THE “PREP-BOT” CELL
The current manufacturing process of getting a blank tool ready for the cutter grinder involves numerous operations and high employee involvement. Automating the machines and incorporating a 6 axis robot allows for unattended operations and frees up the operator to complete other essential tasks.
The Cell Process
A centrally located robot eliminates the need for individual operators to be present at each machine. The cell functions autonomously with the robot transitioning the blanks to each station on a set schedule.
The robot has 2 independent encompassing grippers to move the blanks to each station. One gripper removes the processed blank and the other gripper inserts a new blank into the station.
Once the system is fully loaded (wet), there will be 4 blanks in process: (1) getting cut to length in the Cut-Off Machine, (1) getting chamfered in the Chamfer Machine, (1) getting measured/verified in the OD Laser Micrometers, (1) getting etched in the Laser Marking System. *1.
The ultimate goal is to have one completely processed tool placed into the outgoing pallet, located on the conveyor system, within the cycle time of the Cut-Off machine. Therefore, the robot has to transition a new blank into the subsequent stations, those stations are required to process and complete the new blank prior to another blank coming off the Cut-Off Machine.
The cycle time of the Cut-Off Machine is dependent on the rod (blank) diameter. A larger rod diameter results in a longer cycle time and a smaller diameter has a shorter cycle time.
Once the outgoing tray/pallet is fully loaded (i.e. a standard batch size) with processed blanks, the conveyor system moves the pallet to a designated area for the cutter grinder and a new empty pallet automatically moves to the robot loading area.
The operator is in total control, but ultimately responsible for initially inputting the parameters into each machine/station, loading the Cut-Off Machine, loading/unloading pallets from the conveyor system and ensuring that the overall cell is working efficiently.
*1 Laser Marking System must be supplied by the customer at this time.
R.O.I. Less than a Year
Reduce Your Overhead
The PREP-BOT Cell Concept effectively takes the once separated system consisting of numerous people down to one individual with no loss in production.
Reduce Your Overhead
The PREP-BOT Cell Concept effectively takes the once separated system consisting of numerous people down to one individual with no loss in production.
R.O.I. Less than a Year
CELL LAYOUT
STATION #1
Carbide Cut-Off Machine “BOSS-FA” by Wayne Machinery
Servo Driven Infeed, 1A1R 200mm (8”) × 1mm (.040”) × 32mm (1-1/4”) bore diamond grind wheel (CBN for HSS). Capable of machining rod diameters 3-40mm (.120-1.5”) and 25.4-430mm (1-17”) long.
ROBOTICS #6
Fanuc LR200i
6 Axis with a reach of 717mm (≈28”) Payload: 7kg (≈15lb) at wrist, and 2 independent grippers
STATION #2
Chamfer Machine by Wayne Machinery
Servo Driven Infeed, 1A1 200mm (8”) × 13mm (1/2”) × 32mm (1-1/4”) bore diamond grind wheel (CBN for HSS). Capable of machining chamfer angles between 0°-90° and conical points.
STATION #5
Conveyor System
Conveyor System to move pallets from robotic loading area to prep/staging area for cutter grinder.
STATION #3
Laser OD Micrometers
OD Laser Micrometers to verify rod blank diameter prior to etching part number onto blank.
STATION #4
Laser Marking System
Laser etch blank shaft towards the chamfered end.
STATION #1
Carbide Cut-Off Machine “BOSS-FA” by Wayne Machinery
Servo Driven Infeed, 1A1R 200mm (8”) × 1mm (.040”) × 32mm (1-1/4”) bore diamond grind wheel (CBN for HSS). Capable of machining rod diameters 3-40mm (.120-1.5”) and 25.4-430mm (1-17”) long.
STATION #2
Chamfer Machine by Wayne Machinery
Servo Driven Infeed, 1A1 200mm (8”) × 13mm (1/2”) × 32mm (1-1/4”) bore diamond grind wheel (CBN for HSS). Capable of machining chamfer angles between 0°-90° and conical points.
STATION #3
Laser OD Micrometers
OD Laser Micrometers to verify rod blank diameter prior to etching part number onto blank.
STATION #4
Laser Marking System
Laser etch blank shaft towards the chamfered end.
STATION #5
Conveyor System
Conveyor System to move pallets from robotic loading area to prep/staging area for cutter grinder.
ROBOTICS #6
Fanuc LR200i
6 Axis with a reach of 717mm (≈28”) Payload: 7kg (≈15lb) at wrist, and 2 independent grippers
