Innovative servo-based die transfer system helps manufacturers save costs and improve productivity for the high-demand automotive market

Transcription

1 Schneider Electric Case Study DieBotics Grand Rapids, Michigan Innovative servo-based die transfer system helps manufacturers save costs and improve productivity for the high-demand automotive market

2 The Background The world s automotive industry is booming again after several years in decline. During the downturn, many auto part suppliers and assemblers dissolved, leaving the remaining providers to make up for the shortages. With such high demand for press capacity and resources, auto parts manufacturers are willing to invest in solutions that get more efficiency out of their existing systems with higher throughput and more flexibility to make many kinds of parts. The Challenge We ve added value to the existing operations for stamping companies by increasing their efficiency. Payback is often less than two years. - Kishen Kavikondala, VP sales & marketing DieBotics (Grand Rapids, Mich.), a manufacturer of part transfer systems primarily for the automotive industry, saw an opportunity to help an underserved market: tier 2 and tier 3 automotive part stampers. A smaller-sized, lower-cost transfer system would help such manufacturers improve productivity for significantly less cost than a traditional larger transfer system. In 2012, DieBotics unveiled a new polar-movement transfer system that was servo based and modular to fit smaller, 120-inch die presses. While DieBotics makes transfer systems that use Cartesian movement (straight line moves in three axes), the newest models use polar movement that works like a robotic arm to make rotating moves that are faster and more precise. Typically, die shops have been making transfers one at a time, engineered for a particular part. They were often larger systems that were resized to fit smaller parts. These systems were time consuming and costly to build, so many tier 2 and tier 3 parts companies chose not to use large transfer systems. The new DieBotics transfer system has a modular design that can be changed to work on different parts, making it a more flexible and cost-effective solution for companies that produce a variety of products. The size of the system, coupled with the modularity and flexibility, allowed DieBotics to expand a market that had been ignored before. We ve added value to the existing operations for stamping companies by increasing their efficiency, said Kishen Kavikondala, VP sales & marketing. Payback is often less than two years. The smaller press market has traditionally been served by mechanical transfers, but they are often expensive and the moves were fixed. The servo-based DieBotics transfers system is programmable and allows modularity, faster speed, and better accuracy than a mechanical system. The advantage of the servo-driven programmable transfer is that it can be easily set and modified to optimize movements for reaching in, rep, and pitch, versus a mechanical system that has fixed positioning. In turn, companies can make parts quicker and improve the output of their existing equipment. DieBotics 2

3 Often, presses must be slowed down to ensure enough time for a mechanical system to be in position. In a servo-based system, the repeatability and timing is more accurate, so the press can run at full speed. The shot height and speed of the press can be more confi dently adjusted compared to a mechanical transfer that s designed for a specifi c part and die. The DieBotics servo-based transfer system is programmable and can be moved from one press to another, giving parts manufacturers the opportunity to expand their capabilities more cost effectively. The transfer can be mounted directly to the die or onto a subplate and interchanged as needed. For companies running manual operations, there s an even greater opportunity to signifi cantly increase their throughput with a low-cost automated transfer system. In Mexico, a DieBotics transfer system helped a parts manufacturer triple the productivity of its $2 million press by increasing to 20 strokes per minute from the original hand-fed 6 strokes per minute. The Solution The DieBotics team was looking for a supplier that could provide a wide control and system hardware coupled with simple software interface to suit their type of pick, move, and place systems and also allow customization for their customers specifi c needs. The existing systems that DieBotics and their competition were using were more general purpose control systems that needed a lot of software development for their type of application. On-board inputs/outputs, embedded networking, and intuitive set-up features save DieBotics up to 15 percent in assembly time compared to other motion controllers. At that time, the DieBotics Design offi ce in Hyderabad, India, was already working with Schneider Electric on some material handing systems controls requirements. Schneider Electric recommended that the management team of DieBotics in the USA look into Schneider Electric as a potential supplier of control systems to DieBotics. As a result, the team was able to visit the Schneider Electric R&D facility in Bangalore, India, to better understand Schneider Electric R&D and global support capabilities, which further confi rmed their decision to turn to Schneider Electric for their innovative machine solutions needs. DieBotics selected Schneider Electric as their main supplier of a motion control solution that cost 15 percent less than competitive components but could still handle the complex robotic action of the polar transfer system. Each transfer system uses one Modicon TM LMC058 motion controller and three to fi ve Lexium TM 32 servo drives and BMH motors. The Modicon LMC058 motion controller is easy to install because it has embedded CANmotion network for real-time communication to the motors and drives. On-board inputs/outputs, embedded networking, and intuitive set-up features save DieBotics up to 15 percent in assembly time compared to other motion controllers. DieBotics 3

4 The Modicon controllers use G-code through SoMachine TM, a single software suite for all the motion control components, which simplifies programming and gives customers peace of mind. SoMachine s G-code move commands are a benefit because they are universally understood, which helps gain acceptance by our customers, said Tim Launiere, president. When customers look at the clean control panel and then hear that it uses G-code commands, they feel at ease. It s a great selling point. The Lexium 32 servo drive has a power density of 548 W to pack maximum power into a small footprint, saving on cabinet space and reducing cost. The BMH synchronous three-phase features a SinCos Hiperface encoder for automatic transmission of data from the servo motor to the servo drive. SoMachine s G-code move commands are a benefit because they are universally understood, which helps gain acceptance by our customers. - Tim Launiere, president The transfer system s modular design allows DieBotics to stock the off-the-shelf Schneider Electric components so when an order comes in, assembly can move quickly. DieBotics teams can assemble four transfer systems simultaneously. Lower Price Is a Game Changer DieBotics transfer systems cost 35 to 40 percent less than standard transfer systems, so companies that normally shied away from a transfer have realized the potential to expand their businesses. This price point has given DieBotics an advantage over the competition. With my design, I tried to make it as simple as possible, Launiere said. My philosophy is to look at how everything integrates together so I understand every aspect of the structure, the function, and the requirements. I can design components to serve more than one function. Therefore, the system is smaller in size and the price is lower. Worldwide Support DieBotics has filed for a global patent on its transfer design to protect its intellectual property around the world. The company s goal is to provide transfers to markets that have previously not been able to afford this technology, particularly in Asia and South America. Schneider Electric s international presence has been an advantage for us, and it was one of the driving factors for choosing to work with Schneider Electric, Launiere said. We saw there are Schneider Electric offices everywhere across the globe. They have operations in more than 100 counties, so we know we can get support and service wherever we go. DieBotics 4

5 Make the most of your energy SM Schneider Electric provides inspired and comprehensive energy solutions that transform the way businesses manage their environment, efficiency, and costs. As the global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in energy and infrastructure, industrial processes, building automation, and data centers/networks, as well as a broad presence in residential applications. Schneider Electric is dedicated to making individuals and organizations energy safe, reliable, efficient, productive, and green from Power Plant to Plug TM. Schneider Electric USA, Inc. Automation and Control Center of Excellence 8001 Knightdale Blvd. Knightdale, NC Tel: Schneider Electric Canada 5985 McLaughlin Rd. Mississauga, ON L5R 1B8 Tel: Schneider Electric. All Rights Reserved. Schneider Electric, Modicon, Lexium, SoMachine, Make the most of your energy, and Power Plant to Plug are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. All other trademarks are the property of their respective owners _US April 2015