When world-renowned machine builder Impianti Genesis was awarded the contract to support a manufacturer of fluidic fittings wanting to change to automated production, the main challenge that had to be overcome was the high number of different versions and sizes of fittings, thus requiring an extremely flexible machine.
Relying extensively on Bosch Rexroth's 'Easy-2-Combine' components with standardised interfaces, the machine builder developed a new machine capable of producing 1200 fluidic fittings per hour in a number of different versions and sizes of fitting. Available in South Africa from Tectra Automation, the Easy-2-Combine range played an important part in completing the new machine within the prescribed time-frame of only four weeks.
The focal point of the machine is an innovative rotary table with eight automation stations, directly connecting the manual placing and automatic removal of the workpiece. The primary reason for selecting the Easy-2-Combine system is due to its ability to combine individual components in a straightforward and faster way. Impianti Genesis opted for linear modules, mini slides, rotary modules, grippers as well as pneumatic valve manifolds with Profibus interfaces.
"The individual components of the broad, modular-designed product spectrum offer optimum compatibility," says owner Piergiorgio Fausone. "By using this Easy-2-Combine solution we could reduce design costs, minimise assembly costs and, at the same time, achieve a high level of flexibility in assembly."
Centring rings are used for the interlocking mounting of components and are fitted into standardised bores of the elements. Complex adapter plates can be dispensed with, resulting in an easier, more compact and, above all, faster construction.
The versatile number of combinations also permits the realisation of complex applications. This means that the user is not simply limited to pneumatically driven components, but can also select the electrically driven linear axes from the Easy-2-Combine system.
The Rexroth GSU slide unit, representing a new generation of pneumatic linear drives (especially compact due to the rodless construction) was incorporated into the new machine. This guaranteed high rigidity and precise guide slide bearing. With its speed capabilities, the drive permits cycle times of up to 1,5 m per second - and the stroke of the GSU is freely adjustable. It is also easy to set the stroke length with the compact mini slides of the MSC Series. A further advantage here is the symmetrical design, meaning that no distinction needs to be made between left and right-handed versions. The sensors and air supply lines can be mounted left or right or both on the same side, resulting in less cabling. In addition to this, no connecting plates are required, which also saves time.
Alongside the reduced construction and installation time, the machine builder can also put together an easier, more straightforward package for the customer, as well as simplified machine maintenance. By keeping the stroke setting and shock absorbing functions separate, it is no longer necessary, for example, to reset the machine when replacing the shock absorber.
Pick-and-place functionality is delivered via the handling modules which can be directly combined. These also include the RCM rotary module and a GSP-Z Series gripper for the centring of round workpieces. The pneumatic rotary module conforms to the high requirements for precision when handling and excels in its power performance. In this way the drive with double pistons offer a high torque and a power transmission without play. With the GSP-Z three-finger-gripper, the guide casing and clamping jaws are adjusted to one another. With each finger the gripper exerts 350 N, so that the middle gripper achieves a total of more than 1 kN.
The control system of the innovative machine used for the automated production of fluidic fittings is effected via HF04 valve manifolds with Profibus connection. The Profibus protocol simplifies the communication between the eight machine stations within the rotary table. This, combined with the flexibility of the valve concept, permits easy retro-extension of the machine.
Fausone was visibly pleased with the result of the collaboration. "Our customer is now able to double production, while improved process control means that defective components are removed at each stage of production, ensuring that the quality of the end product is 100% right."
For more information contact Ian Jacobs, Tectra Automation, 011 971 9400, ian.jacobs@tectra.co.za, www.tectra.co.za
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