Compact Machining Cell Layout for Automated Workpiece Changeover
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Solution Overview
Problem
Compact machine tools with limited workspaces face challenges in automation due to space constraints, requiring innovative solutions for handling and tool changes while maintaining precision and efficiency in fine mechanical processing.
Innovation Solution
A manufacturing system integrating a compact machine tool with a handling cell and a combined transfer and storage device, allowing for partial or fully automated workpiece and tool changes, utilizing a handling unit with multiple interfaces and a buffer memory to optimize space usage and enable high-precision processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a compact machine tool with small workspace is used, then manufacturing precision is improved, but automation capability deteriorates due to space constraints for handling units and transfer systems
Solution Approach 1:
The handling unit is positioned within the machine tool's workspace envelope, utilizing the vertical space above the workspace for robot mounting. The robot's base is arranged on the machine tool's column or overhead structure, nesting the automation component within the existing mechanical envelope rather than requiring external space.
Solution Approach 2:
The system transitions from horizontal arrangement to vertical arrangement by mounting the handling unit on the overhead structure. This utilizes the vertical dimension (Z-axis) to accommodate the robot and transfer system, freeing up horizontal workspace while maintaining automation capability.
2Productivity
If automation technology is added to compact machine tools, then productivity is improved, but device complexity increases due to integration requirements
Solution Approach 1:
The handling unit is designed with multi-functionality, serving both as a workpiece transfer mechanism and as a loading/unloading station. The same robotic end-effectors and positioning systems are used for both automated transfer and manual intervention tasks, reducing the need for separate specialized components.
Solution Approach 2:
The control system acts as an intermediary that coordinates between the machine tool's machining operations and the handling unit's transfer operations. It manages the synchronization, positioning, and coordination required for seamless integration without requiring complex mechanical linkages between the two systems.
3Manufacturing precision
If workspace size is reduced for compact design, then manufacturing precision is improved, but loss of time increases due to limited access for workpiece changes
Solution Approach 1:
The buffer storage预先 stores multiple workpieces in ready-to-machine positions within the workspace or immediately adjacent to it. The handling unit can quickly retrieve pre-positioned workpieces without requiring time-consuming external handling operations, reducing workpiece change time while maintaining compact dimensions.
Data Source
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AI summary
A manufacturing system (120) for machining comprises at least one, in particular compact, machine tool (10) and a handling cell (124). The machine tool (10) is designed for multi-axis machining and is equipped with a tool holder (44) and a workpiece holder (60) that are movable relative to each other in at least three axes. The handling cell (124) has a first interface (170) to the machine tool (10), which connects laterally to the work area (144), a second interface (210) for transfer purposes, a handling unit (150), in particular in the form of a handling robot, and at least one buffer storage unit (164, 166), wherein the handling unit (150) is designed for automated workpiece changeover. A machining system (250) comprises at least one such manufacturing system (120) and a combined transfer and storage device (252).