FLEXIBLE ROBOTIC FINISH
WEISS’ ROTARY INDEXING TABLES EXPAND ROBOTIC POLISHING PROCESSING OPTIONS FOR COMPLEX GEOMETRIES
Author: Bill Eppich, Vice President WEISS North America
Publication Date: October 2017
Abstract: The SHL robot heaves an enormous polishing unit over the work pieces that the heavy duty rotary indexing tables from WEISS replaces with a fresh batch once processing is complete. To date, more than 1,100 SHL robotic grinding and polishing systems have been implemented worldwide.
Since the 1980s, SHL (Böttingen, Germany) has been leveraging industrial robots for its automated grinding, polishing, and deburring systems for the automotive, medical, and processing industries. Typically, heavy duty robots with powerful articulated-arms seem somewhat oversized for the delicate tasks and complex geometries such as polishing roof rails and trim for cars.
In depth consultation with industry leading specialist for rotary tables and automation, WEISS (Buchen, Germany), and its’ subsidiary WEISS North America, Inc. (Willoughby, OH), revealed that a powerful robot coupled with a series of heavy duty rotary indexing tables (TC 220 / NR 750 / CR 750) from WEISS would provide an optimal standardized and flexible solution.
Ultimately, using grinding and polishing machines swivel-mounted on WEISS’ rotary indexing tables vastly expanded the processing options for complex geometries and under-cuts.
ROBOTIC CHALLENGE
In the late 1980s, the automated grinding and polishing of mass-produced parts was typically carried out by special cam- operated or CNC-controlled machines. As fixtures, fittings, and components from the medical technology and automobile manufacturing industries became more and more complicated, the use of freeform surfaces began to increase and economic solutions needed to be found for the growing product variety and smaller series.
Whereas robots provided the degree of flexibility required for this operation, they have their limits when faced with highly complex geometries. In order to reach the farthest corner and the deepest radius, the grinding and polishing machines, to which the robot holds the work pieces, needed to be able to swivel into specific positions.
Karl-Heinz Oberkampf, Production Manager at SHL, recalled the early years of this dilemma stating, “In the first installations, we mounted our grinding and polishing robots on a construction we put together ourselves from gears, transducers, and locking mechanisms−which involved a lot of work. In the medium term we were looking for a standardized, yet flexible solution.”
ROTARY INDEXING TABLE SOLUTION
SHL consulted with WEISS Technical Sales agent, Wolfgang Lehnert, noted, “We have a wide range of rotary indexing tables that enable the development of standardized swivelling and positioning units. Using the same dimensions and load data, we offered both fixed-position and user-programmable tables, both with and without their own drive as required. This means we were able to offer SHL not only a high degree of standardization in design and construction, but also the greatest possible flexibility when it comes to the drive and control system.”
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SHL had finally found the right basis for its swivelling and positioning units. In a typical robot cell, several grinding and polishing machines are mounted on a rotary indexing table or arranged in a fixed constellation around a robot. The articulated arm grips a component and guides it along the polishing disks and grinding belts. The WEISS rotary indexing tables allow processing at various angles and even enable travel during processing.
ROTARY INDEXING TABLE SOLUTION
For the heavy grinding and polishing machines, Oberkampf stated his choice of the user-programmable WEISS NR 750 rotary indexing ring, “Our customers want more design freedom with larger installations.”
SHL also increased use of the WEISS rotary indexing tables for special machines and feeding systems. One such case is the polishing robot, in which a user-programmable WEISS CR 750 heavy-duty table takes care of changing the work piece carrier.
CONSULTATION / COLLABORATION
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WEISS’ consulting service wasn‘t just limited to selecting the right rotary index tables. According to Oberkampf, “The WEISS team also supported us in selecting the drive – even though we often order the tables without one!” The drive and control system are selected in accordance with the customer‘s requirements, which means that lots of different motors are used. In some cases, the rotary indexing table is even controlled by the robotic control system as an additional robot axis.
ROBOTIC / ROTARY INDEXING TABLES CONCLUSION
Finally, the SHL robot heaves an enormous polishing unit over the work pieces that the heavy duty rotary indexing tables from WEISS replaces with a fresh batch once processing is complete. To date, more than 1,100 SHL robotic grinding and polishing systems have been implemented worldwide.
Noting the success of their mutual cooperation, Oberkampf stated, “We enjoy working together with WEISS−particularly on special projects. Our companies share a similar philosophy as anyone can deal with normal cases. It’s only in special cases that a company’s consulting and service show how good it really is.”
Here's what some of our other customers have to say about WEISS North America
"Ultimately, the engineers from Netafim were impressed by the quality that WEISS delivers. And for WEISS, close cooperation with customers has always been a key part of the company philosophy. After all, the company sells complete solutions and not just components."
Dale Beaver, President
Innovative Products & Equipment
"“We were able to connect the frequency inverter control on the TR 750 to our higher level machine control system with no issues. In fact, the binding machine was already up and running just a few hours after installation.”
Anton Jost, Product Manager
Kugler-Womako
“We enjoy working together with WEISS−particularly on special projects. Our companies share a similar philosophy as anyone can deal with normal cases. It’s only in special cases that a company’s consulting and service show how good it really is.”
Karl-Heinz Oberkampf, Production Manager
SHL
CORPORATE PROFILE:
An integral part of the Weiss global network, Weiss North America (ISO-9001 Certified) leverages over 45 years of reliable world-wide expertise to comprise an integrative, customer-specific approach to its vast array of electromechanical products. Our 100% vertical range of manufacturing ranges from rotary indexing tables, handling systems, and linear assembly systems−providing flexible technology for turnkey solutions that incorporate electronics, mechanical systems, software, and comprehensive engineering support. This enables us to provide pre-installed, intelligent, and highly convenient solutions for the entire field of kinematics.
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