Robot handles truck axles at forging press

As soon as the robot controller receives the signal from the controller that the material can be removed, it sends the corresponding command to the KR 350. The robot has to be able to handle 42 different axles using its gripper. The corresponding programs for this are stored in the robot’s controller. The robot is largely shielded from the harsh environmental conditions by a protective suit. Once it has gripped the red-hot steel, it moves with it on a linear unit to the forge hammer and places it in the recess of the bottom die.

At the forge hammer, the number of strokes depends on the form and weight of the axle. Once the machine operations are completed, another manipulator takes the axle to a trimming press. From here the axle is fed automatically into the calibrating press. There it is picked up by a second robot and placed on a traversing carriage, from which it is removed by a crane gripper and placed in a rack for cooling.

• KUKA KR 350 robot
• PC-based KUKA robot controller, including control panel with Windows interface
• Gripper; because of the variety of axles to be handled, both wide and narrow jaws have been provided
• Linear unit with a length of some 4.5 meters
• Robot programming
• Commissioning
  
  

Integration by Lasco Umformtechnik GmbH, Coburg, Germany.

• High cost-effectiveness
  
  The lasting gains in productivity and process reliability are based on high repeatability, with tolerances under a millimeter, and nearly 100 percent availability. At the same time, it was possible to save two operators per shift.
  
  
  
• High flexibility
  
  The robot’s high flexibility is of great importance merely for handling the many different types of axle. KUKA provides additional flexibility, however, through the simple programming of new axle types via the KUKA Control Panel's familiar Windows interface.
  
  
  
• Short cycle times
  
  The KR 350 achieves short cycle times of about 60 seconds per axle, including the motions to and from the bending press and the forge hammer. The precise cycle time is determined by the size of the particular axle and therefore its dwell time in the induction furnace and at the forge hammer. Since the robot is faster than the andromat that was used before, Schöneweiss now has reserve handling capacity in this area. The company would consequently have no problems adapting the handling system should some day larger quantities of smaller axes be produced, requiring shorter cycle times.