When buying a new machining center, you usually start with the range of parts and then think about the tools and, if necessary, the automation after the machine. The “R-C2” vice automation from Gressel and the “Robobox” from Spinner Automation show that it sometimes makes sense to put the cart before the horse: Fichtner CNC-Technik invested in a complete package with a five-axis “Spinner U1530”. <\/p>\n\n\n\n
“We are a small company that now has eight employees. When we were founded ten years ago, we specialized in milling small, complex special parts,” reports owner Julian Fichtner. “Gradually, we expanded and now also manufacture small series. With a few exceptions, we cover everything technologically.” In other words, vertical integration. The aim is to stand out from the competition with high-precision, filigree components. In addition to the domain of 3- and 5-axis milling, Fichtner is also developing further in turning. The company recently invested in a new turning machine. At present, 90 or 95% of milled parts are produced, and 5 to 10% are turned parts. “The customers for these parts mainly come from the special machine construction sector. We also serve a wide range of customers from the food industry, the cosmetics sector and medical technology.” One customer from the special machine construction sector, for example, is a large injection molding company. This was also the initial customer for the automation project. <\/p>\n\n\n\n
Admittedly: Until then, Fichtner had tended to hold back on investments in automation. Nevertheless, he followed developments in this field very closely. “Robot technology has been around for years. However, I could never imagine investing in it because automation was based on prism grippers. For a long time, it was also said that only round parts could be automated,” he says. “Consequently, I would have had to equip my 5-axis machine with a prism gripper. But we often produce complex individual parts. How was I supposed to get these parts out of the machine without huge effort?” <\/p>\n\n\n\n
Running on multiple tracks<\/strong><\/h2>\n\n\n\n
The topic of automation then became acute through the special machine manufacturer, which also produces hydraulic components for injection molding machines. The background: \u201cWe had been supplying this manufacturer with special parts and devices for years. During the Corona period, he approached us to see if we could machine steel castings for him. These parts would be very difficult to produce on his fully automated machines. The idea was for us to buy in continuous casting blanks, machine them and keep his production running.\u201d For a while, Fichtner took over the processing from the customer, at that time on two machines. When a new decision had to be made after coronavirus, the special machine manufacturer was so convinced of the quality that he wanted to continue manufacturing in Gunzenhausen. \u201cWe hadn’t done much with castings until then. Especially not series production,\u201d says Fichtner, describing some of his considerations.\u201d He was now asked to analyze his entire range of parts to see what could possibly be automated. The idea was to use a new production cell to produce the cast parts as recurring small series in the second or third shift, with complex individual parts being produced on the machine during the day. <\/p>\n\n\n\nThe production cell in its entirety: Workpiece handling for the “Spinner U1530” is handled by the “R-C2” vice automation system from Gressel and the “Robobox” from Spinner Automation.<\/figcaption><\/figure>\n\n\n\n
The solution from the showroom<\/strong><\/h2>\n\n\n\n
The decisive factor remained. By this time, Fichtner had already come across Gressel vice automation. With great enthusiasm, as he emphasizes: \u201cAt the time, Gressel was the only manufacturer that automated via vice. The flexibility it offered was the decisive factor: I wanted a machine with this system. At the same time, I wanted to buffer as many parts as possible.\u201d The pallet changer has been a mega solution for decades, \u201cbut then I would have needed dozens of pallets and vices, which is very expensive.\u201d In this situation, chance also helped a little: \u201cI visited Spinner Automation’s in-house exhibition in H\u00f6sbach. That was in the middle of the coronavirus era. Back then, my customer had already told me that if I wanted to take over the series, I would have to do it soon.\u201d There were just three or four months left to put a suitable system into operation. \u201cSo I quickly bought an automation cell from the showroom, consisting of an R-C2 vice automation system from Gressel and a Robobox and U1530 from Spinner.\u201d While the R-C2 system enables unmanned 6-sided machining using a robot-guided R-C2 module, R-C2 centric clamp, \u201cVero-S\u201d console and 6-sided station, the Robobox works as a universal robot cell with five drawers for holding parts. The U1530 is designed as a 5-axis machining center in a moving column design with travels of 1530 x 530 x 465 mm (X\/Y\/Z). The installation and commissioning of the cell – including the vice automation – was carried out by Spinner Automation and BG Werkzeugmaschinen within the deadline. <\/p>\n\n\n\nRobot-assisted vice automation makes it possible to conveniently handle numerous components of different shapes and sizes.<\/figcaption><\/figure>\n\n\n\n
Today, in his daily work with the cell, Fichtner always analyzes the shape of a raw part first in order to determine the best way to handle it. It is then placed in one of the five drawers, for which shaping systems are sometimes manufactured so that the parts fit precisely in the Robobox and the Fanuc robot has an exact reference plane. Based on the size of its parts, Fichtner has specially adapted the storage areas and implemented a smaller grid in the upper drawers. As soon as the parts are placed in the Robobox, an employee at the control panel agrees the size and position of the component and the corresponding vice. This also includes the appropriate jaws. Once the program has been selected, the robot knows its component-specific task. The U1530, which is equipped with the console for adapting the Gressel vices, is now supplied with parts unmanned by the Robobox with R-C2 automation. After machining, the parts are placed back in a drawer. This procedure is used for 90% of the parts. In exceptional cases, an employee carries out certain inspection work after the parts have been retrieved and inserted. Five vices in three different sizes are used for unmanned processing. Parts weighing up to 30 kg including vice and jaws can be handled. <\/p>\n\n\n\nThe Robobox works with five trays that can hold a wide variety of parts.<\/figcaption><\/figure>\n\n\n\n
Producing around the clock<\/strong><\/h2>\n\n\n\n
The U1530 is a particularly versatile machine that can also be used to machine the rear sides of components if required. This makes it ideal for processing complex parts during the day shift. If the employee leaves in the afternoon, he has already quickly converted the machine with the zero point plate, started the robot and thus prepared the cell for unmanned production in the second and third shifts. If a series of cast parts is due, Fichtner also runs the cell for 24 hours at a time. If the cell is unmanned, this can take up to a week. The employee who looks after the cell also operates a 3-axis machine. On the U1530, he only has to clear out the drawers early in the morning, check the last parts produced and reload the Robobox. Thanks to the long autonomous machine times, Fichtner can also respond well to vacation times or similar.<\/p>\n\n\n\nFichtner considers the automation solution to be extremely easy to operate.<\/figcaption><\/figure>\n\n\n\n
Completely ready in the tray<\/strong><\/h2>\n\n\n\n
What is surprising at first is that Fichtner produces very little with the 6-side station. “This is due to our main product, where only four to five sides need to be machined,” explains the owner. “We have also managed to program the entire machining process so that the component is finished in one clamping operation.” The decisive factor for him with vice automation is therefore the flexible handling of complex parts. The example of sliding blocks shows that 6-sided machining works perfectly. “If we didn’t have the 6-sided station here, we would have had to touch all 200 parts again. But this way they were ready in the tray.” For difficult parts that need to be produced with high precision, Andreas Brunhofer recommends probing on the second side during 6-sided machining: “At the same time, the part can be intercepted so that it is always 100% on the plan system,” continues the automation product specialist at Gressel. “Last but not least, it is very important that cleaning takes place in the machine.” In this constellation, Fichtner always has the option of unmanned complete machining for new parts. <\/p>\n\n\n\nFive vices are in use in Gunzenhausen, which can accommodate the entire relevant range of workpieces.<\/figcaption><\/figure>\n\n\n\nFichtner often only works on four or five sides of the workpiece. This in no way detracts from the efficiency of automation. <\/figcaption><\/figure>\n\n\n\n
Almost blind trust<\/strong><\/h2>\n\n\n\n
“We are very satisfied with the automation,” summarizes the owner, not surprisingly. “It is easy to operate, requires no teaching of the robot, not even any special control or programming knowledge.” The machining sequence is always the same, which is mapped by the Spinner Automation software. “When we produce something new, my employees now go through it with almost blind confidence.” The ease of use also applies to vice automation. “For me, it’s the ultimate. It allows me to handle many parts of different shapes and sizes very easily. And I don’t have to make something for every part. That’s why I wanted the cell.” He now also receives inquiries from colleagues who do not have automation but need to produce 1000 parts. With his automation, Fichtner can do this cost-effectively and broaden his base. In particular, he can take on parts that he previously had to keep his hands off due to the handling.
<\/p>\n\n\n\nJulian Fichtner (left) and Andreas Brunhofer.<\/figcaption><\/figure>\n\n\n\n
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