The robot transfers the truck axle to the forging press

Current status/task

In the forging production line of the auto parts manufacturer Schöneweiss, it is necessary to link the press brake with the forging hammer. This requires the delivery of 180kg, red-burnt trucks and bus front axles. So far this work has been done by the so-called andromat. A manipulator equipped with a gripper and an operating cabin requires two operators for each shift. While an operator operates the robot, another operator can rest after a very stressful job or handle some lighter tasks. Since it is time-consuming and labor-intensive to use after the andromat has aged, it is necessary to replace it.

Implementation measures/solutions

The robot transfers the truck axle to the forging press

With the installation of the KUKA robot KR 350, Schäneweiss increased its productivity and process reliability. Since the axle is rather heavy, the gripper weighs up to 100kg, and the torque on the long lever arm is very large, this six-axis robot is a unique choice. When deciding to invest, the KR 350 was the only robot that could bear such a heavy load at the time and had the desired range of action. During this period, the KUKA robot launched the KR 500 with a higher load capacity; this model has a load capacity of 500 kg, but such power is overkill for the task.

Once the robot control system receives information from the press brake control system that it can remove the material, it sends the instructions to the KR 350. In general, a robot can transmit 42 different axles through its gripper. The corresponding program is stored in the robot control system. Most of the robot is covered by a protective cover, which protects it from external adverse environments. Once the robot grabs the red-hot steel, it will go through the linear slide to the hammer and place the steel in the concave of the lower die.

The number of forging hammers is determined by the shape and weight of the axle. After the machine has completed its work, the other robot will transport the axle to the trimmer. From here, the axle will be automatically transferred to the press for calibration. There, another robot grips the axle and places it on a frame; a crane grab then removes the axle from the frame and places it on a rack for cooling.

System Components / Contract Scope

KUKA Robot KR 350

PC-based KUKA robot control system including control panel with window operator interface

Holder for wide and narrow clamps for different types of axles

Approximately 4.5 meters long linear slide

Robot programming

put into service

Integrated by Formosa Technology, Coburg, Germany

Result/effectiveness

High economic efficiency

The high repeatability tolerance and near 100% availability of tolerances in the millimeter range is the basis for continued growth in productivity and process reliability. This also saves two operators for each shift.

Great flexibility

The flexibility of the robot is enormous, as it can transmit many different types of axles. This has already taken a fundamental significance. In addition, the functions provided by KUKA for programming the new axle type through the familiar window interface on the control panel also increase the flexibility.

Short cycle time

The KR 350 has a short cycle time and can deliver one axle every 60 seconds. This includes the round trip between the press brake and hammer. Takt time is determined by the size of each axle and the corresponding time spent in induction furnaces and forging hammers. As the robot is faster than the previously used andromat, the Schöneweiss company now has production potential in this field. Thus, if there is a situation where it is necessary to produce more small axles with a short cycle time, the company can make corresponding adjustments without any problems.