Innovative automation solutions by FRAI Robotic Technologies

Autonomous production methods have long been used by automotive manufacturers, the aerospace industry and mould construction companies to produce equipment for machine tools. Other sectors with less of a focus on automation are now showing increased interest in this area, above all due to the possibility of introducing autonomous night and weekend shifts. Depending on the customer’s requirements, WFL and FRAI use automation solutions such as articulated robots, automated linear and area gantries and even mobile robots for automated workpiece loading. Peripheral transport and storage systems for workpieces, tools and clamping devices can be integrated as required.

FRAI as the perfect partner

WFL subsidiary FRAI Robotic Technologies is the perfect partner, from initial concept development of an automated system to implementation and set-up, right through to system maintenance. The range of gantry loaders and robotic cells makes it possible to offer comprehensive automation concepts with maximum customer benefits and to the highest quality standard. This brings some key benefits for the user, such as continuous productivity with minimal operating effort, in particular when it comes to repeat orders. However, robots are not only used in large-scale series production; there are also many advantages to automation for small batch sizes, when used in combination with easy-to-program software. Customer-specific options, such as unloading samples, inscribing, cleaning, measuring blank parts and even additional processing tasks performed by the robot (e.g. deburring) enable further increases in efficiency.

How automation has changed over time

The ever-greater variety of models has meant that transfer lines have tended to be replaced by flexible line chains or by individual cells with a variable material flow. Using intelligent software in combination with the relevant automation solutions not only enables workpieces to be loaded and unloaded but also means that machining centres can be set up fully automatically through the automatic replacement of tools and clamping devices. In addition to the classic handling solutions, WFL turnkey projects are often fitted with a higher-level host computer system. This ‘brain’ takes over the entire logic and logistics from within the fully self-sufficient, flexible production cell. In addition to workpiece measurement and tool management, ODA (operational data acquisition) data is also transferred to the customer’s MES (manufacturing execution system).

Robot systems can also link up multiple machining centres

An automation solution implemented by WFL and FRAI has been specially developed for flexible batch production and is designed for the automation of four machine tools for handling different shafts. The 6-axis robot with 500 kg payload is mounted on a seventh axis. An automatic gripper exchange system has also been attached so that a wide variety of grippers can be connected and disconnected fully automatically as required when the system is operating in automatic mode. An integrated drip tray collects cooling lubricant and chips. Automatic changeover of jaws, tailstock tips and prismatic tools in conjunction with a servomotor gripper for covering an extremely large product range allows for set-up-free operation of the machines and automation solution.

Holistic solutions – mobileCELL

mobileCELL is a hybrid solution, which impresses with its combination of wide-ranging functions and advantages. There was a time when the classic robot cell could only load and unload workpieces. This basic function was then enhanced with gripper exchange systems. Due to the significant disadvantages of a location-bound robot cell and the costs for intralogistics tasks, a solution was discussed which would produce benefits for the customer. mobileCELL consists of an appropriately large automatic guided vehicle (AGV) with a robot cell construction: The robot, workpiece and tool gripper, along with buffer positions for workpieces and tools, and the necessary control & safety technology. The machine moves completely freely. It is not blocked or obstructed. The AGV collects the required tools and workpieces in the warehouse, it then travels to the front of the machine, locks itself in place on the floor and exchanges parts and/or tools. The vehicle then moves away again and receives the travel instructions for the next machine. The space in front of the machine it has just loaded becomes clear again.