GFMS - Automation - Scalability
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The GF Machining Solutions Transformer modular automation system addresses concerns about flexibility and cost of automation systems. It is expandable and scalable, allowing customers to start with one or two machines and expand to twelve. The open architecture design allows for integration of different machine tools and manufacturing technologies. The system uses standardized modular components like pallet racks and magazines, and a robotic pallet changer, that can be quickly configured or reconfigured to meet changing production needs. This flexibility provides faster payback on the investment than traditional automation systems.
GFMS - Automation - Scalability
- 1. GF Machining Solutions EDM I Milling I Laser Texturing I Tooling & Automation I Customer Service Automation System Loads up Expandability, Scalability and precision
- 2. Automation System Loads up Expandability, Scalability and Precision Manufacturing automation technology boosts pro- ductivity, profitability and global competitiveness. However, many shops are reluctant to commit to an automation system due to concerns about flexibility and cost. Determining the scope of an automation system involves trying to anticipate a facility’s future needs, and system design, assembly, and installation can include long lead times and significant expense. The System 3R Transformer modular automation system from GF Machining Solutions addresses those concerns. The system is expandable and scal- able; a shop can begin with automation of one or two machines and then easily expand the cell to include up to 12 stations. The system’s adaptability and flex- ibility ensure that it will never be too specialized or too small to meet a facility’s future requirements. OEM automation systems often are designed to integrate certain machine tool brands or styles. The open architecture approach of the Transformer system permits integration of differing manufactur- ing technologies including mills and turning centers, EDM machines, measurement devices and even part-cleaning equipment. Unconstrained by compat- ibility issues, individual operations can be optimized and incorporated to achieve full automation of an entire process. The basic components of the Transformer system are a robotic pallet changing unit and modular racks or rotating magazines that store pallets fitted with referencing chucks from System 3R. The chucks pro- vide repeatability of 2 µm and enable the transfer of parts from one machine to the next without the need to check positioning or repeat setups. System 3R tooling allows palletization of workpieces and EDM electrodes of a wide range of sizes. Dif- ferent versions of the system feature pallet sizes from 54 mm x 54 mm to 700 mm x 500 mm, and the pallet-changing robot can handle part/pallet combi- nations weighing up to 200 kg (440 lbs). In a one-, two- or three-machine cell, a stationary ro- botic changing unit accesses either a bookshelf-style or a rotary pallet magazine. A rotary magazine pro- vides three times the capacity of a bookshelf maga- zine, in the same amount of space. To handle as many as 12 machines, the pallet-chang- ing robot rides on a modular rail system. The rail system is made up of standardized sections that can be quickly added and linked to produce the length needed to service the number of machines desired for the cell. Most automation arrangements are engineered to meet the requirements of specific part production and shop environments. Expanding or changing the system requires dismantling the prior setup and building a new one from scratch. With the Transform- er system, on the other hand, the standardized modu- lar components combine to create customized auto- mated solutions. Together, the modular nature of the robotic handling, rail and magazine components and easily updated software enable a Transformer sys- tem to be expanded or modified in a matter of a few days rather than in the weeks or months required with traditional automation arrangements. Plus, modularity and simple connectivity enable a shop to expand a Transformer rail system while the rest of the system continues to operate. Standardization of components also contributes to lower equipment costs. There are two control modes for the Transformer system. It can be operated as what is called a sim- ple system, which works much like a toolchanger in that the machine tool sends direct commands to the robot. Or for multiple-machine cells, full capa- bility and flexibility is achieved with the use of Work- ShopManager software, which links all machining processes together in a clearly-arranged production system. The software’s CellManager employs with pallet-identification systems, including visual labels or RFID technology, to record the position of every pallet at any given moment. This permits control of every aspect of the cell, from automatically loading jobs to each machine to recording and monitoring cycle times for each operation. Production data can be entered manually or imported through a data exchange interface with major enterprise resource planning (ERP) systems. The software permits random loading of pallets and on-the-fly modification of work order and priorities. As a result, the system handles small and large pro- duction lots with the same level of efficiency, to the extent that automated one-piece production is pos- sible. When a cell houses a variety of processes, the WorkShopManager software is especially essential in maintaining production flow. Payback on the investment in a Transformer system is rapid, a result of significantly increased machine utilization. The system’s accuracy and reliability permit lights-out operation that multiplies machine utilization by a factor of three or four. A selection of grippers, including turning, tilting, tipping arm and double-effector units is available to maximize flexibility of the pallet-changing robotic unit. In-process accessories that enhance system capabilities include in/out loading stations for larger pallets that can be operated without stopping produc- tion; a station for draining workpiece cavities after they are machined; and a cleaning station that pre- pares a part for precision inspection on a CMM. The Transformer automation system is especially suited to lights-out production of small to medium size precision components in tool and die and mold- making operations, as well as any other tight-toler- ance manufacturing applications.
- 3. GF Machining Solutions Your Contact GF Machining Solutions 560 Bond St. Lincolnshire, IL 60069 USA Website: www.gfms.com/us Phone: 847.913.5300 Email: info.gfms.us@georgfischer.com Facebook: facebook.com/gfmachiningsolutions Twitter: twitter.com/gfms_us Youtube: youtube.com/agiecharmilles