Product category:
Flexible machining cells and systems (FMS)
News Release from: Fastems Divisions, Helvar | Subject: Pallet handling, robotic deburring, production
Edited by the Manufacturingtalk Editorial
Team on 24 June 2004
Flexibility is the keynote in pallet
handling
Automatic pallet handling systems that fit a wide variety and mix of machine tools was presented at METAV along with robotic production and deburring cells and the latest control system software.
Fastems from Finland is an expert in the field of automation, for any amount of machine tools from any manufacturer This is realized with an automatic pallet storage, loading stations for machining pallets and material stations for raw material and finished parts
This article was originally published on Manufacturingtalk on 23 May 2001 at 8.00am (UK)
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At their stand on METAV 2004 at Duesseldorf, Fastems presented the latest developments of their flexible manufacturing technology.
The company exhibited a "made to measure" Multi-Level System Light Duty (MLS-LD) system with a loading and a material station.
The system can store and transport 500 x 500 mm machine pallets as well as 600 x 400mm material boxes.
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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.
This year, a horizontal machining center Hueller Hille "Bluestar 5" has been integrated into the system.
At METAV 2004, this innovation from Hueller Hille was presented as part of a flexible manufacturing system for the first time.
MLS-LD is controlled by the latest release of Fastems' MMS (Manufacturing Management System) PC-based control software incorporating many new features.
The company also highlighted its Flexible Pallet Container (FPC), launched at the last EMO in 2001.
This versatile and expandable alternative to pallet pools at equivalent costs has enjoyed considerable success in the interim.
Up to April 2004, 54 Flexible Pallet Containers and 11 FPC system extensions have been sold worldwide.
In addition, a robotized deburring cell and/or loading cell can be integrated into all Fastems FM systems.
Both robot cells can also be used as stand-alone solutions.
MMS boosts FMS productivity At METAV 2004, Fastems presented 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 Windows interface, providing machine operators with essential information in a clear and understandable format.
It is a modular, scalable system that can be customized 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.
Now, after delivering more than 200 MMS control systems around Europe and the USA, we have upgraded the system with innovative features that was introduced at the Duesseldorf METAV.
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 prioritize orders in real time and to assign jobs automatically.
This helps to ensure that the most urgent work pieces are always dispatched to the machine tool first.
This way our customers can prioritize the use of their production resources as well as significantly improve the punctuality of their on-time deliveries.
As a result, they optimize scheduling and decrease lead times, factors with a direct effect on competitiveness.
Another new MMS feature is the "Autopilot" which revolutionizes 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.
Parts that need to be loaded, machine pallets and material pallets for ready 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 work piece 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.
A whole FMS in one container - the Fastems Flexible Pallet Container (FPC) has started a new era in shop floor automation.
It turns any machining center into an automated FMS, maximizing 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.
FPC provides machine suppliers with a complete FMS in a 'container', designed for a specific machine tool type.
Each container houses all customized equipment required for automated storage and handling of from four to 30 pallets.
Unattended machining is available for pallets up to 3200kg overall weight, and the new FPC-3200 increases maximum pallet size from 800 mm 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 from one to three containers, one or two loading stations and up to three machine tools.
The system can be upgraded easily with additional pallets, machine tools or new container units to meet the factory's future needs.
New stacker crane technology - the traditional DMC-MD has now a sturdier companion, DMC-XMD, which extends the load handling capacity of the MD series up to 2,500kg.
These new, medium-duty models are additions to Fastems' stacker crane selection which now extends from 700kg light-duty models to 9,500kg extra heavy-duty stacker cranes.
The new MD stacker cranes have three numerically controlled axes and they use telescopic, adjustable forks for handling the pallets.
A rigid double mast construction increases stability and minimizes mast deflection, which is essential when handling machine tool pallets.
They are designed to lift loads to a height of 20 metres, enabling the customer to utilize the full height of his production facility.
Speed, flexibility, efficiency and accuracy are the core features of stacker cranes in an FMS.
The 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 4.0m/s.
The XMD is available in 2.5 or 3.0m/s models.
Owing to the modular structure, the new models 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 MD stacker crane series is the optional sliding height measuring system (SHMS) which enables storage layout optimization.
DBL: Robotic Deburring Cell - continuous repetitive movements can increase the risk of RSI (RSI=Repetitive Strain Injury).
These 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 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 FM system.
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.
RPC: Robotized Production Cell - Robotized Production Cell, RPC, is the latest Fastems innovation: it is an automated production cell that easily adapts to today's rapidly changing production requirements.
The RPC is a "ready for use" product.
It is an automation system assembled on a sturdy base with a minimum of construction components.
Since it is based on standard components, the RPC is competitively priced.
It enables you to increase the utilisation rate of your existing machinery with a small investment.
It can be brought into use quickly and it is easy to relocate.
It offers operators a new dimension of freedom for parts handling and a wide selection of standardised auxiliary devices adds to its application opportunities.
This investment also reduces the overall unit costs and provides you with the possibility for unmanned production cycles.
The implementation of the RPC is quick: Fastems delivers a pre-assembled unit with all necessary grippers and adapter plates, including programming for one sample part.
The ready-made interfaces can be used with most common machine tool makes.
And as it doesn't need to be fixed to the floor, the RPC is a truly movable and flexible solution.
RPC's development work continues and its accessory selection is being diversified.
At the moment, accessories are available for deburring and finishing applications and well as for cleaning and inspection.
Fastems targets 8760 hours availability Fastems' origins date back to the 1950s.
Today, it is owned by the Helvar Merca Group.
Fastems 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 utilizing FMS from Fastems 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 350 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 2000 materials pallets, several loading stations, assembly stations and numerous machine tools - a complete factory itself.
All systems endeavour to utilise the 8760 hours available in a normal year.
The utilization rate reached in practice comes close to achieving this goal.
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