人与机器专家
成功案例 03.04.2019

机器自动化迈入新阶段

组合式磨床自动化解决方案

概述

飞利浦公司奥地利克拉根福(Klagenfurt)工厂每年大约生产 2000 万片用于理发器和剃须刀的刀片。为了使复杂的磨削过程尽可能高效,公司引入一个开创性理念:磨床上料及全自动工件运输。

 

荷兰电子巨头飞利浦公司克拉根福(Klagenfurt)工厂坐落于奥利地威尔特湖(Lake Wörthersee)东岸,工厂约有 380 名员工。其中约 180 名员工在理发器和剃须刀生产线上工作,另外约 200 名员工从事研发工作。克拉根福工厂是这一荷兰公司的主要研发机构之一,也是其最重要的刀片产地。

飞利浦优质生活事业部的首席工具设计工程师 Christian Rassi 解释了生产理发器和剃须刀系列高质量部件所涉及的内容:“打磨刀片是生产过程中最耗时、成本最高的步骤之一。所以我们全部磨床都采用自动化。现在我们打算将这两个不同的流程,也就是刀片分离/上料与磨床研磨组合起来,集成在一个配备两台机器人的自动化单元中。这将是我们关键一步。”

具体地,一台 Mägerle 磨床和其上下游操作能自动运行和协调。这项复杂任务的主要挑战在于应对通过 AnyFeeder 系统到达的成批刀片。产线上的第一个机器人将刀片逐个分离并插入刀槽。此后,第二个机器人负责 Mägerle 磨床上料,以及取出、清洁并分离加工完成的刀片。

这两台机器人的规格完全不同,正如 Rassi 所说:“鉴于所需的周期时间,只有高精度、高速的设备才适合成批刀片的进料分离和刀槽填放。而对于磨床上料,我们需要一台坚固、全封闭的、工作半径足够长的六轴机器人。两台机器人最好来自同一制造商。”

飞利浦公司该项目团队对机器人选型有严格标准。公司管理层人员拥有丰富的机器人技术经验并且对市场非常了解,经过详细分析后确定了解决方案,决定使用史陶比尔机器人。 “通过六轴 TX90L 我们看到史陶比尔成熟的机床自动化机器人,” Rassi 说道。“高精度的 TP80 快速拾放机器人 运动性能非常出色,能切实满足上料工位使用需求。其他制造商都无法提供这种完美匹配的机器人组合。”

Stäubli TP80 FAST picker removes the unsorted cutter blades from the belt and slots them into a magazine at ultra-high speed.
TP80 快速拾放机器人从传送带上取走未分类的刀片,并以超高速度将其插入刀槽中。

内部设计团队提出的开创性解决方案

设备组件确定后——刀片的传送和分离由配备静态图像处理系统的 AnyFeeder 处理——项目即可加以执行。多年来奥地利 Vipro 自动化公司一直负责飞利浦克拉根福工厂中所有 Mägerle 磨床的维护工作,整套设备正是飞利浦内部设计团队和 Vipro 的合作成果。

自动化解决方案由飞利浦团队设计,设备的装配、编程和调试主要由 Vipro 负责。Vipro 近几年专门从事批量传送工件的分离应用,具备相当丰富的专业知识来开展该项目。这一点对整套设备极为严苛的要求来说非常必要。同时,自动化解决方案必须具备高柔性,能够在短时间内更换工具,应对不同类型的产品加工。此外,整套设备必须尽可能地减少占用空间。

仔细观察,您就会发现,连一厘米的地面空间都没有被浪费。巧妙、节省空间的解决方案是工程师们经验丰富的有力证明,例如仔细选择转运点在装配线上的位置,使其位于两台机器人的工作范围内;让综合夹具站处于在工作单元的背面等。同时,工程师们还确保设备最重要的组件可用无碍。Rassi 补充道:“我们必须尽可能高效地利用可用空间,所以我们一直在努力将所有相关组件都安排到生产区。”

一目了然的单元工作流程

整个流程一开始,AnyFeeder 传送批量刀片,放到 TP80 的进料台。TP80 通过吊装摄像头接收刀片的位置数据。软件的快速计算使机器人能够立即确定刀片的位置和方向。

借助这些信息,TP80 拾取刀片插入刀槽,确保这一阶段不会对整个流程造成任何延迟,充分发挥其高运动性能。Rassi 表示:“只有快速拾放机器人TP80 能实现所需的周期时间。传统 SCARA 机器人无法实现。” 此外,TP80 所执行的刀槽装载工作要求最大精度。每个刀片都有两个小孔,需要对应刀槽中的一对小销钉。为此,机器人要在百分之二毫米的误差范围内运行。

一旦刀槽内刀片装满——根据类型刀片数量在 54 到 96 片之间不等——六轴 TX90L 就会抓起刀槽,慢慢放入磨床内夹紧装置。随后,机器人拖动一个特制的铲刀状刀具穿过整个刀槽,确保所有刀片精确放置无突出,否则会对磨削过程产生严重影响。

磨削完成后,TX90L 取出刀槽,并放置在清洗刀片的工位。之后,TX90L 用吸盘移走已清洗的刀片,放入可容纳大约 1000 片的更大的刀槽中。为处理多种工作,TX90L 更换不同类型夹爪的过程完全自动化,由一个工具快换装置执行。

刀槽相对较长,因而放入磨床夹紧装置时需要很高的准确性,高精度的 TX90L 能完美满足要求。此外,机器人必须承受磨削灰尘和润滑剂/冷却剂,得益于全封闭设计,TX90L 同样表现优异。

史陶比尔机器人的卓越性能,为飞利浦开创性设备理念的成功做出重大贡献。“磨削过程非常重要,影响着飞利浦理发器和剃须刀享誉世界的品质,”Rassi 补充道。“新工厂以四班制全天候生产,生产过程比以往任何时候都更加高效。有了这个理念,升级其他磨床只是时间问题。”

刀槽装满刀片后,六轴 TX90L 机器人抓起刀槽...
FAST picker TP80 & TX90L industrial robots
Machine tending with industrial robotTX90L
...并将其放置在磨床的夹紧装置中。

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