Product category:
Flexible machining cells and systems (FMS)
News Release from: Fastems Divisions, Helvar | Subject: Automated pallet handling - FMS systems
Edited by the Manufacturingtalk Editorial
Team on 26 September 2005
Containerised FMS automates machining
centre
A compact, containorised flexible workpiece pallet load/unload and racking system provided a quick and efficient way for an actuator maker to automated a machining centre.
With motorised actuating and control fittings, piping systems for the distribution of liquid, gaseous or granular substances can be automated The firm Auma Werner Riester has earned an illustrious reputation in the production of electric actuators for fittings, and has become a byword for quality and reliability
This article was originally published on Manufacturingtalk on 23 May 2001 at 8.00am (UK)
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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.
Alongside the well-known flexible manufacturing systems by Fastems in the form of automatically working racking apparatus, there are also container variants, in which a PC-controlled stacker crane delivers the workpieces to the machining centre and takes the finished parts out.
Under which conditions such container solutions effect an economical manufacturing automation is illustrated by the following example.
"When the drinking water from the Bodensee reliably reaches all connected customers and that going well beyond the Stuttgart area, our actuators, which move the large fittings in the metre-thick piping, contribute to the success of the Bodensee water supply," explained Steffen Baumeister, team leader in the Ostfildern Auma plant, thereby highlighting one of the most impressive applications of Auma actuators.
Nevertheless, it should not go unnoted that one finds Auma actuators put to the most varied of uses practically all over the globe.
They are used in sea water desalination plants, in power plants and in chemical plants, to name just a few examples.
The responsible sales and service branches, which are located in the most important industrialised countries on all continents, carry out maintenance and repair jobs.
Reports Baumeister: "We were faced with the task of increasing the production of gear cases and electronics housings in an efficient manner".
"A machining centre that operates automatically enabled us achieve this goal".
"Unmanned operation is planned for the third shift".
"The two day shifts are to be carried out with multi-machine control".
"To attain this goal, the machining centre needs not only a sufficiently large tool magazine with an automatically operating tool changer, but also an automated handling system that passes the workpieces over to the machine and subsequently takes the finished parts out".
"For these tasks, we provided for, in consultation with the supplier of the machining centre, a flexible manufacturing system by the Finnish company Fastems." The company, which belongs to the Helvar Merca group, supplies customised racking systems in which an automatically working stacker crane takes over the handling of the machine pallets on which the workpieces are clamped.
The clamping of workpieces to the machine pallet and the clamping of finished parts is done on the loading stations, which form part of the fittings of this kind of flexible manufacturing system.
For particular applications, Fastems developed an automation system that fits into a 20ft container.
Baumeister emphasised: "Fortunately, we were able to talk to Klaus Maurmaier - Fastems Sales Manager for Germany - in time".
"After Maurmaier saw the limited space we have, he introduced us to the flexible pallet container (FPC)." * FPC - an automation system in a 20-foot container - the basic model of flexible pallet container includes the external enclosure of a modified 20ft container.
Inside this are a pallet rack and a stacker crane that runs on a floor rail and side rail.
The connection to the machining centre, as well as at least one loading station are located on the long side, opposite the pallet rack.
The master PC controls the flexible pallet container system".
""We offer such flexible pallet containers, which we call FPCs, in four models", says Maurmaier and goes on to say: "The FPC 750, FPC 1000, FPC 1500 and FPC 3200 are all named after the transportation weight, the numbers referring to kg".
"The transportation weight depends on the design of the built-in components".
"The design of the built-in components is determined by the size and maximum weight of the workpieces that the machining centre can accommodate".
"Thus, the sum of the weights of the workpiece, the machine pallet and the chuck determine how high the load-bearing capacity of the pallet rack must be and which loads the integrated crane and the loading station have to bear".
"However, how large and how heavy the workpiece may be is determined by the machining centre".
"In order to be able to operate an FPC economically in practice, we have defined a maximum size for machine pallets".
"This is 1000 x 1000mm." The larger the volume and weight of a unit of machine pallet and workpiece, the smaller the number of slots in the container.
"For this reason," continues Maurmaier, "We were grateful that the machine manufacturer from whom we generally get our order arranged a consultation with Mr Baumeister".
"In this way, we not only got to know the on-site conditions, but we also discovered that the largest workpieces were clearly smaller than was permitted by the machine chosen".
"For these reasons, we were able to offer the firm Auma a flexible pallet container as the most economical variant and equip it with ten slots." * Capacity increase through container combinations - "Although actually getting the 20ft flexible pallet container into our very low-ceilinged production facility turned out to be a matter of millimetres in the end, it had already been determined in the planning phase that there was even some free space for the extension of the available pallet place offer," recalls Baumeister with satisfaction - even today".
"Maurmaier adds: "To the basic design of a flexible pallet container, a maximum of two further containers can be connected".
"These extension containers do not have their own stacker cranes, nor do they have their own controller".
"The stacker crane of the base container supplies all three containers".
"Every container is already prepared for this extension in the factory by means of corresponding drill-holes, which fit each other exactly when mounting".
"The rails for the stacker crane are connected individually".
"In this way, one can, for example, fit in a beam between two containers so that available floor space is used in the most efficient manner".
"When the stacker crane travels from one container to the next, the telescopic mast retracts to allow the stacker crane to pass beneath the two upper container frames".
"For stability reasons, the container frames must not be broken".
"At Auma in Ostfildern we have mounted a 2.5m long mini container with two slots onto the base container".
"Taking this into account, the solution now contains a total of 12 pallet places." * Flexible adaption to the manufacturing process - "The pallet containers", Maurmaier goes on to explain, "Adapt to the technological conditions of the particular manufacturing process within the scope of the defined parameters".
"Depending on the size of the connected machine tool, one or two machines that work with the same pallets can be connected to a container".
"When a machine is connected, one can decide whether one wants to work with one or two loading stations".
"Naturally, the same applies for the two extension containers, which one can connect when operating to a maximum." Says Baumeister, "In our case, the machine is connected offset to the side, such that there is only space available for one loading station." * Technological procedure - "The rough parts that are to be machined", explained Steffen Baumeister, "come from a foundry nearby".
"Depending on the size of the rough parts, we clamp either two or up to eight workpieces".
"In the case of electronic cases, which are being machined in two clampings".
"Here, we clamp in each case a rough part and a part that has already been machined in the first clamping".
"By means of this combination, at the end of every machining process we always get a finished part, which is deposited in the lattice box pallet put in place for the purpose".
"To facilitate clamping, the machine pallets can turn 360 degrees on the loading station." Clamping and unclamping are also made easier thanks to a further measure: a soft rubber mat, which is extremely comfortable for the feet, lies in front of the loading station".
""During clamping," explains Baumeister, "the loading station is shielded from the interior of the container by a sliding door".
"When the workpieces are clamped, the loading station is closed at the operator side".
"Only then does the inner door open so that the stacker crane can take control of the machine pallet".
"The stacker crane lays the workpieces brought into the system in this manner either directly into the machine or passes them on to a pallet place, on which they remain until they are to be machined".
"When a machined pallet is discharged, the safety doors to the loading station open and close in reverse order." Maurmaier adds: "The stacker crane, which must take up the machine pallets securely from both sides, works with a patented parallelogram system designed so as to be easy to use, which assures that the system works reliably." * Benefits to user - "With the base container and the mini container, I have put the available slot to optimal use," points out Bauimeister and adds: "A second extension is even conceivable if there were further alterations to the layout of the production facility".
"In this way, the FPC system offers a future-oriented extension possibility".
"Most importantly, however, the flexible pallet container system fulfils the agreed performance requirements: It makes multi-machine control and unmanned operation possible right into the third shift".
"When we set on average 30 minutes for the machining of parts on a machine pallet, then the machine can, thanks to the 12 storage places, work unmanned for six hours when production scheduling is optimal and operation is problem-free".
"When the six hours are up or if the machine comes to an unforeseen standstill, the control system is capable of getting help on its own", adds Maurmaier and explains: "The container system controlled via the master PC is connected to a modern alarm transmission system, which with the aid of its alarm transmission program and its GSM modem sends SMS messages to the on-call service".
"It is possible to send the messages in a fixed order to various employees in order to guarantee that help comes to the machine".
"Conversely, an authorized employee can call up the current operational status even from outside via this alarm transmission system, since the master PC knows at any given moment how many pallets are still in the queue." Furthermore, Baumeister points to the good price-performance ratio: "The installed FPC variant with a total of 10 pallet slots is just as expensive as a pallet pool, which, firstly, would not use the available space as well and, secondly, offers only eight slots." Maurmaier adds: "The price advantage of FPC is the sum of many factors".
"The container with all in-built components is pre-assembled in our factory in Finland".
"Even the loading station is pre-assembled and is pivoted into the container for transport".
"In this way, the time required for mounting at the place of installation as well as transport and installation costs are reduced considerably".
"Nevertheless," points out Maurmaier, "One should only use the FPC where one cannot or does not have to store significantly more pallets with a flexible manufacturing system".
"Looking at the price alone can lead to costly wrong decisions".
"For this reason, we are pleased to offer our professional assistance." Baumeister says: "I have learned from my own experience the worth of such consultations".
"During the course of the consultation, Fastems presented a practical cost-efficiency calculation that was subsequently confirmed during operation".
"In this way, one receives during the investment process an additional, fact-based decision-making criterion.".
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