Compact Machining Cell Layout for Automated Workpiece Change
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Solution Overview
Problem
Compact-design machine tools face challenges in automation due to limited space, requiring innovative solutions for efficient and partially automated or highly automated manufacturing processes, especially in precision machining applications like watch manufacturing, where traditional automation equipment cannot be arbitrarily miniaturized and direct visual monitoring is necessary.
Innovation Solution
A manufacturing system incorporating a handling cell with a handling unit, buffer storage, and a combined transfer and storage device that allows for lateral access and efficient workpiece and tool changes, enabling partial or full automation within the limited space of compact machine tools, while maintaining operator access and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If compact-design machine tools are used to reduce installation space, then the working space is reduced, but automation equipment cannot be arbitrarily miniaturized and requires additional space
Solution Approach 1:
The handling unit is integrated within the machine tool housing, with the robot movable along a guide that is provided in an overhead area of the machine tool. The robot can be retracted into the housing when not in use, allowing the automation equipment to be nested within the compact machine tool structure rather than requiring separate external space.
Solution Approach 2:
The guide for the robot is provided in an overhead area (vertical dimension) rather than occupying horizontal workspace. This allows the robot to move laterally for workpiece handling while the guide structure utilizes the vertical space above the working area, effectively adding a dimensional layer to accommodate automation equipment.
2Area of stationary object
If the machine tool working space is reduced for compact design, then installation space is saved, but space for direct visual monitoring by operator is reduced
Solution Approach 1:
The machine tool is divided into functional zones: a working space for machining operations, an overhead area for the robot guide, and a lateral area for operator access. This segmentation allows each zone to serve its specific purpose without interfering with others, maintaining operator accessibility despite compact overall dimensions.
Solution Approach 2:
The handling unit with robot acts as an intermediary between the operator and the workpiece handling tasks. The robot performs automated workpiece loading and unloading, reducing the need for operator intervention in the limited working space while maintaining operator access for monitoring and control.
3Productivity
If automation equipment is added to compact machine tools, then productivity is improved, but the device complexity increases
Solution Approach 1:
The handling unit with robot serves multiple functions: workpiece loading, workpiece unloading, and potential tool changing operations. This multi-functionality reduces the need for separate dedicated equipment for each task, thereby limiting the increase in device complexity while maintaining productivity improvements.
Solution Approach 2:
The robot is equipped with a gripper that can automatically grasp and manipulate workpieces without additional assistance. The system performs self-service workpiece handling operations, reducing the need for complex external feeding or removal mechanisms and thereby limiting complexity growth while improving productivity.
Data Source
AI summary
A manufacturing system for machining comprises a machine tool and a handling cell. The machine tool is arranged for multi-axis machining and includes a tool holder and a workpiece holder, which are movable relative to each other in at least three axes. The handling cell comprises a first interface to the machine tool, which is laterally coupled to the working space, a second interface for transfer purposes, a handling unit, and at least one buffer storage, wherein the handling unit is arranged for an automated workpiece change. A manufacturing line for machining comprises at least one manufacturing system and a combined transfer and storage device.