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In Focus - Archive October 2011
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With efficient gripping systems, productivity can be greatly increased.
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13.10.2011 -
For a number of years, everybody was talking about the energy efficiency issue. Increasing energy costs, a growing environmental awareness, and the political guidance were all triggers for many companies to highlight the energy consumption of machines and components in their communication with the public. Efficiency is much more than simple energy efficiency now, especially when considering the
time- and cost aspects in regards to efficiency. When all these factors have been considered in a holistic way, the full potentials for modern machining and production become visible. The modern clamping devices and gripping systems make it clear how complex the possibilities are.
Efficiency is one of the central driving forces of economy. When the ratio between the size of a provided service and the necessary expenses are compared, it describes in the classical sense the economical efficiency. The DIN EN ISO 9000:2000 defines efficiency as the "relation between the used resources". The aim of every commercial enterprise is to achieve the highest possible return for any given effort. Efficiency is given if the quotient from return and effort is equal or greater than 1.
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Energy-efficient: the PPU-P from SCHUNK is the world’s fastest pneumatic Pick & Place unit on the market. It is equipped with micro valves by default.
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Costs, time, and energy
In relation to manufacturing and production, efficiency is grouped in three sections, cost efficiency, time efficiency and energy efficiency, whereby all three are related to one another. Efficiency is a solution, if one efficiency aspect is not growing at the expense of the other two. A particularly energy-efficient plant is only successful, if the involved acquisition costs and the current operating costs do not rise disproportionately. The same applies for a time-efficient plant. Therefore a reduction of cycle time is only efficient if it isn’t outweighed by a disproportional increase of cost.
A similar problem arises in case of time- and cost efficient measures, which go to
the expense of energy consumption, and thus of the environment. Although the predominant view is that natural resources and energy are infinitely available, there is no reason to conserve energy. In the US it has long been possible to sell vehicles with an astronomical fuel consumption. However, environmental awareness has become much more predominant all over the world. Due to the energy taxation, and the subsidization of energy-efficient solutions, legislators are making laws that will penalize a company that has high pollution emissions, while offering incentives for companies who implement environmental-friendly solutions. Therefore, environmental-friendly technologies are in much greater demand today than they were ten years ago. Rising energy costs have also encouraged companies to conserve their resources.
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Cost-efficient: the most powerful hydraulic expansion toolholder ever: TENDO E compact from SCHUNK.
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Cost efficiency: the crux of the matter
Cost efficiency of capital goods has always been a decisive factor of success on the market. The old bit of business wisdom "profit lies in procurement" is still valid. Ideally, companies want higher effects for lower costs, which is much more cost- efficient, and thus a more attractive product to the customer. In the past, the net purchase price was the most decisive factor in the purchasing decision. Today, the overall costs of a product in relationship to the entire period of use (Total Cost of Ownership) are more important than ever before. In view to the cost efficiency, those products are the most attractive ones, which offer a substantial improvement of performance, are more economical, have a longer service lifetime, and allow for higher flexibility, or which minimize the maintenance effort. A highly typical example is the TENDO E compact hydraulic expansion toolholder. Its price is lower than that of conventional hydraulic expansion toolholders. At the same time, it can transfer torques of up to 900 Nm at a diameter of 20 mm in dry clamping condition. No other hydraulic expansion toolholder on the market achieves such a high torque.
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Time-efficient: theVERO-S quick-change pallet system minimizes set-up times, and also ensures maximum precision.
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Time efficiency allows higher productivity
A second also important factor is the time efficiency. It can be achieved on two levels in manufacturing and production: by reducing assembling time to make the parts. Non-productive times are also reduced particulary the set-up and waiting times. One of the most efficient instruments in the field of clamping devices is the quick-change pallet systems, such as the VERO-S from SCHUNK. It helps to reduce the set-up times and thus the downtimes of the machine by up to 90%. The workpieces are set-up in parallel time to primary machining outside the machine, and are quickly and highly precisely clamped by means of a quick-change pallet system in the machine. This increases the output, lowers costs, and excludes operating errors during the clamping operation. In case of scheduled orders, and for "rush jobs", the manufacturing process is interrupted for only short periods of time. It is justifiable that quick-change pallet systems are considered to be a highly efficient set-up time killer. Those who want to know the productivity potential of such a quick-change pallet system in their own factory could easily determine it. A general rule of thumb will be: the longer a machine has to be set up, and the shorter the actual time of machining, the faster their investment will pay off. Examples from the production of individual parts and small batches show what is possible. If a switched-off machine is set-up for 20 minutes and then the workpiece is machined for 10 minutes, a quick-change pallet system can shorten the manufacturing process in the machine by about 66%. In other words, three times more components can be machined on the same machine, which enormously boosts the productivity potential. SCHUNK, the competence leader for clamping technology and gripping systems has gone one step farther with the VERO-S, which has a pull-in force of up to 40000 N. Moreover, all the functional components are made of hardened, stainless steel, and are therefore corrosion resistant.
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Efficiency by retrofitting: the valve box from SCHUNK reduces the compressed air consumption and shortens cycle times.
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Energy efficient modules lower costs and increase the output
Finally the third decisive factor is energy efficiency. Increasing energy costs, legal requirements, and the demands of climate protection, make the efficient use of energy an important competitive factor today. Thereby the effects which can be achieved by using energy-efficient modules, can partly exceed the aspects of energy consumption. In case of pneumatically actuated gripping systems with fully integrated micro valves from SCHUNK, enormous benefits are achieved. They noticeably minimize air- and energy consumption, while providing for high cycle times. The smaller the actuator, the higher the efficiency, therefore micro valves which are used for small component handling and assembly can cut cycle times in half. Electrically driven pneumatic valves are now so small, that they can be directly located at the air supply of the actuator, and the consumption of expensive compressed air is massively reduced. Up to now, the compressed air of the air supply got completely lost. If micro valves are used, just the piston area of the actuator has to be filled once with compressed air, and not the complete air supply per cycle. In most cases, this reduces air consumption by up to 90%, and accelerates the response characteristics of the actuator.
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BLUE SIGMA - In total more efficient
With BLUE SIGMA, SCHUNK the competence leader for clamping technology and gripping systems is promoting a symbol which will set new standards. Products and solutions that preserve resources while also saving energy, costs and time, will be represented with the BLUE SIGMA. "Increased efficiency happens on several levels at SCHUNK, which are intermeshing, and are generating total efficiency", said Matthias Poguntke, Business Unit Manager for Product- and Portfolio Management Clamping Technology and Gripping Systems at SCHUNK. "It is our goal, to link all the relevant factors effectively", said Poguntke. The spectrum ranges from cost-efficient TENDO-E compact hydraulic expansion toolholders to time-efficient VERO-S quick-change pallet systems, to the energy-efficient valve technology. BLUE SIGMA, the goal of the innovative family-owned company, informs the users that it is worthwhile to consider efficiency as a whole, and to think far beyond simply saving energy.
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12.2011
Clamping solutions for automated mass production
Efficient manufacturing means automated manufacturing. This particularly applies if large series are machined. This is when the clamping vises, which are the direct interface to the workpiece, playing an important role. In only a few seconds, they have to mount the components, safely and precisely align them, clamp them with-out deformation, and after machining they have to be reliably released. In view of the several million clamping cycles, which have to be carried out by many clamping vises being exposed to chips and coolant, process reliability is one of the decisive factors of success.
 more...
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11.2011
Modularity the factor of success
When designing gripping systems for handling and assembly applications, standardized modular systems will play an increasingly important role in the future. They reduce the necessary time for project planning and commissioning, and lower the investment costs. Due to the standardization, they offer optimum preconditions for stable processes. Since modular designed units can be flexibly modified and enlarged, they can be re-configurated for any changes that come up in the future.
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10.2011
Producing more efficient
For a number of years, everybody was talking about the energy efficiency issue. Increasing energy costs, a growing environmental awareness, and the political guidance were all triggers for many companies to highlight the energy consumption of machines and components in their communication with the public. Efficiency is much more than simple energy efficiency now, especially when considering the
time- and cost aspects in regards to efficiency. When all these factors have been considered in a holistic way, the full potentials for modern machining and production become visible. The modern clamping devices and gripping systems make it clear how complex the possibilities are.
more...
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09.2011
Welding demanding materials crack- and pore-free
Laser welding technology is second-to-none, regardless of whether you are dealing with gears and injection molds or delicate and challenging welding works. When conventional cw lasers and many Nd:YAG-lasers reach their limits, modern process strategies can help to machine demanding welding metallurgies, different types of materials, or micro components process reliably and efficiently. Laser welding is particularly used if components have to be joined at a high welding speed, because slim welding seams, and a low thermal distortion are required. Compared with other welding techniques, the energy during laser welding fully penetrates into the material.
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08.2011
More than a "Stopgap":
Intermediate sleeves ensure safe clamping and precision
They appear to be unimposing - but they are located at a decisive interface in the chain of the metal cutting process. Between toolholder and workpiece, the intermediate sleeves influence reliability and precision of the clamping operation. The thin-walled, mostly slotted precision sleeves cover the difference between the clamping diameter of the toolholder, and the workpiece which has to be clamped. Functioning like reduction inserts, they multiply the fields of application of the toolholders or arbors, compensate tolerances, and ensure safe and gentle clamping of gear wheels. The newest sleeve design can do even more. Intermediate sleeves with nozzle effect extend the tool service life and increase the volume machining.
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07.2011
Changing, machining, compensating -
current trends in robot accessories
In dealing with industrial robot efficiency cycle rate and process reliabilty largely depend on their front ends, the grippers and other tools, but also from the effectors’ interfaces to the robot arm. Robot accessories have a great influence on the robot’s performance, flexibility and fields of application. Latest developments of quick-change systems, driven tools, compensation units, and power sensors show that the potentials of modern accessory components are enormous. Experts assume that their importance for handling, assembly and manufacturing will continuously increase.
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06.2011
Deformation-free clamping:
From the plastic chuck jaw to the hybrid chuck
In case of rings, housings and other workpieces which are highly deformable dur-ing processing, conventional 3-jaw chucks quickly reach their limits. If the clamping forces are too low, there is no secure hold. If they are increased, workpieces de-form, and precision is reduced. A comparison shows the alternatives, the differ-ence between them, and how users can achieve an optimum result.
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05.2011
Service robotics is the future key market
Insiders are convinced that golden times lie ahead for service robotics. Around the world companies and institutes have recognized the potential of robots as helpers for humans, and are working on everyday solutions. All different kinds of businesses are interested in service robotics, from large companies, to innovative startups, and also conventional manufacturers of industrial robots, electronic and automation components.
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04.2011
Having set-up times under control
You cannot earn money with a turned off machine. However, in many companies the workpieces are still set-up in a complicated and time-consuming way on a grooved table while the plant is turned off. But solutions exist, which optimize the machine tool load. Modern quick-change pallet systems demonstrably accelerate the machining process, and at the same time, ramp up the precision and process reliability score. This leads to a reduction of set-up costs of up to 90%.
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03.2011
Toolholders for micro cutting
Clamping tools used for micro cutting have their own rules. The subtle tools, the high spindle speeds, and the extreme precision requirements are a challenge for every tool manufacturer and user. Those who want to achieve continuously precise results, need mountings with a high run-out accuracy and balancing grade. Moreover, they should be as slim as possible and resistant to dirt. Furthermore, they have to assure that even small tools can be precisely adjusted and exchanged.
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02.2011
Leight-weight design increases efficiency of Gripping Systems
Light-weight modules are now playing an increasing role in the area of gripping systems. Integrated into the system, they are saving energy at the same efficiency, or achieve a considerably higher efficiency at the indentical energy consumption. In both cases, the efficiency of the whole system is increasing. This is why the lightweights are so interesting for plant manufacturers, system integrators, and users. Since light-weight solutions had the reputation of being overly expensive in the past, recent developments now show that efficiency and cost control can go hand-in-hand. Modern designs, materials and techniques are paving the way to lighter solutions, which are rigid and robust, too. This also offer many more advantages.
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In Focus - 2013
In Focus - Archive 2012
In Focus - Archive 2011
In Focus - Archive 2010
In Focus - Archive 2009
In Focus - Archive 2008
In Focus - Archive 2007
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