Product category:
Flexible machining cells and systems (FMS)
News Release from: Fastems Divisions, Helvar | Subject: Open architecture FMS and robotic deburring
Edited by the Manufacturingtalk Editorial
Team on 22 August 2003
Open architecture FMS shown with robotic
deburring
A company that specialises in interlinking any number of machine tools with a standardised work handling system will demonstrate an 'open' FMS at EMO 2003 as well as robotic deburring.
The Finnish company, Fastems, which specialises in interlinking any number of machine tools of any make using its automated storage and retrieval systems for machine pallets and raw material, will show the latest versions of its 'open architecture' flexible manufacturing system (FMS) technology on its stand at EMO The company will exhibit a medium-duty, multi-level (MLS-MD) storage system for eight 630mm machine pallets and six material stations, and has chosen a Mori Seiki NH5000 horizontal machining centre for demonstration purposes
This article was originally published on Manufacturingtalk on 23 May 2001 at 8.00am (UK)
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At the end of October 2000, the first phase of a GBP 600,000 flexible manufacturing system project became operational at the Poole factory of Westwind Air Bearings.
It has also decided to link in a Fastems-built robot cell (see description below) for loading and unloading machine fixtures and carrying out deburring of machined parts automatically.
MLS-MD is controlled by the latest release of Fastems' MMS (Manufacturing Management System) PC-based control software incorporating many new features (see description below).
The company will also highlight its flexible pallet container (FPC), launched at the last EMO in 2001 (see description below).
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Coventry-based Viasystems has installed a new, flexible manufacturing system (FMS) for machining the front and rear extrusions that go into electronic equipment racks.
System serves any make of M-C with pallets
One of the main benefits of the Fastems FPM compact pallet storage and retrieval systems design is that the pallet crane can deliver pallets to a variety of machining centres.
Designed as a versatile, expandable alternative to the pallet pool at equivalent cost, it has enjoyed considerable success in the interim with 24 FPCs and five system extensions sold worldwide up to the end of July 2003.
Robotic deburring cell - dusty and noisy working conditions and repetitive movements in unpleasant positions, leading to the risk of RSI, are typical problems associated with traditional manual deburring, which also often results in poor or variable quality.
Automation is the answer, as Fastems will demonstrate at EMO 2003 with its new DBL robotic deburring cell, which removes burrs efficiently and to a consistent, selectable quality standard, allowing operators to concentrate on other tasks.
DBL is a standard, modular system built to provide a customer with the best solution for his application.
The cell can work as a stand-alone unit or as a part of an FMS, as at the exhibition.
It can be installed in a day and moved from one place to another easily if the factory layout changes.
The cell is equally appropriate for medium or large batch production as it is for repetitive production of large single pieces that require a lot of deburring.
It is possible to use CAD geometry of the component to program the deburring cycle, rather than having to create the program using the teach-in method.
The result is faster programming, which may take place in advance of a physical part becoming available.
MMS boosts FMS productivity - at EMO 2003, Fastems will introduce the latest version of its Manufacturing Management System, MMS.
The versatile control software, designed specifically for multi-level FMS, has been enhanced with new features to raise productivity and so extract maximum benefit from investment in factory automation.
Fastems' MMS is a versatile, PC-based control system that covers production information, resource management and production planning with a single, user-friendly interface, providing machine operators with essential information in a clear and understandable format.
It is a modular, scalable system that can be customised to meet individual needs and is applicable to various production profiles from predictable mass production to small batch sizes and unpredictable demand.
"The first MMS control, launched at EMO 1999 in Paris, benchmarked the first move towards Windows and the PC platform," recalls Matti Nurminen, manager of Fastems' Research and Development department.
"Now, after delivering nearly 200 MMS control systems around Europe and the USA, we have upgraded the system with innovative features that will be introduced at the Milan EMO." Pasi Kauhanen, Product Manager, Control Systems, says, "In the latest version, new functionalities are divided between process and planning application modules which enable our customers to adapt the system in response to their own production philosophies.
The process module includes control applications for machine operators on the shop floor, whereas the planning module provides information, calculation and simulation tools for those who are responsible for production planning and production management." The enhanced, order-based production planning system is able to prioritise orders in real time and automatically assign jobs to ensure that the most urgent workpieces are always dispatched to the machine tool first.
"This way our customers can prioritise the use of their production resources as well as significantly improve their on-time deliveries," continues Kauhanen.
"As a result, they optimise scheduling and decrease lead times, factors with a direct effect on competitiveness." Another new MMS feature is the Autopilot control application which revolutionises operation of the loading station.
Intelligent software selects the optimum pallet for clamping the part, based on the availability of resources such as raw materials and machining fixtures, and the priority level of the production orders.
"Under Autopilot's supervision, users can concentrate on the machining process and let the software do the complex and time consuming optimisation work," Kauhanen points out.
"Parts that need to be loaded and machine pallets ready to receive those parts are automatically retrieved from the store in the order designated by the system supervisor.
Production Log is a new information management application that follows the production flow of a workpiece and records which machines and programs have been used during its production.
Company management is provided with detailed information about the time for processing each order, allowing CNC cycles and cutting times to be followed and any production failures to be tracked and the reasons behind them analysed.
Complete FMS in a container - the Fastems Flexible Pallet Container (FPC) has started a new era in shop floor automation.
It turns any machining centre into an automated FMS, maximising return on investment.
"Many machine tool manufacturers and dealers across Europe and in the USA acknowledge the value of this versatile and expandable alternative to conventional pallet pools," explains Jukka Niemi, Product Manager at Fastems.
"FPC provides machine suppliers with a complete FMS in a 'container', designed for a specific machine tool type.
Each container houses all customised equipment required for automated storage and handling of from four to 30 pallets," he continues.
"Unattended machining is available for pallets up to 3200kg overall weight, and the new FPC-3200 increases maximum pallet size from 800mm to 1000mm." Of compact design, an FPC is economically priced and can be installed in a day as it is virtually a plug-and-play system.
Another advantage is that it may be relocated easily when the factory layout needs revising.
Depending on a customer's requirements, an FPC can comprise one to three containers, one or two load / unload stations and up to three machine tools.
The system can be upgraded easily with additional pallets, machine tools or new container units to meet a factory's future needs.
New stacker crane technology - at EMO 2003, the latest Fastems' FMS cranes will be unveiled, called DMC-MD and DMC-XMD, designed for carrying loads up to 1500kg and 2500kg.
These new, medium-duty models are additions to the company's crane programme which now extends from 700 kg light-duty models to 9500kg extra heavy-duty cranes.
All operate with three numerically controlled axes and use telescopic, adjustable forks for handling the pallets.
A rigid, double mast construction increases stability and minimises mast deflection, which is essential when handling machine tool pallets.
Explains Tero Rapila, chief design engineer for the new models, "They are designed to lift loads to a height of 20 metres, enabling a customer to utilise the full height of his production facility.
Speed, flexibility, efficiency and accuracy are the core features of stacker cranes in an FMS.
Our new models enable higher systems with larger and faster transfer capacities.
They also ensure optimum use of floor space and their modular and compact structure makes installation quicker and easier.
Enhanced diagnostics results in faster recovery from an interruption." DMC-MD provides three different speed/performance classes: 2.0, 3.0, and 4.0 m/s.
The -XMD unit is available for 2.5 and 3.0m/s operation.
Owing to their twin motor drive and modular structure, the new units can be easily upgraded when there is a need to increase capacity.
The number of components used in their construction has been reduced from 500 to 300 for reliability and ease of maintenance.
Another feature of the new cranes is the optional sliding height measuring system which optimises space utilisation and storage layout.
Fastems targets 8,760 hours availability - Fastems, whose origins date back to the 1950s, is owned by the Helvar Merca Group.
It is one of the leading suppliers of flexible manufacturing systems (FMS) in Europe and an open system integrator supporting all major machine tool manufacturers with proven software and hardware modules.
Users are able to choose a combination of machine and pallet handling system which best suits their production requirements.
Companies utilising such FMS have experienced rapid return on investment by reducing inventories at different stages of the manufacturing process.
Often the result is a factory that occupies half of the floor space which would otherwise be needed, with two thirds less work-in-progress and one third fewer people.
To date, Fastems has delivered more than 300 FMS in 15 countries.
They range from small systems consisting of two-level high-bay storage with eight machine pallets, one loading station and one machine tool to the biggest delivery so far that has about 2,000 materials pallets, several loading stations, assembly stations and numerous machine tools - a complete factory itself.
All systems endeavour to utilise the 8,760 hours available in a normal year and come close to achieving this goal.
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