is just a tool to put a whole system together, what sets a robot apart is what goes on the end of it and what else you can do with it. When a job comes in, a designer, salesman, chief electrician and myself will brainstorm the whole system. Then we make sure the customer knows exactly what we've come up with and what we can offer them. Ideally, that means one robot has to do the exact job they want and be cost effective. We design everything three-dimensionally and work with software for robot and mechanical design. Every project is different. ROBERT: Do you do a lot of process analysis? STUART: Absolutely, and if you get that right, the end result is easy. ROBERT: Would my skills in mechanical and electrical programming fit into these projects? STUART: Have you learned PLC (programmable logic controller) programming? ROBERT: Not through university but I realise PLC programming and some other design tools are common to the industry. STUART: They are, so your knowledge of robotics and design areas such as CAD and PLC are important. Most large integrated systems with a robot will include PLC controlling elements such as conveyers, doors, sensors and safety. ROBERT: Is the industry still growing? STUART: Right now, robotics is growing at a faster rate than machine tool manufacturing because of Australia's occupational health and safety standards. ROBERT: What about opportunities for new graduates? STUART: There are limited opportunities in this company in that we're a sales organisation selling products to an end user and that tends to be cyclical. We're very busy at the moment but how business will be in six to 12 months depends on what happens with the Australian economy. Once you finish your degree, you could work for a company that has a lot of automation systems or you could consider a sales environment. At the end of the day, anything you do in this industry is sales. Even as a fitter piecing something together, you're working in a sales environment -- your final product and how you service that product helps go towards the next sale. ROBERT: But I imagine there is still a fairly big scope for improvement in the industry. STUART: There is and there will always be jobs in this industry but from this company's perspective, finding good application engineers can be difficult. It's a small industry where a lot of people move from company to company. New graduates are likely to enter this industry earning anywhere between $35,000 to $60,000, depending on the person, their calibre, the company and package.
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ROBOGUIDE - The latest simulation package from FANUC |
Robot system integrators and end-users can now make significant reductions in design and programming time by using a new simulation package from FANUC Robotics. ROBOGUIDE is a cost effective solution for engineers to design, prove and programme robot systems either concurrently with new product design or for making modifications to existing equipment and programmes. A FANUC Robotics Virtual Robot Controller and programming capability operates within the 3D feature rich simulation tool. Designers can choose from a wide range of ‘drag and drop’ customisable objects such as conveyors or machine tools to simulate system layouts. Alternatively CAD models of existing parts, fixtures and grippers can be imported in IGES format. Enabling a virtual environment, the package allows the user to programme the robot using familiar FANUC TP programming commands. In addition to recording mid-air tool locations, ROBOGUIDE can generate a robot trajectory along virtual objects such as moving across the face of a table, following an edge or contouring a curve. A virtual pendant ensures engineers are able to work with a familiar interface. The virtual controller provides accurate positioning and path following, allowing cells to be designed and locations programmed even before a prototype has been produced. Provided cells are modelled correctly and programmed around clearly defined datum points, the transition time from virtual to real world for a robot cell can be dramatically reduced with cycle time accuracy within 2%. ROBOGUIDE offers a range of application specific plug-ins to further aid the system design engineer. FANUC PROcess software includes HandlingPRO, PalletPRO, WeldPRO and PaintPRO that provides application specific commands and routines to speed up programming. MotionPRO is a plug-in which provides optimisation of programme cycle time, allowing further time savings when commissioning systems. In addition MotionPRO can be used to optimise existing programs.
January 2007 |
Fanuc M-710iC robot |
Fanuc Ltd, the world’s leading manufacturer of industrial robots, recently announced the launch of its new M710iC/50 model robot. Distributed throughout Australia and New Zealand by John Hart Automation & Robotics, this robot offers full 6-axis capability, with a payload of 50Kg at just over 2m reach. The new M710iC/50 provides a very affordable solution to a wide range of machine loading applications. With the new slim line wrist enabling easier access into confined spaces and an overall rating of IP67, this is a versatile robot designed to help many organizations achieve the cost reductions they are seeking in order to remain competitive.
With reduced labour costs, improved productivity, elimination of OH&S issues and in certain cases the extra production achievable through totally unmanned operation, many companies and organizations are reaping the rewards of investing in robotic automation. Once considered too expensive for many companies, robotics now offer a very viable and affordable solution for your production needs, especially considering the benefits they provide. July 2006 To read more on M-710iC click here. |
The M710iC/50 is the first of a new generation of Fanuc robots featuring the recently released R-J3iC controller. With a new, faster and more powerful processor, the R-J3iC allows direct integration of Fanuc’s versatile 2D & 3D vision systems, eliminating the need for the external vision PC required in the past, making it even easier and more affordable to use vision with your robot.
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