Expert Report “Smart Automation”

How great would that be? In times when there is a shortage of skilled labour everywhere, maintaining or increasing productivity in cutting production without full automation? How is that supposed to work? Stay relaxed! The solutions have been around for a long time. Those who think and act flexibly, innovatively and are open to technology in such challenging times can score points - and not just with their customers. Employees will also be impressed.

Briefing: “Everybody, we have a last-minute change of plan. Leo, can you please turn 1,000 ball cups to size on the Haas lathe during the morning shift? And Ria, please finish 200 gearwheels on the Hedelius machining centre.” “Will do boss, no problem.” “Thank you. Have a good evening and see you tomorrow." 

What works today will be a challenge tomorrow

So far today, so good. And what about tomorrow - when there are no more lathe operators Leo and millers Ria in sufficient numbers? Without automation, it will become increasingly difficult to maintain or increase productivity in machining production in times when there is a shortage of skilled labour everywhere. And the challenges for manufacturers have not even really begun. And when the baby boomers retire in the next few years, there will be a shortage of highly skilled labour.

And now? What can be done? Software-controlled automation with robots or new machines with interlinking? Far too rigid, too expensive and not feasible for calling up short and medium-term individual batches of an annual quota. A simple solution is needed that can be implemented quickly, flexibly and cost-effectively with the available machines and the remaining people. The good news is that it already exists. Flexible partial automation boosts productivity outside and between the - caution! - existing machines. In short: Smart Automation.

Optimise existing systems with solutions that already exist

One example: loading cells. “That's nothing new,” you might say. That's true. But where there have long been a number of suppliers with comparable products, it is important to find the right one for you and your production. So let's take a closer look. What should such a loading cell be able to do? We have asked. Well, the most important thing for users is that such a loading cell can be set up quickly, is easy to operate and programme and pays for itself quickly. In everyday use, it should take up as little space as possible, not restrict access to the machine and be quick and flexible to use. It should also be scalable and optional additional equipment should be available. A turning unit for the workpieces as well as other features such as targeted component cleaning are frequently mentioned. Flexible adaptation of the parts storage to workpieces of different sizes and heights is also important to many.

What also stands out in this survey is that many want a supplier who knows exactly what happens during the cutting processes on the machine table. This is because they tend to think in terms of solutions rather than products. For example, suppliers who also have suitable clamping and fixture solutions are considered to have more expertise in providing solutions. It is less important which manufacturer supplies the robot. The price also plays less of a decisive role if a corresponding increase in productivity ensures a short amortisation period.

"Is it already Christmas today?”

Anyone searching for the right solution will come across the flexible Smart Automation robot loading system from Andreas Maier GmbH & Co. KG (AMF) may already feel like Christmas. The new solution, which will be presented at EMO 2023, automates the handling of workpieces on existing lathes and machining centres. A 6-axis robot loads and unloads the workpieces using a pallet truck, quickly set up and intuitively programmed. It removes blanks from one of up to ten drawers below it, which it opens itself beforehand, positions them in the machine for processing, turns them if necessary and removes the finished part for storage in a drawer provided for this purpose. It fits! What more could you want? - Coming soon.

If the machine does not have automatic door opening, the Smart Door from AMF takes care of it. The unit, which can be retrofitted to many commercially available machines at any time, opens and closes the door to the machine automatically. If the machined workpieces need to be cleaned of production residues, the robot transfers them to a Smart Cleaning unit that can be positioned opposite. The parts are cleaned there before they are sent to any further process steps or dispatch Wow! That sounds very promising. Could you be even more specific?

Not even one square metre and no enclosure

Of course. It starts with the programming. “It can be done intuitively and without programming knowledge on the screen,” promises Erik Laubengeiger, Head of Product Management at AMF in Fellbach. This is particularly important when the quantities of production orders are becoming ever smaller and more diverse. It certainly doesn't get any more compact at the moment. Smart Automation has the smallest footprint on the market. At 1000 x 960 mm, the loading cell requires less than one square metre of floor space. This means that the operator can access the machine at any time. Naturally, the robot has already come to a standstill until then. This is because a floor scanner acts as a space-saving alternative to an enclosure in and ensures safety of the employee by slowing the robot down and then by stopping it completely.

The manufacturer implements the small footprint by placing the KUKA 6-axis robot with a load-bearing capacity of 10 kg on the top instead of on the side. At the end of the 6-axis robot there is a double gripper with integrated cleaning nozzle. Thanks to the different gripper geometries, it can remove a finished part and insert a new blank in one cycle. An optional turning and positioning unit enables the precise machining of parts on all sides.

Parts supply also conceivable for unmanned shifts

Underneath, there is a workpiece trolley with ten drawers with grid plates that the robot opens and closes independently. Depending on the size of the workpiece, users can place up to 2000 blanks and finished parts in these drawers. Depending on the height of the components, there are trolleys with different drawer heights. This increases flexibility. This naturally reduces the capacity. The workpiece trolley is conveniently moved in and out from the rear on heavy-duty rollers. If a second trolley is available, loaded takes place externally and parallel to production time. If the Smart Cleaning sister unit is located opposite, the capacity is doubled. This is because it also contains a workpiece trolley with ten drawers.

To ensure that loading runs smoothly and fully automatically, the Smart Door door opener from AMF can also be installed. Smart Door is for machines without automatic door opening. The unit is compatible with all standard machine designs, is easy to retrofit and operate and is suitable for many standard machines on the market. This is welcomed by managers, as their workers are no longer tied so closely to this one machine and can devote themselves to other machines and orders at the same time. "This is exactly the trick we need to counter the shortage of skilled labour and significantly increase productivity at the same time,” says one company director who does not wish to be named.

Cleaning workpieces with power air from Smart Cleaning

Being the third element, this is why he has provided the Smart Cleaning system from AMF, which is also brand new. Once the robot arm has removed a part with the gripper and inserted the next one, it guides the machined part into the Smart Cleaning unit positioned opposite. There it holds it in the air jet, which blows away chips and coolant via six quiet combination nozzles. Meanwhile, the next workpiece is almost finished. "The interaction between the three units works perfectly," says an impressed user. And because everything is set up so quickly, parts can be manufactured to order without having to build up a large warehouse. Specific enough? Okay, and there is more. Because we're not finished yet.

If there is a machine change, Smart Automation and Smart Cleaning can be moved and repositioned effortlessly and flexibly using a pallet truck. We need to scrutinise production and identify further potential where Smart Automation and “colleagues” can increase process reliability as well as boost machine running times and productivity.

Conclusion:
Smart automation for a real boost in productivity

The smart, slim and flexible loading cell Smart Automation with very little space requirement not only ensures greater productivity, but also greater independence from external suppliers. Attached to an existing lathe, it ensures reliable and unmanned continuous loading and unloading. And thanks to Smart Cleaning, the parts arrive spotlessly clean for further processing. Together with Smart Door, this not only opens the door to higher machine utilisation, but also to a real boost in productivity. With regard to the shortage of skilled labour, investment and amortisation, Smart Automation from AMF is a real asset in cutting production. Leo and Ria also welcome this.