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Issue link: https://pm.epubxp.com/i/196884
Programmable Gages Help Create Automation Cell Moving Up the Automation Ladder Te bearings are currently roughed out on four lathes that originally did both roughing and fnishing and were served by four operators. Tese machines are now split into two cells, loaded/unloaded by robots doing only the roughing operation; these cells were among the shop's earlier automation projects. Te semi-fnished parts are sent out to be case hardened to HRC 65 at a depth of 0.070 inch before going through the fnish turning operation. "Our production plateaued at 800 to 1,000 total parts per day with these two cells," Mr. Wardell says. "We had a single operator loading the machines and inspecting the parts. However, you can rely on an operator to correctly inspect only so many parts with this kind of volume, and we needed even more output. "For our next step up, we conceived a fully automated process for the fnish machining, with automatic part loading, post-process measurement, automatic tool compensation, part engraving and boxing/palletizing the parts," he adds. "We had pretty good ideas for the components of such a system, except for the part measurement technology, CNC type and software for tool compensation. Inspection must be fast to keep up with the cycle times on the parts, which can be as short as 98 seconds. Originally, we looked at white light laser inspection because of its speed, but the parts are too refective. We also looked at hard gaging and shopfoor CMMs. Hard gaging was expensive and required setup attention, and the CMM gave no speed advantage. While working with Renishaw on other :: Conroe Machine's hard turning cell was developed using the integration skills, software and programming capabilities of CNC Programmer James Wardell (left) and Robotics Technician Jef Buck. projects, we were introduced to the Equator as a possible solution." Process-Control Tools and Software Te Equator is a low-cost, fexible alternative to dedicated gaging. It uses the comparison method of measuring. A master part with known measurements taken on a CMM is used to "master" the gaging system, with all subsequent measurements compared with the master. Repeatability is 0.00007 inch immediately after mastering. To compensate for shop temperature changes, the Equator can be re-mastered at any time. It uses an SP25 probe for touch and scanning data collection, at speeds as high as 1,000 points per second. Styli are stored in an integral six-port changing rack, and :: A separate part-sorting cell consists of two Equators, a Fanuc LRMate 200iC six-axis robot, multiple lanes of low-profle conveyor, a Fanuc iR Vision system and an ATI quick toolchanger for the robot's end-efectors. The vision system tells the Equator what part number is being presented and what measurement program to run. Good parts are subsequently placed on the appropriate conveyor, and bad parts are placed on a scrap conveyor. productionmachining.com :: 47