High Tech Increases Efficiency in Tough Jobs
The MMC-R modular automated robotic fixture-plate system from Makino competes in general machining markets by increasing machine and labor efficiencies when boring and milling tough and hard materials in high product mix, low volume production runs.
Posted: November 5, 2012
The high-torque, integral drive spindle employs a standard CAT 50-taper toolholder, with an HSK-A100 option. The 10,000 rpm spindle on the a81M has an available 744 ft-lb (1,009 Nm) peak torque rating. The spindle has no corresponding loss of acceleration and deceleration. The quick acc/dec ranges are from 4.4 sec to 3.8 sec at 8,000 rpm. To match that torque, the spindle employs 50 hp from 2,000 rpm to 5,000 rpm. This duty rating and continuous output of the spindle lends itself to difficult cutting.
This horizontal machining center has an X-, Y- and Z-axis of 35.4 in x 31.5 in x 40.1 in (900 mm x 800 mm x 1,020 mm). It has a rapid feed rate and cutting feed rate of 1,420 ipm (36 m/min) in X- and Z-axis and a 1,182 ipm (30 m/min) in Y-axis. It uses a 25 in (630 mm) pallet that is able to handle workloads of up to 10,800 lb (4,900 kg). The thrust capacity of this machine has 25 percent more axes thrust than the previous a81 machine. It uses a center trough-hinged conveyor for fast and effective chip evacuation and has a 40-tool ATC as standard.
The fixture plates used in the automation system are constructed of steel in a variety of sizes based upon the machine size, whether it uses 4- or 5-axis machining, and the specific robot specifications. Delphin interfaces provide secure fixture plate transfer between the robot gripper and the machine tombstone for accurate and repeatable part production. By transporting fixture plates in place of a complete machine pallet, shops benefit from reduced part fixture costs.
The MMC-R can incorporate an MAS-A5 cell controller for coordinated production schedules of fixture-plate transfers, allowing increased manufacturing efficiency through reduced machine downtime. The MMC-R cell controller monitors the conditions of the robot transport and issues transfer tasks to the robot. Being able to implement dynamic scheduling with the MAS-A5 cell control software of the automated system enables an operator to easily produce fast-priority changeovers by simply loading the raw stock, calling up the program and then running the exact parts required.
The MAS-A5 software can implement the same work programs and offsets to follow a job no matter which machine it goes to, allowing for identically produced parts on each machine without discrepancies. Using this cell control software, an operator can manage multiple machines, tools, fixtures, production schedule requirements, programs and program changes. Its tool resource management feature notifies the operator when required tools have exceeded their estimated life. Its tool-life monitoring function informs the operator of how many spare tools are required to finish the current project.
All of this enables the software to offer efficient single-point operation of multiple machines, orders, products and maintenance requirements and provide system monitoring as well as historical data, trending, analysis and tracking. With this software, a shop can cut back on fixture upkeep and machine maintenance, all while saving on costs. By taking the guesswork out of tool and insert-change timing, the software helps to enhance product quality, ensure that operations run smoothly, and save financial, time, and maintenance resources.
A human machine interface (HMI) is integrated into the system for initial setup and alarm/event messaging to ensure in-progress production security. Integrating these modular automation components to their full potential based upon the unique demands of a shop can greatly increase overall efficiency.
Makino Inc., 7680 Innovation Way, Mason, OH 45040-8003, 888-625-4664, Fax: 513-673-0962, www.makino.com.
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