{"id":60250,"date":"2024-09-02T07:28:50","date_gmt":"2024-09-02T05:28:50","guid":{"rendered":"https:\/\/www.gressel.ch\/blog\/complementary-automation\/"},"modified":"2025-02-24T11:57:43","modified_gmt":"2025-02-24T10:57:43","slug":"complementary-automation","status":"publish","type":"blog","link":"https:\/\/www.gressel.ch\/en\/blog\/complementary-automation\/","title":{"rendered":"Complementary automation"},"content":{"rendered":"\n

Complementary automation<\/h1>\n\n\n\n

After a visit from Andreas Brunhofer, Product Specialist Automation at Gressel, a small flyer was lying inconspicuously in the production area of FMV from Keltern-Dietlingen. For Till W\u00fcrtemberger, one of the managing directors of the contract manufacturer, the flyer became the starting point for an automation solution that would massively increase runtimes. <\/p>\n\n\n\n

The machines in manufacturing plants have to run. And the higher the investment, the more urgent this becomes. Manufacturing cells belong in this higher category, especially since robots, handling and storage systems, clamping device stations and parts trolleys are often integrated. At FMV, a dip tank and a dryer for cleaning parts are also added. The manufacturing cell from FMB Maschinenbau in Faulbach was thus tailored to the processing of cooling plates for the semiconductor market. A business that knows boom times and lulls. But what if there was a decline again? Would the system then stop? This is where Gressel’s flyer came into play, which – alternating with part-specific, serial handling in the cell – describes automation for parts of any shape in small and medium batch sizes. FMV has been manufacturing cooling plates for the semiconductor market since 2009. In 2016, these were the company’s first product group to reach a size that made automation seem economical. What today amounts to up to 10,000 units per year was less back then when the decision was made to automate, but it already showed that the planned system would be fully utilized for the next few years with these quantities. Until then, the cooling plates had been manufactured using a 5-axis and a 3-axis machine that ran around the clock. “It was clear to us that we could not simply scale up the existing processes and operate twice as many machines for twice as many parts. This was not possible for reasons of space alone. Nor was it possible in terms of personnel, with whom we could not easily introduce a two-shift model.” However, the decision to automate also made it clear that the system should not stop after the cooling plate orders had been processed. Instead, other parts should be able to be processed as an alternative to the cooling plates. That was the balancing act that FMV faced when Brunhofer visited. “When I then looked at the small brochure, I knew immediately: we need that,” says W\u00fcrtemberger. <\/p>\n\n\n\n

Three pillars<\/h3>\n\n\n\n

FMV, founded in 1976 as a toolmaker for the stamping industry in the Pforzheim area, today has three main pillars: In addition to cold plate production including machining, welding, soldering and final pressure and leak testing, the second is the contract manufacturing of milled parts for mechanical engineering, where services such as hardening, grinding, eroding or surface finishing are also provided. FMV’s core competence here lies in the machining of non-ferrous metals such as aluminum and copper, but also plastics, which includes the prototype phase with quantities of 1 to 10 and small series production. <\/p>\n\n\n\n

“The solution we developed with Gressel and FMB requires hardly any set-up work.” Till W\u00fcrtemberger, FMV <\/p>\n\n\n\n

\"Anwenderbericht_Gressel_FMV_1\"
Detail of a cooling plate. Consisting of 99.99% copper, FMV manufactures the plates in several versions, mainly for the semiconductor industry. <\/figcaption><\/figure>\n\n\n\n
\"\"
A ‘Fehlmann Versa 825’ was converted into a production cell with part-specific automation by FMB Maschinenbau.<\/figcaption><\/figure>\n\n\n\n
\"\"
It takes just a quarter of an hour to assign the component and vehicle-specific data for the next workpiece.<\/figcaption><\/figure>\n\n\n\n

“Our third mainstay is the manufacture of sensor housings, which covers a wide range of products with high quantities,” explains the managing director. “For a sensor manufacturer, for example, we manufacture aluminum housings for light barriers. The quantities here amount to several thousand a year, with dozens of different types.” Due to the part size, the clamping situation and the initial investment, only part handling was an option for the automation of the cooling plate production from the outset. The workpiece-specific procedure is also due to the fact that FMV works with vacuum clamping devices that cannot be palletized. While the handling was therefore tailored to the cooling plates, neither the exact dimensions nor the clamping situation for the alternative parts were known. “We therefore needed a system with which we could react to different clamping situations and part sizes with little effort. Somehow, quantities between 10 and 50 had to be able to be covered economically during handling, teaching and setup,” emphasizes W\u00fcrtemberger. “The R-C2 flyer showed us the solution. It was clear: With this vice automation using a robot and R-C2 module, 50 percent plus of our work can be covered, because everything is always the same on the machine side. I only have to worry about feeding, but I only need a solution for half of the parts. The solution that we then developed with FMB and Gressel also requires hardly any set-up effort.” The handling of the various groups of parts is now clearly separated in Keltern-Dietlingen. With the cooling plates, it begins with preparation on a trolley that is located in the cell. From here, a pneumatic gripper picks up a component and loads it into the machine. After processing, the plate is removed and cleaned. To do this, the robot dips it into a cleaning basin that is integrated into the cell. Adhering chips are removed in this way so that the component is not damaged in the subsequent turning station. In this station, the part is first parked and then inserted and processed again. Once this step is finished, removal, cleaning, turning and insertion follow. <\/p>\n\n\n\n

\"raw
Raw parts prepared for “R-C2” automated production.<\/figcaption><\/figure>\n\n\n\n
\"\"
The robot places the component on the machine’s zero-point clamping system via the R-C2 module.<\/figcaption><\/figure>\n\n\n\n
\"\"
The R-C2 module picks up a centric clamp from the station.<\/figcaption><\/figure>\n\n\n\n
\"R-C2
Six identical centric clamps or three pairs of two identical clamps can be parked in the vise garage.<\/figcaption><\/figure>\n\n\n\n

Finally, the side that has already been processed is finished. While the robot loads the next component into the machine and the part goes through the first work step, the finished component is thoroughly cleaned and dried and placed on the trolley. “When working with the R-C2, we use a vice garage in which we can store six centric clamps,” reports W\u00fcrtemberger. “These can be six identical ones or three pairs of two identical ones each. The sizes we use are the R-C2 80 L-140 and the R-C2 125 L-160, whereby we cover 80 percent of our range of parts with the 80 L-140 centric clamp. The parts that we typically machine have dimensions of 40 x 40 x 80 mm.” The system itself is designed for geometries of 12 x 20 mm with any length up to 220 x 150 x 400 mm. The robot can handle up to 70 kg, but this depends on the distance to the sixth axis. The R-C2 system is designed for vice handling with 30 kg and for pallets with 50 kg. <\/p>\n\n\n\n


The system is operated via two interfaces. “On the first screen, I define everything that has to do with the part: Which base body of the vice do I want to use? What kind of vice jaws do I have on it? How high is the part? What dimension does the vice need to grip?” explains W\u00fcrtemberger. With these four pieces of information, he has already defined everything concerning the part. “I then enter the information about the parts trolley on the second screen. All I have to do here is define the X and Y grid dimensions of the parts and the position at which I want to pick them up. Then I press Start and off I go. With a bit of practice, it takes a quarter of an hour. If a jaw change is necessary, it takes a little longer. However, the large gripping range compared to a pneumatic gripper means that manual intervention is much less necessary.” <\/p>\n\n\n\n


As soon as the component- and carriage-specific details have been agreed and Start has been pressed, the robot moves through the vice garage and scans whether the correct base body is in the correct place. If it is certain that no collision can occur, it picks up the base body, loads it and waits in front of the machine until it can insert it. The robot then leaves the machine room again. “With us, the machine is the master, it controls the cell and gives the robot the signal to prepare the next component. While the first component is being processed, the robot picks up the second vice and the second part and then places them in the preparation station. Now there is a permanent changeover from this station.” <\/p>\n\n\n\n


“The decisive effect of R-C2 automation today is the intended one: we use it to prevent machine downtimes,” summarizes W\u00fcrtemberger. “In the semiconductor market, we are bridging the gap during a downturn that can last six or nine months because the system fits in perfectly with our other customers and their range of parts.” At the same time, vice automation enables the economical production of series of different sizes. <\/p>\n\n\n\n

Workpiece automation R-C2<\/h3>\n\n\n\n

The R-C2 workpiece automation is the solution between pallet automation and robot direct loading, as Gressel vise automation combines both advantages. This means much less setup effort and much more flexibility. With an R-C2 automation system, the employee can work extremely efficiently during the day without any waiting time losses and build up work stock (workpieces fed in, raw parts in the magazine, set-up tools) in the automation system. This work stock is processed by the machine during the day and also unattended at night.<\/p>\n\n\n\n

“We can also optimize the last second for specific parts, which makes us particularly competitive with larger batches.” Of course, the robot requires a certain amount of programming. However, because FMV has put a lot of work into the user interface with FMB, this additional effort is worthwhile even for small quantities. In any case, it is economical to run similar parts automatically in the evening or at night. “We can’t process different parts at night, which is not due to the R-C2, but to our system,” says W\u00fcrtemberger. “We don’t have a higher-level job store manager with which we can realize changing parts. However, this only makes sense for a system that works exclusively with R-C2 automation in order to cover everything and get the maximum runtime.” <\/p>\n\n\n\n

\"\"
After each processing step, the component is cleaned inside the cell.<\/figcaption><\/figure>\n\n\n\n

The managing director is already looking ahead, because a 6-side station is a central point of the future collaboration between FMV and Gressel. FMV is currently examining two basic approaches: The first is the automation of a next machine exclusively with the R-C2 system and a 6-side station, which will enable unmanned 6-side processing. “This is the more likely step, because the existing systems will probably be used primarily for the cooling plates in the next few years,” estimates W\u00fcrtemberger. “Alternatively, we could put the 6-side station into operation on an existing system. For example, at the end of a product life cycle, when it is clear that the parts for which the cell was designed are no longer being produced or are no longer being produced in the same quantities.” As soon as a cell works with the R-C2 70% of the time, a 6-side station makes sense. If the cell is reused in this way, it could be optimized even more for the R-C2, for example in terms of keeping different parts in stock. What exactly the solution will look like remains to be seen. “In any case, the R-C2 is perfect for us,” says the managing director. FMV has been working with Gressel since the 1980s due to the impressive quality, the durability of the products and a supply of spare parts that is adapted to the durability. However, this was the first joint project on automation. That’s why W\u00fcrtemberger didn’t have a flyer yet… <\/p>\n\n\n\n

\"\"
Andreas Brunhofer (left) and Till W\u00fcrtemberger are currently considering the concept of using a 6-sided station from Gressel for unmanned processing.<\/figcaption><\/figure>\n\n\n\n

R-C2 automation prevents machine downtimes and enables economical production. Automation solution from Gressel and FMB at contract manufacturer FMV ensures shorter set-up times and unmanned machining. <\/p>\n\n\n\n

<\/p>\n","protected":false},"excerpt":{"rendered":"

The machines in manufacturing companies have to run. And this is all the more urgent the higher the investment. Production cells belong in this higher category, especially as robots, handling and storage systems, clamping device stations and parts carts are often integrated. <\/p>\n","protected":false},"featured_media":59591,"parent":0,"template":"","meta":{"_acf_changed":false,"content-type":"","footnotes":""},"blog_kategorien":[547],"blog_tags":[548],"class_list":["post-60250","blog","type-blog","status-publish","has-post-thumbnail","hentry","blog_kategorien-automation-en","blog_tags-automation-en"],"acf":[],"yoast_head":"\nComplementary automation | GRESSEL clamping technology<\/title>\n<meta name=\"description\" content=\"Read how automation at FMV is setting new standards and improving performance in the semiconductor industry.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.gressel.ch\/en\/blog\/complementary-automation\/\" \/>\n<meta property=\"og:locale\" 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