Sondermaschinen nach Maß Das Kompendium Projektierung

Compendium
Sondermaschinen nach Maß
Customized
special machines
Das Kompendium
Projektierung
Design
Konstruktion
Construction
Realisierung
Completion
www.fabm.de
GmbH
A big advantage
Büttel und Marx develop smart
solutions of complete automation
at its own headquarters
Büttel und Marx GmbH company
builds special machines for the automation of industrial production processes such as assemblage stations,
inscription units, testing equipment,
measurement stations and makes
available components.
Mechanics
Electrotechnique
Creo Elements/Pro
FluidDraw
Safexpert
eDrawings
EPLAN
PNOZmulti Configurator
Safety Calculator PAScal
Our strong points and your advantage: Büttel und Marx machines are
completely made at its headquarters.
Besides the mechanical construction,
all electrotechnical and necessary
software components are developed
by own qualified personnel.
We offer our clients innovative and
economic solutions, based on
EC Machine Directive and normal
provisions of industry.
Our clients are predominantly
The automotive industry and
the ­industry of providers for
auto­mobiles
The industry of electrical and
household appliances
The metallurgic industry
The industry of plastics processing
The industry of machine
­construction
The industry of medical technique
The certification of our company
according to ISO 9001:2008 is the
expression and
guarantee of the
excellent quality
of our products.
Software
Siemens SPS
Beckhoff TwinCAT
LabVIEW
MS Visual Studio
C-Sharp
AOI systems
Image processing systems
Links to databases
Flash
BDE
http://goo.gl/N5hgS
»If every tool could
p­ erform on order or
from its own initiative
the work suitable to it,
then there would no
longer be n­ ecessary
­apprentices for the
craftsman workers and
slaves for masters«
Aristotel
(384–322 B.C.)
www.fabm.de
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3
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Automation
is a process in the evolution of which the human activities are replaced continuously with the
functions of artificial systems (automated machines, robots, computers) in order to improve
the quality and reduce costs.
Automation steps
From the point of view of
the automation degree,
our technical solutions and
machines are corellated
with your needs.
10 12
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Profit
Evaluation of
depreciation
and profit
t1
Before the technical
development and
completion, there is
the design for the
profitabilty of an
automation solution.
t2
t3
More on page
t4
Analysis of cycles
34 Seconds
16 Seconds
500,000
16 Seconds
34 Seconds
36 Seconds
34 Seconds
26 Seconds
34 Seconds
Printer
A13
Laser / Scan
Parkposition
Posts of
manual operation
A12
A8
A15
A5
250,000
A17
A16
A12
A3
A2
A13
A16
A6
Station 1
Input / Fail
A17
A9
Station 4
Station 2
Complete automation
Systems of
manual manipulation
34 Seconds
38 Seconds
Station 3
A15
A11
A4
10
A7
20
30
40
Start phase
A10
50
A14
60
70
80
A18
Automation of
elements
Automatic machines
with rotary transfer
Transfer systems with
supports of components
100,000
A11
A1
A0
6
Number of
components
An important criterion for the
­economic and technical exposure
of an assemblage and testing
­installation is the analysis of cycles
Positions
8
Period
t1 = design period
t2 = procurement period
t3 = depreciation period
t4 = product use period
Costs
A18
110
120
130
90
100
Duration of cycle 18 seconds
Duration of cycle 18 seconds
Duration of cycle 18 seconds
Cycle
Beginning of cycle
Manual devices
and auxiliary devices
A18
140
Time in seconds
500
Automation degree
25 %
The industrial automation
functions only in interaction
with more components.
Electrotechnique is the
connector between control
software and manufacturing
mechanics – comparable to
the human nervous system as
connector between the brain
and locomotive system.
Other
automation areas:
Test stands
16
More on page
4
and
50 %
Automation for permanent
testing in the temperature panel
18
More on page
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Electrotechnique
& Software
20 22
and
100 %
Special machines
More on page
24
5
Equipment
is the working means that are divided in universal equipment or
equipment dependent on the components to be processed
The equipment is manipulated by a
manual operator or automated equipment and controlled with automated
systems through various manipulation
systems, such as systems of supports
for components, robots, systems of
linear axes, sorting installations, storage systems, »Pick & Place« units and
automated conveyer bands.
The manual devices are necessary
for the production of prototypes
for the production of first samples
as auxiliary means for starting the
preproduction of a product
for the lot production of variants
of types with small lots and
for making products in a very
small number.
6
Our basic competences in the field of devices include the
production of the following
The equipment can be integrated
as tools or supports for components
in a manual operation post, a semiautomated or completely automated
installation.
The equipment characteristic is that
it is used or can be replaced as a
complete module.
1
3
2
4
5
7
Gripping units
Contacting units, for example adapter of needles
Joining and assemblage devices
Stamping and bending units
Welding stations
Cleaning and suction stations
Screwing up units
Lubrication devices
Dosing systems
Milling and drilling units
Marking and inscription devices, for example hot and cold stamping
units, crayon marking units, label printers, laser engraving systems,
stamping units for verification codes, Ink Jet printing systems, needle
stamping units, etc.
Testing units, such as image processing systems, speed – force – track
testing stations, angle – engine torque – speed testing units, units for
the verification of diameter and concentricity, stations for tightness
verification, high voltage testing units
8
10
9
http://youtu.be/QoRURPSb3wg
6
The devices for different applications, such as
1 Manual joining devices
2 Semi-automated pneumatic assemblage device
3 Manual contact and verification device for the cylinders of ignition switches
4 Automated contact and verification device for the cylinders of ignition switches
5 Assemblage device for photoelements
6 Semi-automated cleaning station for double switches with ionized air
7 Welding device for laser welding automatic machine
8 Semi-automated contact and verification device for the ignition switch of the engine hood
9 Manual bending device for diodes
10 Manual assemblage and verification device for the laser distance sensor
7
Manual operation posts
Refined help for the partial automation of processes
The assemblage, verification and
measurement devices and the related
material flow system will be manually
and favourably connected from the
point of view of costs with the manual
operation posts.
3
The condition for all posts on the chair and afoot is the
ergonomic structuring of the workplace, according to
DIN 33400 ff and DIN ENV 26 385
Orientative sizes for the necessary space
We produce manual operation posts in different variants:
Mechanics for cabinets,
in which assemblage
processes are executed,
respectively verification
processes, as well as outside and inside the cabin.
1
Mechanics for double
cabinets and mechanics
for rotary disks
in which processes are
executed simultaneously
outside and inside the
cabin. 2
Mechanics for
lifting doors
in which the technique
of processes is executed
mainly inside the cabin.
3
Open mechanics
The processes being executed exclusively manually,
with electrical instruments
and/or tools.
4
Complex mechanics
In which different processes are executed in different devices, with different
safety doors (here sliding
door and the mechanics of
cabinets). 5
Length
of action
mm
400
Other options for all manual operation posts are mentioned above, namely
construction with console or box, height adjustment of the working bench,
support for feet, visual obturators, drawers, assemblage portal with workplace
illumination, track arm with rails for electrical tools suspended with swing,
energy supply channel, support plate for tools and gripping device.
1
200
4
3
2
4
0
Gripping space
200
800
600
400
200
0
200
400
600
800 mm
2
1
5
8
9
Automatic machines with rotary transfer
Compact and advantageous solutions for the automation of processes
The automatic machines with rotary
transfer and manual equipping and
controlled by an operator are used
at the production of lots with small
quantities.
These increase the automation degree
and thus costs per piece for the produced unit are reduced. The automatic
machines with rotary transfer have the
advantage of being built in a compact
way, they require a reduced necessary space and also have very reduced
switching-over cycles. By comparison,
the costs of investment in equipping
the machines are also reduced.
The automatic machines with rotary
transfer with semi-automation – we
are also talking about hybrid assemblage – are used by an operator who
manually introduces the components
to be assembled, namely the components to be verified. After introduction,
a sensor determines if the component
is correctly placed and the rotary disk
will guide after a station, after the
safety door was manually closed.
Instead of a safety door, a light curtain
can also be used, which will guide the
rotary disk further, immediately after
the operator leaves the area monitored by the light curtain.
The automatic machines with rotary
transfer can be completely automated
by manipulating the location, for
example by a robot.
At the illustrated automatic
machines with rotary transfer,
the component to be processed,
respectively the sample, are
manually placed in the support
for components on the rotary
disk. In a second station will
be carried out for example the
assemblage process. In a third
station takes place the testing
process and in a fourth station
will be marked the component
to be processed and/or it will
be automatically placed on a
taking-over band.
10
11
Transfer systems for supports of components
High power, smart and flexible systems for different requests.
The transfer systems for supports of
components are distinguished by a
larger flexibility. This means that the
processes from the assemblage and
verification line can be removed,
namely completed. Moreover, the
assemblage and verification processes
of great variety can be also carried out
with the transfer systems. It is possible
a combination of manual and fully
automated stations inside the production line.
1
The selection of the support for
­components allows higher sizes.
The particular conditions have an
important role in installation design.
The complex assemblage sequences
require a larger flexibility when
­selecting systems and structuring
design.
3
The transfer ­systems
for supports of
­components are
distinguished by the
following installation
designs:
System with
connection in series:
Square construction
System with
by-pass connection:
Mixed system:
A2
A1
A3
A4
Round construction
U-shaped construction
The automation of ­verifications
The samples delivered on pallets
or on supports for components
will be taken over from the conveyer band in the verification station by a portal robot. There, the
components will be connected,
tested and the measurement of
the introduction/extraction force
and rotation moments will be
carried out.
1
Lifting assemblage for lines
The conductor pads for exhaustors will be placed manually on
the supports for components and
then they will pass through a
heating station, plasma cleaning
station, assemblage station for
arm lifters with automated label
supply, as well as a Pick&Place
unit with grabber for needles and
a final pressing unit.
2
The assemblage of the
­operation field for the door
The operation fields for the door
will be assembled in different
variants, in manual and automated stations, namely cleaned,
tested, screwed up and marked.
3
Module assemblage
At this assemblage system for
supports of components, the
individual components will be
placed and assembled manually
in the fastening places on the
support for components. In different stations, the components
will be tested and adjusted. In
the last stations takes place the
thermal welding of the entire
subassembly.
4
2
4
12
http://youtu.be/FzWDQXm7Cw8
13
Manual manipulation systems
For the complete automation of processes
»Catch things, from the place
they can be picked up«
Epiktet (50–138 A.D.)
The manipulation technique is the
material means or devices which
transport the material flow from one
post to another.
In the automation technique, robots
are used for completely ­automating
the assemblage and/or testing process. For this are used loading and
unloading stores in order to maintain
the buffer of components.
Portal axis robot
In the right part of the image
you can see two portals with 3D
arm with 5 axes each.
X-Y-Z axis will be completed by
a rotation axis to which is
connected another linear axis.
Portal
with 2D lines:
http://youtu.be/li9qUrRkpLE
3D arm portal
with 4 axes:
Within this completely automated
assemblage process, the injector is
assembled in the nozzle casing, by
means of two sorting containers and
a storage bin of components, as well
as a 2D line portal with pneumatic
grabber.
3D space portal
with 3 axes:
In the figure below it is illustrated
a 2D line portal with double,
pneumatic grabber.
The robot with articulated arm exists, for
example as robot with 5 and 6 axes with 5,
namely 6 rotation axes.
In the left part of the image you can see a
WIG welding automatic machine using a
robot of 6 axes.
14
http://youtu.be/PRqSUaVToiI
http://youtu.be/EHMNM43UOd4
15
Test stands
Installations for the verification of products or other components
The life duration ...
The test stands are important means
for assuring the quality, for reducing
at minimum the losses of products.
The life duration of products can be
presented tipically in a diagram, the
so-called »duck curve«, as failure rate,
depending on the life duration (see
the chart).
determines the period in which a
technical product can be used without
replacing the central components or a
complete failure. In order to ensure the
quality, it is important to test the mechanical and electrical characteristics
of the new products even from the time
of their development. For this purpose,
test stands are used for determining
the life duration. For this, the samples
are mechanically fixed in supports and
Examples
1 Test stand for electric tools
2 Test stand for switches of electric tools
3 Test stand for safety switches
4 Test stand for safety switches for hinges
5 Test stand for screwdrivers
exposed to a permanent alternating
request (for example rotation moment
and/or traction force – compression
force).
This happens uninterruptedly, usually
for a period of up to three months.
Within this period, the parameters to be
measured will ve recorded (for example
moment of rotation, force, speed, track,
current, temperature).
Incircuit Tests ...
End of Line Tests (EOLT) ...
are testing procedures by which the
(electronic) pretested product is subject
to an intermediary verification before
continuing the production, namely
assemblage. By intermediary verifications, the products that are not good
are evacuated before reaching the
final process (final assemblage or final
production). The intermediary verifications will be carried out for example at
conductor plates and even at modulary
equipped conductor plates. The adhesion problems, errors at components,
including couplings, are tested.
are testing procedures in production
by which the 100% functioning of
newly produced products is verified at
the end of the production process.
Also, these serve for ensuring the
quality, their name coming from the
fact that most automated test stands
are directly at the end of assemblage
and production lines, from spatial
point of view.
3
»Bathtub« diagram
For presenting the failure rate
of a product depending on its
life duration
λ (ppm)
t = time in years
λ = failure rate in parts per million
Failures due to ageing
Real error rate
Constant of accidental errors
Previous failures
t (anno)
2
1
16
4
5
17
Automation for permanent tests
in the temperature panel
Stress-Screening
Stress-Screenings are the tests concerning the life duration, in which the ageing of products is strongly accelerated
by using quick and extreme modifications of the temperature (Temperatures
of –70°C up to +250°C). Hot stamps,
rooms for high temperatures and temperature testing cabinets are used for
this purpose. It can be verified either
in constant temperature conditions
or in conditions of temperature that
modifies in time. Through this testing
procedure, the development time of a
product until it will be ready for the lot
production is reduced, along with the
simultaneous reduction of costs.
1
Examples
1 U
nit of pressure sensors in the temperature room
2 U
nit of pressure sensors in the temperature cabinet,
with the use of an HF room
3 A
djustment unit for permanent tests in the
temperature panel
4 R otation verification in the room of high temperature
5 V erification of the position adjustment switch for
the temperature panel
6 E lectro-motive unit in the room of high temperature
7 V erification of the step selection switch in the
temperature cabinet, using X-Y linear axis portal
4
3
5
6
7
2
18
19
Electrotechnique and software
The brain and neurological centre of the machine
A part of the automation technique
includes the project and orders. Here
are included the hardware design,
the construction of the control panel,
the installation cabling, the software
­creation and activation of the automation process. Depending on the input
sizes (for example the position of a
button or a sensor) the output sizes
will be modified by using an actor
(for example valves or engines).
The construction of distribution
installations
Electric constructions with
electric scheme
Software
The control panels are created at
random sizes, from the individual
component to the lot production.
This usual construction software allows a
documentation which can be used without
problems at the extensions of machines
and/or modifications of machines and can
be adapted – of course complying with the
current norms for electric safety.
The software of the machines is created on
Hard- and Soft PLCs, as well as on PCs.
For this, we use orders from Siemens (S7)
and Beckoff.
The PC-based software is created with
LabVIEW from National Instruments and
Microsoft Visual Studio.
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Track [µm]
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3500
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1400
3000
2500
1200
2000
1000
1500
800
600
1000
400
500
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1
The illustrated
diagram presents
the force – track
sequence of a switch
depending on the
individual measuring
points.
AOI system with
two high resolution
cameras and double
line light within a
dark cell.
Measuring points
Measuring technique
Electric safety equipment
Programmable logic controllers
IPC orders
AOI systems
deals with determining the physical
sizes, such as length, force, temperature, current, voltage and resistance,
many times depending on time. These
values are determined through special
measuring devices, selected for that use
case.
The registration and processing of
this multitude of measuring data is
­carried out through IPC orders
(Industry Personal Computer).
are redundant at assemblage, do not
have errors and take over the control
functions from the point of view of the
safety technique, forming the interface
between human and machine. This
takes place under the form of protection
equipment such as safety light curtains,
operation with two hands, emergency
stop button, etc.
(PLC) are digitally programmed and are
used as individual device or modular
structure (feeder, main processor, E/A
cards, interface cards, actuating mechanism controller) in the control panel.
will be programmed with programming languages such as LabVIEW or C-Sharp.
These can have extensive additional functions, such as complex visualizations,
protocols and statistics (see also the paragraph Measuring technique).
Complex automatic machines with a variety of functioning sequences for which
are not used additional functions, such as the above-mentioned visualizations,
protocols and creation of statistics, controlled by PLC.
The complex automatic machines for which are used the above-mentioned additional functions receive besides PLC an IPC subordinated order.
The simple automatic machines for which are used additional functions receive only
an IPC order.
The quality of the component to be processed is evaluated with an automated optical inspection. By using an image processing
system – executed with camera, lens and
illumination under a darkening hood – different parameters are evaluated, such as light
brightness, contrast and colour and a limit
value is defined for the good/bad evaluation. The existence and correct positioning of
defective components can be detected, being
determined including the cracks from components. Also, it is possible to recognize the
writing and symbols, as well as to determine
the lengths and width.
The hardware for the
measuring technique
is usually integrated
in a separate control
panel for the control
technique.
22
Mobile touchscreen
for a machine order
Fixed, simple operation panel,
for machine order
23
Special machines
Individuality is our standard
Many technical production processes
are not carried out through conventional automation solutions. For such
special tasks, we developed and built
a variety of special machines for our
clients. Contact us. We will create with
pleasure a special machine, adapted
to your needs.
4
Examples
1 Long Range Radar assemblage automatic machine
2 Assemblage device for frames of solar cells
3 Correction unit for the conveyer band
4 Graphite application installation
5 Separator of cylinder-head gaskets
6 Gas commutation system
2
1
5
http://youtu.be/fl7MUdhgUbA
3
6
24
25
Questions | Notes | Sketches
26
27
Individuality
is our
standard
Customized special machines
Design · Construction · Execution
Mechanics · Electrotechnique · Software
Equipment
Assemblage installations
Testing systems
Systems of robots
Permanent test stands
GmbH
Büttel und Marx GmbH
Development and sale of machines
Vogelsangstraße 41/1
72581 Dettingen an der Erms
Telephone 07123 9446-0
Telefax 07123 9446-100
E-Mail: [email protected]
www.fabm.de