Plug-and-Play Robotic Manufacturing Cells Increase Productivity, Lower Costs

In Booth S-338556, new multi-spindle 5-axis machine tools from SW North America, Inc. (New Hudson, MI) feature integrated robotic loading and unloading, plus vertical pallet storage for workpiece blanks and finished parts. In addition to high speed and high precision machining, these plug-and-play manufacturing cells feature drastically decreased commissioning time so users can realize productivity benefits and profitability much more quickly. The benefits of independent cellular manufacturing include high-level availability and easily scaled capacity, all while increasing production efficiencies and lowering costs. “Cells are especially suited for a shop that relies more on multi-shift operations, where one employee is responsible for several machines,” noted Wolfgang Armleder, the director of development at SW. “Independent cells can also deliver reliable tracking of quality and process data. Loading modules are an ideal basis for this because their deposit pattern is always nearly identical and outward transfer of SPC-measured parts can be planned.”

These new cells consist of dual-spindle SW BA 222 or BA WO2-22 machining centers together with an integrated 6-axis robot for loading and unloading and vertical pallet storage unit for blanks and finished parts. Many conventional automation systems consist of two-part configurations requiring a good deal of time to commission and integrate into production. By comparison, the SW cell is a crane-hook system for straightforward installation and setup. The robot is mounted overhead for increased freedom of motion and the pallet storage unit is set off to the side, allowing manual loading and unloading if needed while occupying a compact footprint. “Components are mechanically connected and completely set up before the cell leaves us,” added Armleder. “Coolant return, swarf conveyor, and electrical installation all take place in our factory, with the result being a complete, independent manufacturing cell for customer use.”

The two-spindle BA W02-22 machining center with linear and torque motors is setting new standards in 5-axis machining. With a compact 4 sq m footprint, shops can manufacture complex workpieces made of non-magnetic materials at high speeds. That makes this machine ideally suited for a highly diverse range of applications in precision engineering, including the watchmaking industry and impeller manufacturing in the automotive industry. Wear-free direct drives ensure the lowest total cost of ownership due to maximum availability. Linear and torque motors in the feed axes also ensure positioning accuracy of less than 0.006 mm, even at maximum machining speeds. The BA W02-22 achieves a Kv factor of 10 and a jerk of 1,200 m/s³ for high-precision micro movements. Together with the extremely low weight of the planetary axes, this notably reduces cycle time in comparison to conventional machines, depending on workpiece geometry.

With a spindle distance of 250 mm, feed axes on the BA W02-22 accelerate at up to 24 m/s² to a rapid traverse of up to 120 m/min. In the first configuration level, the HSK-A40 motor spindles reach the maximum speed of 25,000 rpm within 0.7 seconds. Chip-to-chip time for a tool change is only 1.75 seconds. The double swiveling workpiece carrier allows you to load the BA W02-22 in parallel to production time, increasing production efficiencies. Together with a patented monoblock construction that is critical to stability and accuracy, the SW BA 222 and BA W02-22 design makes overhead mounting of the loading and unloading robot very advantageous. Since the robot can be flexibly configured for specific parts, there is freedom of movement and room for other tasks, such as integrating reclamping, labeling, or scanning. The loading module is fitted with standard aluminum support profiles for holding additional devices.

The powerful 7 kg robot can accommodate workpieces up to 100 mm x 100 mm x 50 mm up to 1.0 kg in mass, and can use multiple grippers to load and unload in parallel with machining time. For small batch sizes, manual loading can also take place. “This design features a special arc-shaped robot loading door, allowing nearly unrestricted access for all setup tasks at the loading station,” explained Armleder. “We created a special solution for this so that swarf and coolant can be reliably diverted from the entire robot area to the swarf conveyor.” The vertical pallet storage unit can be fitted with a maximum of 24 pallets that are 600 mm x 400 mm. System runtime at one minute per every two workpieces is 9.6 hours, the equivalent of a 64 m belt conveyor. In contrast to chain systems, pallet transport is based on an elevator car approach that employs a wear-free ball screw drive, allowing pallet loading and unloading at optimum and consistent heights.

SW North America, Inc., 30160 Lyon Industrial Court, New Hudson, MI 48165, 734-736-4027, www.sw-machines.de/us.