Fast Cycling Linear Assembly System LS 280 In Modular Design

Transcription

1 Technology that inspires Fast Cycling Linear Assembly System LS 280 In Modular Design

2 Technology that inspires V a Pos. 1 Pos. 2 Pos. 1 Pos. 2 Motion sequence impact and jerk free Velocity and acceleration at the workpiece carrier Linear Assembly System LS 280 consisting of two assembly cells, belt sections, corner units and workpiece carriers. Design of an assembly cell consisting of locking station with top support plate, fabricated base frame and guide rail. 2 09/2008

3 Advantages at a glance The cam profile with modified sine curve provides the smoothest passage between peak acceleration and peak deceleration. Proven cam drive Smooth, impact free motion sequence Short workpiece exchange times High positioning precision without additional stopping or indexing modules High level of accessibility Modular system design Autonomous functional assembly cells Adjustment of varying processing times High degree of reusability Stable steel fabricated support frames Proven reliability Maintenance free Complete functional and quality inspection Short time from build up to start up ESD-capability Good price / quality ratio This is the precondition for minimum exchange times and a long service life. Anodised aluminium top support plates and steel plated carrier plates can be machined in accordance with customers drawings. Decentralised control units for each assembly cell: fast and reliable start-up due to function tested control units parameterised according to customer requirements. 09/2008 3

4 The LS 280 production in the fast lane Comparisons with the LS 280: By reducing the transport time, the output of the LS 280 is more than double to that of a conventional system. LS 280 from WEISS 1s Processing time A 0,6 s Transport time 1s Processing time B 0,6 s Transport time 1s Processing time C Production output: 37 parts/min. Conventional system Processing time A 2,5s Processing time 2,5s B Processing time C Production output: 17 parts/min. Comparison of workpiece exchange times Faster cycles higher output The LS 280 is based on a drive principle that is at the forefront for both speed and reliability. It is capable of achieving a cycle rate that other producers find impossible. While conventional systems are reaching their limit at 20 cycles per minute, the LS 280 is far from its limit due to the reduced transfer time. It runs at the speed and precision of a rotary indexing table and provides the flexibility of a transfer system. The customary change of workpiece carriers involving transporting, stopping, lifting and positioning is replaced by one single fast and smooth movement absolutely jerk-free with up to 60 cycles per minute. Simple and flexible The LS 280 s scroll indexing station allows several workpiece carriers to be drawn in at the same time, this enables longer processes to be performed simultaneously. Other linear systems normally require additional components like parallel tracks with switching gates plus more mechanical and electrical components. The LS 280 can achieve a much higher throughput without any of these additional components with minimum effort in one single operation. Jerk and impact-free transportation no vibrations are transferred to the product. The modified sine motion curve of the transport cam linked with the speed controlled belt conveyors provide a linear transport system that is extremely smooth and totally jerk-free. The frequency regulated belt infeed conveyors drastically reduce the speed of the workpiece carriers prior to engagement in the transport cam, this ensures that any possible vibration is completely avoided. Modular system design reduced investment costs. Our refined design features just a few components yet offers solutions of great simplicity and style tailored to meet the individual requirements of customers. The building modules are very easy to connect and therefore keep labour costs to a minimum. When running its compact design and reliability allows for three-shift operation that is maintenance free. 4 09/2008

5 Technology that inspires Cycle pitch 280 mm Cycle pitch 70 mm Cell 1 Cell 2 Cell 4 Cell 3 Cycle pitch 70 mm Cycle pitch 140 mm Cycle pitch of the cell (mm) Workpiece exchange time (sec.) Processing time customer (sec.) Cycle time of a cell (sec.) Resulting cycle time per part (sec.) (1) (2) (3) 1.2 Parallel work with the LS 280 in line (1) Sequential machining per part (2) Parallel machining at 2 parts (3) Parallel machining at 4 parts Adjustment of varying processing times increase of productivity On a rotary assembly machine, the longest processing time determines the cycle time of the system. The LS 280 however, allows the combination of locking stations with different indexing pitches. This enables the execution of several assembly operations with different processing times due to the simultaneous transfer of several workpiece carriers. By carrying out several time consuming operations at the same time, bottlenecks are eliminated. This allows for different, processing times to be integrated separately, thus retaining the fastest possible cycle time and achieving a higher production throughput. Maintenance-free operation high reliability The design of the LS 280 allows for 3 shift fully automatic maintenance-free operation. This is due to the integrated central lubrication system wich automatically feeds lubricant to the hardened ground steel guide rails and the workpiece carrier bearing. The monitoring functions integrated into the control units guarantee the maximum degree of operation reliability. Autonomous function assembly cells flexible and extendable system design The design of the system is based on a modular cell concept both mechanically and electrically. Each individual assembly cell works autonomously due to the decentralised controllers. This ensures that subsequent extensions or divisions into seperate sub-systems are easily achieved. The modular cell design also ensures that no adjustments are required during re-assembly. Short realisation times Time to Market Complete machines can be set up with just a few standard elements in a very short time. Our delivery time is also very short due to all the main components being available in stock. All LS 280 modules feature closed drive units with pre-configured and parameterised control systems. All systems are quality controlled and performance tested prior to delivery. We design the mechanical interfaces such as mounting plates, workpiece carrier plates etc. according to your drawings. The individual assembly cells work independently of each other, this opens up the possibility of sending different cells onto several suppliers. The above elements can result in a time saving of several weeks. All bearing ESD-capability antistatic transport There is no electrostatic charging due to the design which ensures that every workpiece carrier is earthed. 09/2008 5

6 Cell with locking station The locking stations serve primarily for simultaneous transport and positioning of a number of workpiece carriers. Depending on the cycle pitch and station type, the user has a varying number of locked processing positions at his disposal. Along with stable steel base frames and top support plates the locking stations form the basis for an assembly cell of the Linear Assembly System LS 280. The core of the station is formed by a cylindrical cam with which the workpiece carriers are engaged, transported and mechanically locked in a single motion. This reliable working practice enables workpieces to exchange in the shortest possible time combined with a high degree of positioning accuracy. Despite working at high speed, the modified sine motion curve within the cylindrical cam guarantees a smooth, impact and vibration free transportation of the workpiece carrier and avoid therefore vibrations at the transported product. Two versions of the locking stations are available, single or double. Both modules have identical control systems, but differ through the number of available locked positions. A twin cell configuration provides two independent locking stations mounted back to back on one base frame fitted with a wider top support plate. Single locking station Double locking station The top support plate of the locking station is designed to provide a mounting surface for handling modules. These support plates are anodised aluminium as standard. They can also be produced in accordance with customer specifications. 6 09/2008

7 Technology that inspires One-sided top support plate with standard hole pattern in two dimensions Twin top support plate with standard hole pattern in two dimensions Technical data of the locking stations Cycle pitches: Workpiece exchange times: Number of available locked positions at each cycle pitch: Single locking station: Double locking station: Positioning precision: Permissible forces directly at the carrier: Transport direction: Type of drive: Motor power: Motor voltage: 70 mm, 140 mm, 280 mm, 560 mm Pitch 70 mm: approx. 0.4 sec.* Pitch 140 mm: approx. 0.5 sec.* Pitch 280 mm: approx. 0.6 sec.* Pitch 560 mm: approx. 1.2 sec.* Pitch 70 mm: 10 positions Pitch 140 mm: 5 positions Pitch 280 mm: 3 positions Pitch 560 mm: 2 positions (only parallel) Pitch 70 mm: 28 positions Pitch 140 mm: 14 positions Pitch 280 mm: 7 positions Pitch 560 mm: 6 positions (3 x 2 Pos. parallel) X / Y axis +/ mm Z axis: +/ mm X / Y / Z axis: 100 N counter-clockwise Three-phase motor 0.25 kw 230/400 V / 50 Hz * Time from the input of the start signal to the output of the position signal from the station control unit 09/2008 7

8 Cell with locking station Cell with single locking station available locked positions Workpiece carriers in colour are locked in the single locking station. Transport Direction Cycle pitch = 280 Cycle pitch = 140 Cycle pitch = parallel only Number of available locked positions at each cycle Transport Direction Cycle pitch = Number of available locked positions at each cycle Cell with two single locking stations twin arrangement Workpiece carriers in colour are locked in both single locking stations. Transport Direction 8 09/2008

9 Technology that inspires Cell with double locking station available locked positions Workpiece carriers in colour are locked in the double locking station. Transport Direction Cycle pitch = 280 Cycle pitch = Number of the available locked positions at each cycle Cycle pitch = parallel only parallel only parallel only Transport Direction Cycle pitch = Number of the available locked positions at each cycle Cell with two double locking stations twin arrangement Workpiece carriers in colour are locked in both double locking stations. Transport Direction 09/2008 9

10 Belt section The belt sections are used for the transport of the workpiece carriers between locking stations. This ensures a decoupling of the individual cell modules and also serves as a small buffer between the processing stations. The workpiece carriers are friction driven on a transport belt. The belt sections are available in different lengths for individual layouts. The outgoing belt section after a locking station runs with constant high speed while the ingoing belt section before a locking station is always speed controlled. This provides a rapid and jolt free transportation of the workpiece carriers between stations. The high transport speeds also ensure a reduced number of required workpiece carriers on the free belt sections. The integrated controllers frequency regulate the belt conveyors, this guarantees wear is kept to a minimum. Belt section with toothed transport belt Driving unit with motor Technical data of the belt sections Belt section lengths: Min. length between two cells: Transport speeds: Toothed transport belt: Type of drive: Motor power: Motor voltage: 300, 600, 1200, 1500, 1800, 2400 mm (300 mm only useable between the corner unit and the locking station) 1200 mm 19 m/min; 26 m/min; 41 m/min (reduced speeds possible by additional feed rate reduction) PU-belt, Nylon coated, UV resistant, operating temperature up to 80 C Three-phase motor 0,18 kw to 0,37 kw 230 / 400 V / 50 Hz, special voltages on request 10 09/2008

11 Corner unit Technology that inspires 180 and 90 corner units are available for design of the system layout. They determine the geometric execution of the two possible layout types. The workpiece carriers are friction driven around the anodised aluminium corner units. The corner units can be used as an outgoing feed with constantly high speed directly after a locking station. The corner units are not used as an ingoing feed into a locking station, speed controlled belt sections are used for this function. Corner unit 180 system Corner unit 90 system Technical data of the corner units Transport speeds: Type of drive: Motor power: Motor voltage: 15 m/min; 21 m/min; 34 m/min Three-phase motor 0,09 kw to 0,18 kw 230 / 400 V / 50 Hz, special voltages on request 09/

12 Workpiece carrier The workpiece carrier train consists of two workpiece carriers linked together by a connection rod. This forms the basis for the fixture of the workpiece. With longer workpieces the two carriers are linked together by a common carrier plate. The workpieces are guided on a continuous hardened and ground steel guide rail. On belt sections and corner units the transport is provided by friction via a spring loaded plastic shoe which is fitted to the underside of the workpiece carrier. This shoe exerts a constant pressure on the transport belts and corner units. Within the locking station the workpiece carriers are moved and precisely positioned on the transport cam by the engangement of a cam roller. Workpiece carrier train with two single carrier plates Workpiece carrier train with one common carrier plate Dimensions 7 Note The design of the workpiece carrier pin holes enables the manual fitting of the carrier plate or the fixture. The mounting pins are a press fit in the carrier plate and a sliding fit in the workpiece carrier. Dimensions of the workpiece carrier train 12 09/2008

13 Carrier plate Technology that inspires The carrier plates are designed to accept the product fixture. They project outwards from the workpiece carrier base and form the outermost contour of the system. This allows accessibility of the product from both above and below. Components can also be suspended outside or through the carrier plates. Carrier plate with standard hole pattern Carrier plate with customer-specific hole pattern Technical data of the carrier plates Material: St-52; chemically nickel-plated Standard-dimensions (L x W x H): 200 x 160 x 5 mm (with pitch 140, 280, 560) 270 x 160 x 5 mm (with pitch 70) 480 x 160 x 6 mm (with pitch 560 / common carrier plate) (other dimensions and designs on request) Max. payload: approx. 4 kg per workpiece carrier plate (depending on the number of cycles) Support in the case of vertical process forces Vertical process forces can be applied to the carrier plate with the addition of a support from below. The carrier plates, which have an additional hardened rail underneath are supported by stationary cam rollers. This type of support can take vertical process forces of up to approx N. Stationary support 09/

14 Base frame with accessories The fabricated steel frames form the basis for the locking stations of the Linear Assembly System LS 280. Handling modules can be installed directly on the locking stations and require no further supporting structure. The working height of the assembly cell is 1020 mm. The frame height can also be adapted in accordance with customer specifications. If the locking station is integrated into an existing customer machine frame, the frame feet can be dispensed with and the station is supplied on a flat base frame. The base frame legs are machined flat on the front and rear sides complete with a standard fixing hole pattern. This allows for the fixing of optionally available aluminium side assembly plates. The fixing holes are precisely machined in steps of 50 mm to provide height adjustment. Side assembly plate with standard hole pattern in two dimensions High quality switch cabinets are also optionally available for the cells which can be precisely integrated on the front or rear side of the base frames. The cabinets are available in two dimensions. For 180 systems (W x H x D): 788 x 630 x 300 mm For 90 systems (W x H x D): 788 x 630 x 450 mm When using an assembly plate it must be noted that the switch cabinet can only be opened if the plate is mounted in the uppermost position (dimension X = 200 mm between upper edge of the mounting plate and upper edge of the carrier plate). Integrated switch cabinet on base frame 14 09/2008

15 Manual workstation and central lubrication system Technology that inspires For processes which are difficult to automate, cell modules are available for manual workstations. These modules can also be used if production quantities fluctuate or are uncertain. When demand increases, the manual workstations can be replaced by automatic modules. Depending on the requirements it is possible to stop each workpiece carrier individually or the whole workpiece carrier train via a pneumatically operated stop unit. The ingoing belt into the station is speed controlled as per the automatic locking stations. Design of a cell with manual workstation consisting of a station with pneumatic stop unit, fabricated base frame and belt section Footboard integrated in the base frame (optionally available) Central lubrication In order to ensure reliable, wear-free operation of the system, the guide rail tracks and transport cams are automatically lubricated by the integrated central lubrication unit. The lubrication quantity and intervals can be preset. Central lubrication unit Lubrication point in guide rail 09/

16 Control of a cell The individual assembly cells of the LS 280 are controlled by a decentralised control unit. Each control unit consists of two frequency inverters and a drive PLC which are linked by CAN bus and pre-mounted on a metal plate. The first frequency inverter drives the transport cam of the locking station into the mechanically locked position. The second frequency inverter controls the ingoing belt to provide a rapid and impact-free feed of the workpiece carrier into the cam intake. Control unit of an assembly cell All systems are assembled and tested at WEISS. This is where the individual, decentralised control units are parameterised in accordance with the customers system. Once connected the units are immediately ready for use, this guarantees short installation and start-up times. Tests Interference emissions: EN (radio disturbance characteristics) from 1991 Requirements in accordance with EN from 1993 Limit value class A in accordance with EN Interference resistance: ENV radio disturbance immunity from 8/93 ENV conducted disturbances induced by radio-frequency fields from 8/93 EN ESD from 1996 EN BURST from 1996 EN voltage variations from 1995 (limit values and requirements in accordance with EN from 1995) Insulation resistance: Overvoltage category III in accordance with VDE 0110 Type of protection: UL listed IP /2008

17 Single cell 180 and 90 Dimensions Technology that inspires Cell with single locking station for 180 system Dimension X variable: 200, 250, 300, 350 or 400 mm Cell with single locking station for 90 system Dimension X variable: 200, 250, 300, 350 or 400 mm 09/

18 Double cell 180 and 90 Dimensions Cell with double locking station for 180 system Dimension X variable: 200, 250, 300, 350 or 400 mm Cell with double locking station for 90 system Dimension X variable: 200, 250, 300, 350 or 400 mm 18 09/2008

19 Single and double twin cell Dimensions Cell with two single locking stations in twin arrangement for 180 system Technology that inspires Dimension X variable: 200, 250, 300, 350 or 400 mm Cell with two double locking stations in twin arrangement for 180 system Dimension X variable: 200, 250, 300, 350 or 400 mm 09/

20 Layout examples 180 system Cycle pitch 140 mm Cycle pitch 560 mm Cycle pitch 280 mm Cycle pitch 140 mm Number of locked workpiece positions: 15 Cycle pitches used: 140 mm, 280 mm, 560 mm Space requirement of the basic machine (L x W): 6.0 m x 1.4 m Cycle pitch 280 mm Cycle pitch 140 mm Cycle pitch 140 mm Cycle pitch 140 mm Number of locked workpiece positions: 34 Cycle pitches used: 140 mm, 280 mm Space requirement of the basic machine (L x W): 7.2 m x 1.4 m An idea to realisation can be achieved in a short period of time thanks to the clear interfaces, exact CADD data and of course our support /2008

21 Layout examples 90 system Technology that inspires Cycle pitch 140 mm Cycle pitch 560 mm Cycle pitch 280 mm Cycle pitch 140 mm Number of locked workpiece positions: 15 Cycle pitches used: 140 mm, 280 mm, 560 mm Space requirement of the basic machine (L x W): 6.0 m x 2.3 m Cycle pitch 280 mm Cycle pitch 140 mm Cycle pitch 140 mm Cycle pitch 280 mm Number of locked workpiece positions: 34 Cycle pitches used: 140 mm, 280 mm Space requirement of the basic machine (L x W): 4.7 m x 3.5 m The individual modules of our LS 280 can be found as a 2D or 3D file on our website 09/

22 The LS 280 in practice Our LS 280 Linear Assembly System has proved to be very successful throughout the world! More than half of our customers who opted for an LS 280 in recent years, today own two or more systems. Our LS system is used in a wide range of assembly applications in various market sectors including: Automotive, electronics, heating, plumbing, consumer goods, printing, cosmetics, medicine and packaging. You would like to see the LS 280 in action? Then order the LS 280 DVD by fax: +49(0) For further information go to Yes! Please send me the LS 280 DVD. Company: Name: Address: Postal Code: Tel No: 22 09/2008

23 Fax-No. WEISS GmbH: +49 (0) System design LS 280 Technology that inspires Enquiry Enclosure with order Dear Customer, Thank you for your interest in our Linear Assembly System. To ensure we design the system to the exact requirements of your application, we kindly ask you to answer the following questions: Please note! Our LS 280 system only travels in the counter-clockwise direction. System type 180 system 90 system Cycles of the system: per Minute Single locking station Double locking station No: Support plate: 1080 x 320 x 20 mm 1199 x 320 x 20 mm Pitch: 70 mm 140 mm 280 mm 560 mm Max. process time at station: Base frame (for single locking station) No: Colour: RAL 7035 RAL Accessories base frame Assembly plate: 1080 x 320 x 20 mm No: 1199 x 320 x 20 mm No: Switch cabinet: RAL 7035 RAL No: Footboard: RAL 7035 RAL No: Corner units 90 : 4 off 180 : 2 off Workpiece carrier train (consisting of two carriers) No: Carrier plate: yes no Dimension: L: W: Machining according to drawing No: Payload per WC: kg Support for WC: yes no No: Support plate: 1137 x 480 x 20 mm 1199 x 480 x 20 mm Pitch: 70 mm 140 mm 280 mm 560 mm Max. process time at station: Base frame (for double locking station) No: Colour: RAL 7035 RAL Accessories base frame Assembly plate: 1080 x 320 x 20 mm No: 1199 x 320 x 20 mm No: Switch cabinet: RAL 7035 RAL No: Footboard: RAL 7035 RAL No: Belt sections Colour of drive unit: RAL 7035 RAL Length No: 300 mm 600 mm 1200 mm Station with stop unit Length No: 1500 mm 1800 mm 2400 mm Stop per workpiece carrier No: Stop per workpiece carrier train No: Concept Layout (Please provide a dimensional sketch of your proposed system): For technical enquiries Company: Name: Department: 09/2008 Desired delivery date: Phone: Fax: 23

24 Technology that inspires Rotary Indexing Tables TC Rotary Indexing Rings TR/NR Numeric Controlled Heavy Duty Indexing Ring CR Numeric Controlled Indexing Tables NC Torque Motor TO Compact Model Torque Motor TO Ring Construction Handling Device HP 140 Flexible Assembly Machine Pick-o-Mat Side Loading Rotary Unit TH Fast Cycling Linear Assembly System LS 280 Indexing Machine Bases SR/SK Additional Indexing Plate We reserve the right to change or discontinue specifications without proir notice WEISS GmbH Sondermaschinentechnik Siemensstraße 17 D Buchen Telephone +49(0) Fax +49(0) info@weiss-gmbh.de WEISS 09/2008 LS