Product category:
Flexible machining cells and systems (FMS)
News Release from: Fastems Divisions, Helvar | Subject: Modular pallet handling - FMS - machining
Edited by the Manufacturingtalk Editorial
Team on 26 September 2005
Modular 'open' FMS handling can be
modified
FMS for automated handling of machine pallets comprise modular mechanical elements and control/management software that are expandable to suit changing needs.
On its 360m2 stand at EMO, Finnish FMS (flexible manufacturing system) equipment manufacturer, Fastems, presented optimal solutions for automated production in four industry sectors - aerospace, automotive, machine manufacturing and subcontracting It is recognition that different industries have specific manufacturing problems to overcome and require systems to be structured to suit their requirements
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.
The new Fastems approach is therefore very much in step with modern vendor practice in manufacturing.
Fastems' FMS for automated storage and retrieval of machine pallets and raw material comprise modular mechanical elements and MMS control/management software that are expandable to suit a user's changing needs.
The systems have been developed for companies of all sizes to maximise production by transporting machine pallets to and from machine tool(s) efficiently and automatically.
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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.
Right across industry, batch sizes are coming down and just-in-time production is the watchword - an environment ideally served by FMS.
Other benefits of Fastems 'open' automation systems are that they can be used to link dissimilar machine tools, can be retrofitted into existing production equipment and may be interfaced with a company's existing ERP (enterprise resource planning) IT structure.
Among the highlights at EMO, the most notable are a new generation of multi-level FMS; a new, gantry-type robot cell for unmanned lathe tending that offers better access for prove-out; a factory-ready robot cell for machine tool loading into which second operations may be incorporated; and a plug-and-play pallet container system, each tailor-made to suit a specific machining centre.
* Maximum flexibility with modular storage system - Fastems is introducing its latest generation of multi-level, medium duty (MLS-MD) FMS offering a new user interface, an updated, easy-to-clean construction that affords a better view of the store contents, and extra safety features.
Supplied also are a fully-specified, industrially-hardened PC with ergonomically designed keyboard, and faster-operating doors on the load station(s) to shorten operator waiting times.
The improvements to the MLS-MD system are being incorporated throughout the Fastems MLS product range.
The latest systems feature compact, modular construction that can be expanded easily and are said to allow optimum storage of components, tools and ancillaries in a production line, regardless of their weight or size.
The system has been developed to meet the exacting requirements of the aerospace industry, particularly with regard to efficient manufacture of a high variety of complex parts in small batches down to one-offs.
Minimisation of labour, frequent changes of a large number of tools and full traceability of components are all accommodated.
At EMO, an MLS-MD will be demonstrated serving a DMG/DMC 80U machining centre producing aerospace industry components.
* New robot loading cell for turning machines - Fastems also launched at EMO the new RPC-G retrofit robot cell, designed specifically for loading and unloading lathes to deliver increased production efficiency under unmanned production conditions.
The key innovation is that the gantry-type unit's storage system sits at the end of the machine, away from the working area, allowing better access for proving-out a new job than is afforded by an articulated-arm robot system sitting in front of the lathe.
The compact cell is equipped with a Fanuc M-16iAT/16 industrial robot that can handle workpieces up to 13kg or 2 x 6kg and can be interfaced with practically any turning machine.
It will be demonstrated at the show tending a Doosan Daewoo Puma 240 MB lathe.
With its short changeover time, compact design and easy access for lathe maintenance, the cell has been developed with the needs of subcontractors firmly in mind.
Control is based on a Fanuc RJ3iB and the standard cell includes two material trolleys for Euro pallets and component locators.
Installation time is very short, contributing to quick start-up and hence rapid return on investment.
* Standard robot cells improve productivity - Fastems also demonstrated its range of articulated-arm RPC robot cells for loading and unloading virtually any type of machine tool.
Each cell comprises a six-axis Fanuc robot within an enclosure that also houses twin storage trolleys for raw material and machined components.
The cell on the Fastems stand at EMO demonstrated loading and unloading a Heller machining centre to demonstrate automation possibilities for the automotive industry.
There was also an RPC cell loading and unloading a grinder on the Favretto stand.
Either one or two machines may be served by a single RPC, which Fastems stresses is almost an 'off-the-peg' item, so 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.
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.
In addition, the cell itself may incorporate a facility for completing further in-cycle secondary operations outside the machine tool, such as deburring, cleaning, inspection, drilling, or even light milling.
Two of the systems - RPC 10/20 - are designed with trolleys having 600mm x 800mm platform for materials and come with a robot capable of handling either a 10kg or a 20kg payload.
Heavier duty systems are the RPC45/165 which accommodate trolleys having 1200mm x 800mm size materials platform and have 45kg and 165kg maximum handling capacities respectively.
* Tailor-made pallet containers with potential - at EMO, the Fastems pallet container (FPC) was shown on the Kitamura stand, and on the Daewoo stand.
The FPC is a complete production system, tailor-made for a specific type of machining centre, the container holding all of the equipment required for automated storage and handling of between four and 30 pallets, each of which can be of up to 3200kg overall weight.
It is a plug-and-play system which can be easily relocated within a factory.
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.
* 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(s) and pallet handling system that 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 that would otherwise be needed, with two thirds less work-in-progress and one third fewer people.
The company also offers robotic cells for deburring and machine tool loading/unloading.
To date, Fastems has delivered more than 420 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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