May 12, 2015

Servo technology and latest generation robotics

Automatic high speed y large part stamping line for the automotive sector.

Fagor Arrasate event: Servo technology and latest generation robotics

The development of large and ever faster press lines has been a constant in recent years within the automotive industry. The increased cadence allows an ever shorter return on investment period so that investment becomes more competitive.

Fagor Arrasate in collaboration with ABB has developed a fully automatic installation capable of making large components at a rate of 15 parts per minute for a customer in the automotive sector.

To load the blank in 1st press, a vision system is used which locates the position of the blank(s) and informs the robot of the same. In the case of a “single” part, the two robots work in multi-move (the axes of both robots controlled by the same controller), behaving like a single robot with 8 (4 + 4) axes. In the case of a double part, the location of each of the parts is made independently, and each of the robots works autonomously, since the two blanks can be in different locations and orientations relative to one another. Each robot is controlled by its IRC control unit, collecting its part with the required orientation from the information received from the vision system

The head press is servo drive and is equipped with 3 of the latest generation Siemens 1FW4 servomotors with three kinetic buffers connected to a power supply of 630kW. The buffers allow the storage of kinetic energy, to be subsequently transferred, thereby optimising energy consumption and hence saving costs.

The four line presses are designed with the same criteria of flexibility and with DDC (Dynamic Drive Chain) servo technology from ABB which allows fast opening and closing of the press using a servo motor, while using all the flywheel energy of a traditional press for the stamping process. This technology combines, in an economical way, the benefits of a servo-controlled runner with the utilisation of the energy stored in the flywheel for the stamping, minimizing the sizing of the power supply and significantly reducing power peaks.

The TRX – Twin Robot Xbar technology allows the tandem press lines to produce up to 15 parts per real minute.