Robot cells automate machine tool loading

Four robot cells designed to automate loading and unloading of virtually any type of machine tool and thereby maximising machine tool usage and minimising labour costs

Four robot cells designed to automate loading and unloading of virtually any type of machine tool have been introduced by the Finnish manufacturer, Fastems.

Intended to increase competitiveness by maximising machine tool usage and minimising labour costs, the cells are available to manufacturers in the UK through the groups Dartford subsidiary.

Better known as an ?open FMS integrator, Fastems has built over 380 multi-level systems worldwide for unmanned storage and retrieval of pallets for delivery to one or more twin-pallet-change (2APC) machining centres of any make.

The new venture, however, introduces considerable diversification by tackling automation of lathes, grinders and other CNC machine tools, including machining centres without 2APC functionality.

Designated RPC, standing for robotised production cell, each comprises a six-axis, articulated-arm Fanuc robot within a guarded enclosure that also houses two storage trolleys for raw material and machined components.

Payback is rapid, as uninterrupted output can be expected from existing machines tools, one operator is able to look after several machines rather than one, and unattended ghost shift working can boost productivity further.

The robot is able to reposition a component in a lathe chuck for back end-working, if required, or in a machining centre for multiple-face machining, permitting automated, one-hit production of complex components.

In addition, the cell itself may incorporate a facility for completing further in-cycle secondary operations outside the machine, such as deburring, cleaning, inspection, drilling, or even light milling.

Either one or two machines may be served by a single cell, which Fastems stresses is almost an off-the-peg item, so capital cost is minimised.

Only a small amount of tailoring is necessary using a selection of grippers, adapter plates and other standard accessories, all of which are supplied together with a ready-made CNC interface and a part program for production of one component.

Delivery and installation of the pre-assembled, tested and programmed cell is rapid.

As it is not fixed to the floor, the single-lift equipment may be relocated easily within a factory for maximum flexibility.

Two of the systems - RDC LD10/20 are designed to take half-Euro size material pallets (600mm x 800mm) and come with a robot capable of handling either a 10kg or a 20kg payload.

Heavier duty systems are the RPC MD45/165 which accommodate 1200mm x 800mm Euro pallets and have 45kg and 165kg maximum handling capacities respectively.

Each is able to accommodate families of components of various sizes using the same gripper, so the system is able to cope with large variations in batch sizes.

Additionally, a cell may be reconfigured easily for a different type of component.

An application example at a customer in Sweden encapsulates the benefits of using a Fastems RPC.

Bushings are turned in batches of 200- to 2,000-off from bronze bar that must be only 500mm long to prevent undue bending.

The robot feeds bars successively through the lathe spindle and as each machined bushing is parted off, the robot picks up the finished component and places it in the RPC magazine, having first pulled the bar through the chuck ready for turning the next component.

Cycle time is three to four minutes and the magazine can store 320 machined parts, so approximately 16 minimally attended hours running is possible plus a full unmanned ghost shift.

The user changes over the system typically three times a week to manufacture a different component and so far has created 15 new programs in-house.

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