What are the arguments in favor of automation?

Automation is a significant investment that requires clear objectives:

1. Increase profits, improve competitiveness
• reduce the hourly rates for automated machines
• increase productivity by reducing non-productive time
• reduce cycle time
• reduce the opportunity for errors caused by operation
• work with consistent data (process, organization)
2. Minimize dependencies
• less highly qualified personnel
• reduce / eliminate shift working
• increase flexibility with variable capacity
• increased transparency (work progress, operating data)

 

Automation – Under what conditions?

In order to bring automation projects to fruition, a number of conditions must be fulfilled:

• Must be able to make a financial commitment
• Must adhere to controlled processes
• Procedures and organization within the company must support automation and/or must be adapted to obtain the maximum benefit from automation

 

 

Automation 101: The Three Levels of Automation

Level one automation - BRONZE
Preset and palletized head and table tooling

Level two automation - SILVER
Single machine pallet changing system:
(Work Pal, Mikron pallet changer, Form 2000/3000)

Level 3 automation – GOLD
Multiple machine cell with work piece management and
Possible QC solution.
(Work Master, Work Partner, Fanuc custom solutions)

 

 

Organization and expenditure

 

Level one automation - BRONZE
Preset and palletized head tooling

Key points:

1. eliminate manual adjustments
2. eliminate a source of error
3. create a common reference for multiple processes
4. increase accuracy, increase repeatability
5. reduce machine set-up time

Positioning:

• first step into industrialized operation of machine tools
• reference system for EDM and milling
• increase accuracy of manufactured goods 
• external pre-setting of electrodes or cutting tools
• use of automatic tool/electrode changer

 

 

Tooling Reference system – Examples

Reference system tool

 

Level one automation - BRONZE
High capacity automatic tool changer

Key points:

1. eliminate manual handling of tools / electrodes
2. run machine tool in unattended operation
3. reduce hourly cost of machine tool
4. reduce cost of labor
5. increase accuracy and repeatability

Positioning:

• working with multiple cutting tools / electrodes
• working with pre-set cutting tools / electrodes
• facing an increasing complexity of moulds and dies
• reduce impact of increasing cost of labour
• satisfy increasing workload with limited availability of staff

 

 

Integrated toolchanger – Examples

Reference system tool

 

 

External high capacity toolchanger – Examples

External high capacity toolchanger

 

Level one automation - BRONZE
Preset and palletized table tooling

Key points

1. maintain part reference over multiple manufacturing processes
2. reduce part set-up time
3. increase productive time
4. enables in-process offline measurement
5. create a common reference for multiple processes

Positioning:

• first step into automated operation of machine tools
• mould and die shops establishing part pre-set offline
• parts which require to run through multiple machining operations on different machine
• simple change of priority and by temporary removing unfinished part from machine tool without losing part reference

 

Reference system workpiece (pallet) – Examples

Examples of pallet automation

 

Level two automation - SILVER
Single machine pallet changing system:
(Work Pal, Mikron pallet changer, Form 2000/3000)

Key points

1. integrated, economic and compact design
2. minimum footprint
3. available for most commonly used pallet systems
4. low investment cost
5. single source, single responsibility, no risk

Positioning:

• applications with a rather long machining time per pallet
• in mould and die manufacturing
• in high value parts production
• companies with a tight budget to first enter into automatic pallet handling

 

 

Integrated pallet changer – Examples

Integrated pallet changer with/without SIGMA

 

 

SIGMA – Project Specific Setup

 

Pallet handling for single machine automation with job management software (SIGMA)

Benefits:

• centralized pre-set data and NC-programs
• link pallet identity to pre-set data and NC-programs
• reduce non-productive time
• job-batches for unattended operation
• integrate automated single machine cells into existing shop management system

 

Level three automation – GOLD

Multiple machine automation with stock solutions

 

Key points

1. split investment for handling device to more than one machine tool
2. handle multiple different pallet systems
3. handle pallets and electrodes
4. enables integration of basic cleaning or drying operations
5. transparency due to centralized pre-set data and NC-programs

 

Positioning

• die sinking machines requiring handling of large quantity of pallets and electrodes
• operations with short to medium machining time per pallet or electrode (appr. 5 to 15 minutes)
• shops working with well defined structures and reliable processes
• high value parts production small (1/a) to medium size batches (<100’000/a)

 

 

Stock Automation for multiple machines – Examples

Pallet changer to server multiple machines with/without SIGMA

 

 

Stock Automation for manufacturing processes – Examples

Pallet changer to server multiple machines with/without SIGMA

 

 

Multiple machine automation with/without job management software (SIGMA)

 

Benefits:

• maximize return on investment
• reduce footprint
• handle multiple different pallet systems
• handle pallets and electrodes
• 6-axis industrial robot or 3 – axis handling device
• enables integration of basic cleaning or drying operations
• SIGMA: in process priority change
• SIGMA: centralized storage/accessibility of pre-set data and programs

 

Watch a video that shows how turnkey solutions can be highly autonomous.

 

Here’s an example of automation implementation:

Automation with GF AgieCharmilles

• Integration with 6-axis Fanuc industrial robot
• Fully integrated with 3R software WSM-WorkShopManager
• 3R magazines and loading stations
• 3R Tooling ( Macro and MacroMagnum )
• 2 x Mikron
• 1 x CT EDM
• 1 x Agie WEDM
• 1 x Zeiss CMM

 

Automation with GF AgieCharmilles

 

Automation with GF AgieCharmilles

 

Automation with GF AgieCharmilles

 

 

Level 3 automation – GOLD +

Multiple machine cell with work piece management and QC solutions:
(Work Master, Work Partner, Fanuc custom solutions)

 

Tool Master and AC Partner

1. suitable for machines with third party robot interface
2. serves two or more machines tools
3. handles multiple different pallet systems, electrodes and/or pallets
4. enables use of SIGMA cell management software

 

Fanuc Industrial Robots

1. serves multiple machine tools, Fanuc solution available with linear track
2. offers integration of auxiliary processes (cleaning, drying, inspection)
3. enables use of SIGMA cell management software
4. offered in combination with management for customer specific projects

 

 

Level 3 automation – GOLD ++

Multiple machine automation with custom turn-key solutions

Key points

1. use handle parts directly from container or conveyor belt
2. no need for large quantities of expensive pallets and fixtures
3. eliminates the process of manual clamping parts to fixtures
4. integration of auxiliary processes possible (cleaning, drying, deburing, draining off, turning etc.)

 

Positioning

• production of medium size batches (1’000/a - 100’000/a) of identical parts
• production of smaller size batches combining automatic change for palletized fixtures and direct handling of parts
• work piece weight typically less than 10 kg, possible up to 70 kg
• handling of pre-machined, cast or forged parts
• serving machine integrated part specific automatic fixture

 

 

Direct workpiece handling– Examples

Direct workpiece handling with/without SIGMA

 

Customer specific turnkey projects from a single source supplier

 

Benefits:

• entire responsibility for the project is with the supplier
• one qualified project manager coordinates the entire project
• clear technical specification of the project
• scale of the project in accordance with the expectations and budget of the customer (machines, devices, fixtures, application, training etc.)

 

Turnkey-Projects – Examples

"Turnkey-Projects" with/without SIGMA

 

Installed automation 2006

 

3 keys to Ultra Productive Die Sink EDM and Milling

 

 

There are 168 hours in every week. With Ultra-Productive EDM and Milling you can be efficient in every single one of them.