Modular Automation Package for Turning Machines

Machine shops of all sizes continue to seek ways to automate what they do to improve consistency, save time and reduce cost per piece produced. In response to that need, EMCO Maier has partnered with UltraTech Machinery (Cuyahoga Falls, OH), a designer and builder of high production equipment, to offer a modular robotic automation cell that is designed to provide cost-effective, flexible part load/unload for its turning machines.

The new package was demonstrated recently with an EMCO Maier HT45 SMY universal production turning machine, a versatile, multitask production turning/milling center designed for a wide range of applications on bar stock up to 45 mm diameter. The Hyperturn 45 includes high-performance main and counter spindles, two tool systems with a total of up to 24 driven tools, and a stable Y axis with a 70 mm travel in the upper slide system and a Z2 axis in the lower slide system.

"The integration partnership with UltraTech will be a positive for us and our customers," said Philipp Hauser, President, EMCO Maier USA. "Lately we have seen more and more sales activity and RFQs for turnkeys and automation. One of our strategies was to find a local U.S. partner, especially for robot integration. Having Motch & Eichele as one of our bigger dealers, and a partner company of UltraTech, it was clear we should work with UltraTech to develop a solution."

According to Bob Hagarty, CEO of Motch & Eichele, "The challenge was to put a flexible handling solution around a compact turning machine that was also scalable for use with a larger machine. We developed a universal base with left and right hand versions configurable to the machine model. It is a production-proven solution with millions of open/close cycles. We call it the EMCO Factory Automation Solution. It is designed to be easily used in small shops as well as larger plants. The overall package is non-threatening to machine operators. Often, the most challenging portion of an automation solution is part infeed and outfeed. The multi-drawer part cabinet offers a simple, reliable, flexible method to provide a useable buffer of oriented parts to the robot. The user is responsible for very little, including part specific gripper fingers and trays for the drawers, robot path point teaching and minor program modifications as needed for tray unload/load and machine unload/load."

"Since UltraTech's heritage is in production, we knew what this solution needed to be: versatile machine tool construction, easy to install and use and highly flexible," said Steve LaMarre, Director - Automation Sales.

According to a spokesperson, the fully integrated solution is based on the FANUC M-20iA robot, which has a relatively small footprint with heavier payload and larger reach than most other alternatives, and therefore more machine use options.

Part drawers with heavy-duty drawer slides have a weight capacity of 300 lbs. and can accommodate parts up to 6" tall in a useable area of 18" x 24". Actual part quantity is dependent on the locating trays supplied by the customer. The robot has a 20 kg payload with 14 kg available for customer-supplied finger details and part weight. Load/unload times are application dependent, but 6 - 8 seconds has been demonstrated.

All equipment is mounted on a common base plate with forklift pockets. The base has drip pan and walk-on grating under which all robot cables and interconnect wiring are concealed and protected. Simple installation consists of locating the system in front of the machine tool within robot reach, leveling the base using the included screws, and lagging the base to the plant floor. The base package is completely assembled and fully tested prior to shipment.

Users can select end-of-arm tooling from two gripper models and three different mounting configurations based on the workpiece geometry and weight.

Software options are designed to allow easier programming and greater safety and help protect equipment from damage due to improper programming. The user has complete access to the machine controller without interrupting robot operation, as well as unrestricted access for set-up and tool changes.

"I think the new cell speaks for itself," said Hauser, "and with a very competitive price point, it should be well received on the market. Our decision to come up with a great solution has been confirmed by recent industry surveys that indicate automation is becoming increasingly important to our customer industries. The automation package offers a very favorable capability/benefit vs. cost and can be delivered quickly."

"Other solutions have a smaller payload and shorter reach," said LaMarre. "They also are not fully integrated or modular. Our solution uses I/O blocks and cables so it is literally plug & play. Plus, it includes a secure workpiece storage/service drawer mounted on the platform that is easily accessible by the operator, yet the robot can access other drawers at the same time.

"It is very easy for a shop with no automation experience to install this. There is no need for a third party automation house; it is basically a catalog item."

For more information contact:

EMCO Maier Corporation

46850 Magellan Drive

Unit 160

Novi, MI 48377-2448

248-313-2700

www.emcomaier-usa.com

UltraTech Machinery, Inc.

297 Ascot Parkway

Cuyahoga Falls, OH 44223

330-929-5544

sales@utmachinery.com

www.utmachinery.com