Requirements:
- Production of a wide range of screws, from small to large, comprising a total of approximately 250 different components
- High flexibility in handling varying workpiece sizes and production requirements
- Quick and easy set-up
- Optimal accessibility to the machine for the operator for manual or set-up work
- Possibility of automated and low-labour production
- Reduction of set-up times and downtime
- Efficient material supply and workpiece handling
Considerations:
- Use of a large SPINNER TTS lathe in combination with the ROBOBOXL
- Main spindle and counter-spindle for effective complete machining
- Machining of turning lengths up to 1.85 m is possible; in automated mode, we can achieve turning lengths of up to 1.4 m thanks to the storage of parts on Euro pallets.
- Equipped with two turrets and a flexibly movable steady rest
- Robot can be moved completely out of the working area during manual operation
- Sliding cover with locking mechanism for safe automatic operation
- Excellent accessibility to the machine for set-up and servicing
- Pallet-based storage system with up to four pallet spaces, in Euro-pallet size
- Material feeding via pallet truck, pallet mover or forklift
- Hydraulic pallet system for automated workpiece supply
- Double-magnet gripper with electro-permanent magnets
- High flexibility and efficiency despite a wide variety of parts
Solution:
A powerful combination of a large SPINNER TTS lathe and the ROBOBOXL automation solution is used for the cost-effective production of a very wide range of screws. This allows both small and large screws to be machined flexibly in a single, integrated production cell.
The machine has everything required for this: a main spindle and a counter-spindle, each with an 85 mm spindle bore, as well as the capability to achieve turning lengths of up to 1.85 m. The system currently operates with two turrets and a flexibly movable CNC steady rest.
A key consideration in this project was the machine’s ease and speed of access. With around 250 different components, set-up and tool changes must be carried out without any detours. To this end, the automation was designed so that, in manual mode, the robot moves completely out of the working area. Only in automatic mode is the sliding cover closed and locked, and the machine runs fully automatically.
Material supply takes place at the rear of the ROBOBOXL via a pallet system. The raw parts are simply placed on pallets in prism holders and can be conveniently fed into the system using a pallet truck, pallet mover or forklift. Up to four pallets are available simultaneously. The hydraulic system then automatically feeds the workpieces to the robot.
A dual-magnet gripper with electro-permanent magnets ensures maximum flexibility. This allows a wide variety of screw diameters to be gripped without the need for additional changeover parts. This saves time in day-to-day operations and makes the system particularly efficient during production.
A light barrier detects the position of the raw parts in the gripper so that they can be fed into the machine with precision. The finished parts are marked using a nail embosser. Here, component-specific data (DMC, order number, component counter, batch number, company logo) is applied.
Overall, the project clearly demonstrates the importance of a well-thought-out and practical end-to-end solution. Particularly with so many different components, the greatest added value is achieved through close coordination between the machine, automation and the user. The result is a flexible, robust and future-proof production cell that perfectly combines productivity and ease of use.
