Requirements:
1. Loading pre-assembled pallets with knives into the machine
2. Loading knives clamped in packages onto the 4th axis
3. Autonomous production for 24 hours
4. Centralised and simple order management
5. Direct set-up stations at the automation cell
Considerations:
The components had already been manufactured on various machines at the customer's premises, some of them already clamped on pallets. Together with the customer, the pallet clamping was further optimised so that this principle could form the basis of the system.
Solution:
Based on the VC1150 with a 4th axis, which met the requirements for machining and working space, the customer was provided with the solution they needed.
The machine table of the VC1150 is equipped with a zero-point clamping system for 400x400mm pallets on the table. Next to it is a 4th axis with a tailstock, which is also equipped with a zero-point clamping system. The position of the tailstock was queried with external monitoring to ensure that there were no unknowns during automated operation. The machine also has laser tool monitoring and a measuring probe. This means that after the pallet has been loaded, the zero point can be determined if necessary, dimensions can be checked after completion, and the tools can be monitored via the laser and readjusted if necessary. Topics such as tool breakage detection are also handled automatically in order to secure the process in unmanned operation.
The pallets for both clamping types are loaded by the operator directly at the automation cell on one of the two set-up stations. Connections for screwdrivers and air guns are available directly at the set-up station. This eliminates the need for additional handling of the heavy pallets. After loading, the pallets are stored by the robot in a pallet rack. A total of 32 pallets can be stored. When storing, the operator also informs the robot directly which component is on the pallet, which is then used to select the appropriate processing programme during loading.
The visualisation system allows the operator to view the status of each pallet at any time, see which programme is assigned to which pallet, manage pallet priorities and also initiate the removal of pallets.
The system has an email system to provide feedback in the event of a malfunction or if the storage runs out when no one is in the building. If necessary, an email is sent to the persons assigned to the respective time slot so that in the event of a malfunction, it is known and can be rectified even if no one is present in the company.
