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URC Cylinder Liner Loading
This cell handles cylinder liners for Federal
Mogul. The liners were used in various diesel engines.
URC Automation designed the cell, robot tooling,
controls, fixtures, and software.
URC Automation provided and installed the
equipment, programmed the parts and provided on-site training for
two cells.
The customer liked our design so well that we
upgraded the robot tooling on two existing cells done by another
integrator.
A quick return on investment was realized as
existing Nissan and Mori-Seiki machine tools were integrated by URC
Automation into the robot cell.
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URC Automation
integrated three existing machine tools with a new FANUC
robot for a three operation machining application.
A simple gravity
feed conveyor with an escapement and locating device queues
up raw cylinder liner castings for the robot.
The robot has a
dual gripper configuration allowing it to extract a finished
part and load a raw part at each machine tool. |
| A mechanical
collision sensor protects the machine tools and robot
gripper from damage during setup and operations.
The robot picks up the raw casting and
exchanges it for a finished part at machine #1.
The robot then goes to machine #2 and exchanges parts for
the second operation. |
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The third
machining operation required the robot to exchange parts on
a precision mandrel. The liner had to be slid onto the
mandrel 12 inches within a very tight tolerance.
After exchanging parts at the last operation, the robot
moved the finished liner to a stamping machine which stamped
a serial number onto the liner.
The finished part was placed on an out-feed conveyor. |
| Here is a
close up view of the URC designed robot dual gripper.
Quick-change sensors indicate open or close on each gripper.
Non-scratch neoprene pads provide gentle but precise
handling of the liners.
An Applied Robotics collision sensor provides quick reset
of the robot wrist in case of collision of robot tool during
setup or operations. |
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This is a
complete view of the robot cell with Parker-Hannifin IPS
guarding around the cell. A
PLC controlled the in-feed and out-feed conveyors.
URC Automation built two of these
systems for Federal Mogul.
Total robot turn-key cost utilizing
existing machine tools was approximately $170K for
each cell. |
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Robot Loading Benefits |
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Labor Reduction and Reallocation
Lower cycle time, 25% to 400%
Integrate existing machine tools, saving more
money
Throughput and Yield Improvement
Reduce Stress Injuries
Injury Avoidance and Safety
ROI's 12 - 18 months
Quality Improvement
Predictable Production
Flexibility
Material Savings
Reliability and Downtime Reduction
Great for dull, dirty and dangerous jobs
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