Flexible Press Automation Case Study

Roberto Dudda November 2016

Comau SpA- Press Automation Business Line

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Introduction to Comau

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Press tending the traditional Approach

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Automated Racking solution - The advantages / Savings - FCA Melfi Case study - The solution

Agenda

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- What were the savings / key gains - Considerations to ensure successful implementation

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Automated Press tending examples

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Press tending specific Robots

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Next steps in press tending automation

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Introduction to Comau

Automation Systems Robotics and Automation Products Powertrain Machining

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Press tending traditional Solutions 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; •

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)

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Automated Racking Solution – The advantages / savings AUTOMATIC RACKING with 6 axis robots is an excellent alternative solution solving several problems, applicable both in new

and in existing press lines. 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) Property of Comau - Duplication prohibited

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Automated Racking Solution - FCA Melfi Case Study 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)

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Automated Racking Solution - FCA Melfi Case Study 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

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Automated Racking Solution - FCA Melfi Case Study 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

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Automated Racking Solution - FCA Melfi Case Study

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

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Automated Racking Solution – The Solution 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)

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Automated Racking Solution – The Method Adjustable Conveyor - Adjusts to support varying part shapes - Automatically adjustable

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Automated Racking Solution – The Solution The Method • Study of special stations for stillage autocentering • 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

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Automated Racking Solution – The Solution The Method • Study of special stations for stillage autocentering • 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

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Case Study – Savings and Key Gains • 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)

Station for by-pass and programmed inspection Manual operations in case of station Switched off

• 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)

Station for manual inspection

• 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

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Considerations To Ensure Successful Implementation •

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

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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);

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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

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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

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Example  of  “in  line”  inspection  as  “cycle  time   neutral”.  Measurement  is obtained during conveyor transfer at up to 800 mm/sec 15

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Press Tending Specific Robots

SMART 130 3.7 SH

PRESS 100 3.2 Axes Number Payload [kg]

G2 – G3 lines

100 638

Max Reach [mm]

3209

Speed AX2 [°/s]

120 102

Speed AX3 [°/s]

120

Speed AX4 [°/s]

190

Speed AX5 [°/s] Speed AX6 [°/s]

Axes Number

6

Axis 5 Torque [Nm]

Speed AX1 [°/s]

BRIC modules & conveyors

SMART5- NJ Press 130-3.7 SH

SMART5- NJ Press 100-3.2

190 250

G1 lines

6+1

Payload [kg]

130

Axis 5 Torque [Nm]

1226

Max Reach [mm]

3742

Speed AX1 [°/s]

120

Speed AX2 [°/s]

95

Speed AX3 [°/s]

112

Speed AX4 [°/s]

180

Speed AX5 [°/s]

175

Speed AX6 [°/s]

250

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 autocentering or turning tables. Property of Comau - Duplication prohibited

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Next Steps In Press Tending Automation AGILE 1500: First model of autonomous mobile platform providing modular and wide ranging solutions for logistic matters: • • • • • • •

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)

AGILE 1500 – available in 2017

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

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