flexible press automation - lbcg · made in comau flexible press automation case study roberto...

Made in Comau

Flexible Press Automation Case Study

Roberto Dudda Comau SpA- Press Automation Business Line November 2016

Made in Comau Property of Comau - Duplication prohibited

Introduction to Comau

Press tending the traditional Approach

Automated Racking solution

- The advantages / Savings

- FCA Melfi Case study

- The solution

- What were the savings / key gains

- Considerations to ensure successful implementation

Automated Press tending examples

Press tending specific Robots

Next steps in press tending automation

Agenda

2


Introduction to Comau

3

Automation Systems

Robotics and Automation Products

Powertrain Machining


Press tending traditional Solutions

4

• Heavy and large parts: HEALTH AND SAFETY ISSUES for operators (parts over 16 kg need turn-over every 2h, no women, workers 20 to 40 years old).

• Troubles in manual handling of very large parts (RISK OF PART DAMAGE) and precise positioning inside stillage.

• Difficult handling of parts coming out from HOT FORMING press lines (TEMPERATURE OVER 250°C).

• HIGH SPEED lines (over 20 ppm for large sizes or 40 ppm with dual feed) need over 30-40 people/ 3 shifts + logistic (fork lift drivers) and very long conveyors (20-30 m)

At the end of every automatic press line (tandem or transfer system) a racking station is required to palletize stamped parts

inside dedicated containers or loading directly in conveyor systems. The simplest solution is MANUAL RACKING using several

workers, dependent on line throughput and part size.

Potential issues particularly with new high speed press lines;


Automated Racking Solution – The advantages / savings

5

Main advantages in automatic racking are:

• ERGONOMIC issues solved

• Process QUALITY issues solved (aluminum parts, deformability, same

stillage used in press shop and in BW shop)

• FLEXIBILITY issues solved (it’s possible to work in automatic or manual

mode, it’s possible to rack several different parts)

• Cost reduction and SHORT RETURN ON INVESTMENT (manpower

saving, line efficiency)

• Simpler interface with automatic material handling (like AGV systems

connecting press shop to warehouse or directly to BW shop)

AUTOMATIC RACKING with 6 axis robots is an excellent alternative solution solving several problems, applicable both in new

and in existing press lines.


Automated Racking Solution - FCA Melfi Case Study

6

Overview of solution

• Existing transfer press line Komatsu brand

• Speed: 10 spm (instantaneous)

• 3 shifts per day 6/7

• N.15 different parts / stillage

• N.2 COMAU robots on 7th ax. track motion

• N.4 stands with automatic centering

• N.2 auto tool changers (tuning tables)

• N.1 vision system to check part positioning

• Stillage code control with magnetic tags (RFID)



7

Before : • One single lane conveyor just 10m

long • 3 people working per shift for small

parts + 2 drivers • 6 people working per shift for large

parts + 2 drivers • Racking from conveyor sides due to

logistic problems



8

After : • 2 multiple lanes conveyors with 2

axis auto- adjustment • 1 operator for check + 2 fork lift

drivers • Same existing area and logistics as

before • Quality station before racking and

selectable part exit



9

Stillage example

• 2 car models – 14 different parts

• Minimum size: mm L1450 x W 1200 x H 1500

• Maximum size: mm L 2650 x W 1550 x H 1250

• Max. weight (outside roof) : kg 16

• Racking from the bottom to the top, from the front, from the side and overlapping on several rows


Automated Racking Solution – The Solution

10

The Method

• Analisys of parts and containers

• Lay-out definition according to Customer needs

• 3D simulaton for all parts (robot reach and cycle time)

• Study of special conveyors to solve swinging part problems

• Study of software interface with old press automation system (20 years old)


Automated Racking Solution – The Method

11

Adjustable Conveyor

- Adjusts to support varying part shapes

- Automatically adjustable



12

The Method • Study of special stations for stillage auto-

centering

• Study of vision system for IN-LINE part

position checking and robots trajectory correction

• Study of auto-tool change stations with

turning tables and commercial end effectors

• Pre-assembly in COMAU facility to test and program

• Installation done in 2 phases (2 weeks each

in summer and Christmas shutdown) due to

production needs



13

The Method • Study of special stations for stillage auto-

centering

• Study of vision system for IN-LINE part

position checking and robots trajectory correction

• Study of auto-tool change stations with

turning tables and commercial end effectors

• Pre-assembly in COMAU facility to test and program

• Installation done in 2 phases (2 weeks each

in summer and Christmas shutdown) due to

production needs


• Main saving obtained is MANPOWER (12 people / day saved in case of light parts and 24 people /day in case of heavy parts, with personnel turnover)

• HIGH FLEXIBILITY with easy station change from automatic to manual mode: for example, in case the press line runs as back-up of another twin line, it’s possible to park robots, open the gates and manually rack parts (not programmed for auto racking)

• Possibility to check PART QUALITY before and after the racking station (checking station in line and table at the end of conveyor, selecting 1 part every XX produced parts

Case Study – Savings and Key Gains

Station for manual inspection

Station for by-pass and programmed inspection

Manual operations in case of station Switched off


• STILLAGE - Must be designed for an automatic loading and unloading; - Part quantity per container should be carefully considered to reduce internal logistics; - Stillage must be checked for damage before use to ensure no damaged pallets are

used

• CONTROL QUALITY - Stamped parts need good level of quality control; an inspection station is required as

there are no longer operators present - Solutions with vision system on line to check parts can be added (presence of holes,

cracks, etc). Automatic surface quality check at the moment cannot be done on line (due to too long cycle time with existing hardware);

• THROUGHPUT RATE

- Consider if parts need turnover before racking – increase in cycle time - Racking of dual feed means double throughput if divided left and right in different

stillage

• INTERNAL LOGISTICS - Solutions for automatic racking need be considered alongside internal logistics, flows,

existing stillages (same used in BW lines?), AGV systems - Possibility to rack in automatic mode or in manual mode, easy change over

Considerations To Ensure Successful Implementation

15

Example of “in line” inspection as “cycle time neutral”. Measurement is obtained during conveyor transfer at up to 800 mm/sec

Made in Comau Property of Comau - Duplication prohibited 16


Press Tending Specific Robots

20

G2 – G3 lines

SMART5- NJ Press 100-3.2

G1 lines

SMART5- NJ Press 130-3.7 SH SMART 130 3.7 SH

Axes Number 6+1

Payload [kg] 130

Axis 5 Torque [Nm] 1226

Max Reach [mm] 3742

Speed AX1 [°/s] 120

Speed AX2 [°/s] 95





PRESS 100 3.2

Axes Number 6

Payload [kg] 100

Axis 5 Torque [Nm] 638

Max Reach [mm] 3209







Dedicated robots for press application with special reach, special gear boxes in axis 1 and 6, double motors in axis 1 for higher acceleration + application software. Conveyors designed and produced inside COMAU. BRIC modules to mount robots upside down including auto tool changers on top. Stands with stillage auto-centering or turning tables.

BRIC modules & conveyors


Next Steps In Press Tending Automation

AGILE 1500: First model of autonomous mobile platform providing modular and wide ranging solutions for logistic matters:

AGILE 1500 – available in 2017

• High performance vehicle (best in class payload / size + speed) • Modular, scalable, fully customizable and re-configurable • Multiple navigation systems implementable • Synergy: integration with Comau Systems solutions • Ease of Use – Plug & Play • Human-robot collaborative and WCM oriented • Factory 4.0 solution ready (full connectivity)

RAIO –RECOGNISENSE ALL-IN-ONE: Integrated vision system: • Higher Resolution • Wider Field of View • No Floor Space Impact • Scalable Solution One Software to Manage: 2.5D (XY-Rz), 3.5D (XYZ-Rz) and 6D (XYZ-Rx Ry Rz) • All in One Product, no need for further PC to process the images cost-effective

Made in Comau

Via Rivalta, 30 - 10095 Grugliasco - Torino ITALY - www.comau.com

http://www.comau.com

flexible press automation - lbcg · made in comau flexible press automation case study roberto...

Documents