Agile mould workshop automation is produced

The new-style MegaCell product that Rexam company produces aims utmost ground with it full automatic the mould mold insert that mode realizes unmanned value to defend and electrode production, and can be changed easily into type of hand movable mould in order to suit " define oneself " the job. "From at the beginning we know MegaCell must be designed very neatly. " the department of Rexam mould production business that place of Rexam Healthcare company belongs to (RMM) manager Len Graham says so. The attends to by the robot production that the automation engineering group that MegaCell is RMM is carrying out is unit, it will finish the production of whole pattern automatically. Current, the construction of MegaCell is undertaking in grading. The first phase of construction is finished satisfactorily already, this child treatment unit is comprised by several machining center and electric spark machine, they put the both sides in a robot respectively, such designs are for the production of electrode of brief fossil Chinese ink and mold insert of mould of sclerotic tool steel. According to the plan, rexam company still will raise more child treatment is unit, with existing robot orbit end to end, build finally integrated full automatic turn product line, enclothe almost whole pattern to make a process. MegaCell was reflected a few bold designs and moving characteristic, among them a lot of already included in the first phase. Mr Graham says: "The first stature treatment is unit it is one kind facilitates patulous in the future prototype. It follows the main principle of the agile automation of the MegaCell that we are developing. " Mr Graham thinks: Be based on this to plant " flexibility " , this treatment unit can produce the electrode with very wide range or mold insert not only, the mode that also can defend with unmanned value or hand are moved from the definition treatment mode moves. When Mr Graham and his group is beginning to develop MegaCell idea, move an operation to the hand respect demand is very high. Although a few concepts that process unit are started formerly, but the double mode ability with this unit treatment is the most important, because it reflected the specific characteristics of mould production and automation (graph 1) . Graph robot of a 1 Workmaster is serving to be mixed at all machine tools in treatment unit equipment, and it won't be in to operator define workpiece to cause explanation of interference Mr Graham to say oneself from the treatment on the machine of the line, great majority resembles RMM the job that such mould workshop does not suit automation to machine too. This kind " machine from the definition " the workpiece of tray of unwell and the mould part that tool bag draw together needs to repair, operable standard or urgent workpiece. "If die manufacturer wants to preserve a can duplicate tradition,the hand uses automation system of the function, this is highbrow, vice versa. Do not have double standard function, indemonstrable the validity that this automation invests, or make this automation and the reality that the mould produces antipathic. " Mr Graham says. According to the design, any machine tools that configure in the first phase can leave a line to operate, common like, independent CNC machining center or electric spark aircraft move in that way. Compositive measure in the 3 coordinate of the first phase machine also install with same way. No matter leave the facility of line position how, the others in this treatment unit can continue to play effectively movement in automatic mode. Process unit advocate accuse a system to meet already discharged decided exercise leaving a line to be laid aside temporarily. After operator finishs what define oneself to work from the line, press pushbutton can resume automation production in the exact position when pausing formerly. "Because machine unit to have double standard function, it can undertake almost all electrode treatment, work in order to support the others of mould workshop. " Mr Graham says, "No matter we still need 100 need 1 only, can handle in the first phase. " no matter why be being planted,operation pattern falls, unit of this stature treatment can offer ± 0.

0001in (1in=25.

4mm, similarly hereinafter) or taller precision. Be a whole world to create mould Rexam company is the international consumable that is headquarters with British London packs a supplier, it is the whole world the biggest pull one of coal tub manufacturer easily. The medical treatment ministry of the company is etc of rigid package of medicines and chemical reagents the banner supplier of rigid package of equipment of plastic medical treatment. The mould of Rexam company creates a department (RMM) for its in the factory of Buffalo Grove all factories offer a mould to make a service. The pattern that RMM produces includes to enrage the Injection Mold Tooling of acupuncture point high accuracy, high; The monolayer type, type that fold a layer, retreat buckle type, much material and rotate all sorts of configuration such as cube. RMM still is a lot of is in medical treatment, pharmacy, general case, every day object and family nurse the exterior client that waits for the market offers Injection Mold Tooling. Current, the factory of RMM has close 100000ft2 (1ft2=2903mm2, similarly hereinafter) the space has mould design and production, center of development of a product undertakes mould Acceptance Test is mixed short-term try move, and one group is used at management, groom and the office of the conference. Cut of vinculum of bag of its engineering capability and electric spark forming machine are bed, CNC Milling, of all kinds grinder (coordinate grinder, surface grinder and round grinder of inside and outside) , machining center of 5 axes much mission and laser engraving tool. After the design that Mr Graham was holding the position of 8 years and the adviser that install automation mould to make a system, 2011 end joins Rexam company formally. 2003, a brief beehive type pattern that designs by Mr Graham produced device to draw attention of quite a few. The originality that a lot of automation moulds make got developing on this device. "Those who attract me to go to Rexam company is a chance that increases the flexibility that the mould creates and productivity to new standard. I also like here mould to make the mind of the group very much, it is a characteristic of Rexam company production culture. " Mr Graham says. MegaCell includes as similar as the first phase 4 treatment unit, it is the core that the most advanced pattern that RMM place drives makes a technology. "Its sophisticated technology performance is on a lot of levels. " Mr Graham explanation says, "Double standard moves a function especially important. " one of main difficult problem that double standard function solved mould workshop to move the place when changing a system to be faced with to one each in changeover, if why abandoning the case of flexibility,leave implementation high yield namely. "Successful mould creates a company must both holds concurrently. " Mr Graham says. Good to do work from the definition and had defined oneself the first phase runs orbital a side to have forming machine of two electric spark in the robot; Another side is machining center of CNC of two Mu Ye, one is used at the milling of electrode of black lead, copper and mold insert, another is used at black lead milling only. One aspect of the matter is two disc conveyer belt that have 250 places the memory of tray of System 3R Macro of type (graph 2) . In another end it is a Cai Sisan coordinate measures machine and type of bookshelf of a System 3R Dynafix to assemble and unassemble station (graph 3) . Install this stature to machine unit job to began in September 2012, to March 2013, all machine tools and equipment already all reached the designated position, devoted move. Buy of this treatment odd first wife has a lot of inside the double standard of buy runs unit. Graph the store that 2 acetabulum put on goods shelves of disc conveyer belt implement in graph two of 3 the first phase an electric spark forming machine and assemble and unassemble a side that stands in treatment unit, another side is two machining center are measured with 3 coordinate machine Nextpage for example, all machine tools join from flank and robot, such operations are in with Control Panel before personnel can take a machine tool freely. The robot enters the airspace that operator is in impossibly. Safe interlock prevents the front door of the side door of the robot and operator to be opened at the same time. Before pressure mat regards amid of farther safety precaution installation as an electric spark machine, because rise,fall the arm that coal tub can not hold back a robot completely enters working area. Step on cushion to be able to prevent a robot to enter work area, loose cushion removes automatically namely prevent, the accident when because this won't appear,the machine tool works. Dou Chaotong of all machine tool one direction, the superintendency personnel that processes unit and observation personnel can see the activity of operator. Accordingly, two electric spark machine on the right side of by the robot from left and responsible attend, two left machining center are by the robot from on the right side of attend. Etc of system of condenser, filter, hydraulic pressure assists equipment to be located in the corridor side of the machine tool, with convenient examination and maintenance. 3 coordinate are measured machine construction of type of the door that it is dragon, its ahead is the corridor of operator, rear the orbit that is a robot. When the robot is moving, smooth act can protect the area of operator. Treatment assembles and unassemble unitly the station is located in robot orbital other a side, undertake protective through interlock and smooth act likewise. A these 4 machine tools, 3 coordinate are measured machine and one assembles and unassemble the Dynafix tray receiver that stood to deploy identical System 3R. These receiver use general fixed workpiece interface. The sufficient tray that processes unit is changed made sure 3 coordinate are measured machine is OK accurately certain work place, be in tray pass in and out child when any tray receiver in processing unit, maintain in ± 0.

The error less than of 0001in (graph 4) . The Macro that is like System 3R or Magnum this kind of small tray, can install go up in bigger Dynafix tray, in order to lengthen treatment cycle. The radio frequency that the robot passes installation to go up in all tray identifies chip (RFID) can reclaiming or make when memory tray identify. Graph 4 it is robot or operator no matter when undertaking tray lades, measure with 3 coordinate on the machine tool there is identical tray receiver to be mixed accurately in order to ensure on machine but reduplicative locates crucial bridge Mr Graham says, design a such systems, want to make define the job to be able to use the dominant position that tray changes already oneself, can with agile, the hand moves an operation compatible, this is a challenge that designs a group to MegaCell. This solution used the special magnetism sucking disk that develops by Hermann Schmidt company, with join of 3R tray receiver. These magnetism acetabulum all provide precision abrade pass, the side course of exact location, the fixed position of workpiece is completely but reduplicative. This magnetism acetabulum acted as child exercise of unmanned in charge of mixes the automation that processes unit to define the bridge between job of workpiece hand movement oneself, mr Graham explanation says: "Our target is to make there is enough work from beginning to end in these groovy tray, keep in order to hold the machine day and night in treatment unit moving below automatic mode. Meanwhile, from the definition workpiece can secure the frame in magnetism acetabulum to go up, be sent by the robot next or to load is moved from line defensive position in the machine. " had magnetism acetabulum, can install all sorts of individual or many clamping apparatus. These clamping apparatus all change a system at tray of System 3R Dynafix accessorily, include lesser Mini tray and Magnum tray or the workpiece that all sorts of other convenience to secure plant. When holding key, magnetism acetabulum can intervene child treatment assembles and unassemble unitly the job of the station, send 3 coordinate to measure machine with test and verify the position of all workpiece, convey to go up to proper machining center or electric spark machine next. Any other installation secure device to be able to move with this kind of means in the workpiece on Dynafix. But, magnetism acetabulum is not special work at be being defined oneself. Peg or lining cannot use the work that clamping apparatus of tray System 3R secures this kind, can use V form piece or vice will place hold, fixed go up in magnetism acetabulum. Accordingly, magnetism acetabulum rose child those who process unit is automatic move serviceability with the hand. Mr Graham emphasizes, why to no matter use,plant operation mode, assure child a crucial factor that machines unit benefit is minute of admeasure of every workstation measure a ball. These measure a ball to use affirmatory object the position to some reference point. Coordinate locates (X, Y and Z) always build with mechanical deflection going up with the impact that measures a ball, no matter whether is this workpiece installed,go up in magnet, or in the clamping apparatus on magnet, in the Macro that still goes up in Dynafix or Magnum tray (graph 5) . Graph the 5 tray that contain port of System 3R Macro are measured in 3 coordinate by clip in the Dynafix receiver on machine, installation has near another Macro unit advocate the treatment unit that tool ball or other work define oneself is in this treatment unit, the most important element that is used at treatment to define work oneself is sightless, namely the modification that this treatment unit controls software and system of CAM process designing. For example, machining foundation of unit and overall pilot is the Workshop Manager software of System 3R. This software aims to work orderly through pressing a plan, dog the track of each tray, mobile tray pass in and out machines a station to wait, coordinate what automation processes unit to move. The supplier revised this system for RMM, make operator OK according to the numerical control system of any machine tools the instruction interrupts automata. The numerical control system on every machine tool also needs to revise, make its can be broken away from and participate in the interface of Workshop Manager afresh. In practice, operator meets those who choose to go to the lavatory to stop to nod switch mode normally, finish in current tray task for example when. Move an operation in one's hand when switch when, the robot can take away current tray, send memory conveyer belt to reserve it. The robot perhaps is taking the tray that carries RFID to define work oneself (go up in magnetism acetabulum normally) return, perhaps activation interlock, make operator can open the door of the machine. Begin from this, operator runs a machine tool with groovy means, be like it is an independent machine tool in the workshop. After defining the job to finish oneself, operator sends " return automatic mode " signal makes Workshop Manager system new intervene the control to the machine tool. Mr Graham says, the machine tool inside treatment unit moves mode to fall to move from the line in the hand everyday normally make an appointment with 4~6h. In the time of the others, they move below the case that 80 ％ defend in unmanned value, this depends on the arrangement of workaday Cheng. The target of each machine tool is to process a kind of work every week at least 125h. "We think this is the longest cutting time, it is reasonable and feasible, still must put apart is proper surplus makes first item inspection, undertake test and verify to all component. " Mr Graham explanation says, "Every machine tool in making process unit measures machine implementation with 3 coordinate this one target, the client that can help us shortens production is periodic, improve integral quality, reduce mould cost finally, thereby benefit. " MegaCell " super demon " although the first level of MegaCell is overall already,move, but be not its all character and function got be developinged adequately. The formulate of automation construction team of RMM an item that improve and rises is only, in be being carried out, already was close to now finish. "The first phase is lab of a job, the help we make MegaCell becomes automation mould to make most intelligent system. " Mr Graham expresses, he calls MegaCell " super demon " . Improve the project of productivity of the first phase to include further: ● exercise attempers proper lead, make a robot can timely shift reachs the designated position, the preparation that undertakes assembling and unassemble has been made in workstation, in order to eliminate the time lag of as a result of robot shift production. ● uploads Internet through wireless video, make the client can examine the operation that having remotely. Treatment unit superintends personnel can long-range video monitoring and long-range birth control pass mobile equipment to move in the home child treatment is unit, examine moving process to examine report. ● intercurrent process designing. Do not have between the PowerShape with Delcam, PowerMill and PowerInspect seam be linked together. This concept is to build " one-stop " process designing is conversational, from mould of SolidWorks 3D CAD the design begins. Before programmer is establishing the cutting tool method of black lead electrode, use PowerShape to establish electrode model and program of relevant electric spark aircraft first. The model that uses this electrode next establishs milling program through PowerMill. The electrode that machines when place measures the examination on machine in 3 coordinate when, should machine unit technician to use PowerInspect to ensure place needs " crucial " the requirement gets satisfaction. In ● treatment moving process corrective be based on 3 coordinate to measure of machine detect data. For example, measure when 3 coordinate machine detect electrode a certain dimension a bit hour, it can give out signal to give electric spark machine to surround in order to adjust what last essence of the electrode in the program burns orbit parameter. New deflection capacity can be downloaded automatically to be installed in order to update original order. Final hold the RFID appraisal on the tray of this electrode whether is it the result that adjusts program place good to arrive. ● electrode presses dimension automatic sorting in order to optimize electric spark handling time. This strategy is the dimension that already was machined according to its allocates electrode to measure of rough machining or finish machining. The electrode that approachs upper limit relatively suits tall in rough machining tatty to use a case most. Those applicable that approach lower limit adjust convention to surround at finish machining orbit. The construction of the 2nd phase plans 2014 begin first quarter. This treatment unit will include 5 axles the lathe of machining center, surface and round grinder of inside and outside and tool of a spot. Will deploy a 3 coordinate to measure machine and a robot. There is disc conveyer belt in the first phase and the boundary of the 2nd phase, make tray can mobile between treatment unit. This phase will be the treatment unit that the last compose builds, it is the independent treatment unit opposite the workshop, it will include to make the machining center of a few horizontal of mould board and mould base. Without competitive Graham the gentleman says between mode, the double standard ability of MegaCell concept reflected the important principle that the mould makes. "Important is not the level of automation, the standard that applies however. " in other words, the treatment unit that runs below type of hand movable mould does not use an advanced technique on behalf of its little, it is more sufficient favourable geographical position used his to produce latent capacity instead. The function that should machine unit treatment to define work oneself increased its extraordinary gain capacity, it is almost like the job that because define the flow of workpiece and tray oneself,changes without what seam. Two kinds of mode are to stem from need, and complementary. "The key is to should make the handling time of every machine tool the biggest change. " Mr Graham says. Actually, it is operator or robot can make the machine tool maintains no matter move, this is done not have how old difference, want a machine to busy as far as possible only. Want a machine to busy as far as possible only.. CNC Milling