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   EDRAGON TECHNOLOGY CORPORATION

■ AMS, Automotive Manufacturing Solutions :
傳送自動化的好處
更高的生產力始於高效的物料處理
Conveying automation benefits
Higher productivity starts with efficient materials handling

圖片
圖片

https://automotivemanufacturingsolutions.com/technology/conveying-automation-benefits
What are the main factors under consideration when looking to transport parts along an automotive assembly line or move materials around a production plant? Speed, safety, reliability, flexibility, space and energy savings? Most probably, all of these and more besides. For this reason, many solutions are bespoke to fit the requirements of a specific application. With regard to transporting vehicle chassis along an assembly track, examples of the latest best practice installations can be seen at the Castle Bromwich, UK, plant of Jaguar Land Rover (JLR), which wanted to accommodate the XF Sportbrake on the same line as its XF saloon. 
 
JLR turned to Comau to build a dedicated tabbing and framing cell that takes the Sportbrake body floor out of the existing XF saloon assembly line to have the unique side body panels, roof and other components put in place, tabbed and then welded by robots before being returned to the main assembly line. Comau selected LB Foster Materials Handling to design, make and install the conveyor system which lifts and transfers the cars for the cell.
 
The first stage of the process features a powered roller conveyor, mounted on a hydraulic scissor lift table, which itself is mounted on a traverse car to create a bridge over some of Comau's equipment. The lift has to raise the body floor by 1.75m to enable it to enter the tabbing and framing cell.
 
When the body floor is received at this first station, operators manually attach the side body panels and other structural elements which are tabbed to hold them in place for welding. Once this work is complete, the scissor lift raises the body and the transfer car moves forward at the required height to feed it into the welding area. The roller conveyor supplied by LB Foster at this station is mounted on a special lifting assembly provided by Comau. Once the body is in the welding cell, the conveyor is lowered – leaving the body on its skid – to enable welding by robots.
 
The second stage of the project required LB Foster to complete a special take-out station that would provide an inspection facility for quality purposes. The work had to be completed over one weekend and involved the modification of an existing transfer car. Two apertures had to be cut from the sides of the transfer car to allow a new extending fork transfer device, with cam lift, to extend one side and pick up the body. This is then moved in the opposite direction and deposited on a modified roller bed outside the fenced area so that operators can carry out quality inspection on the assembly.


XF Sportbrake, JLR Castle Bromwich
With the panels tabbed, the XF Sportbrake body is raised and moved into the welding station

The final stage of the project involved providing a one-way through route from the welding station back into the main production line. This was achieved by installing a powered roller conveyor, mounted on a scissor table, just after the welding station and a further unit at the start of the return line.
 
The side transfer was accomplished using another extending fork system, but this time without a lift. The forks move the body on its skid 6.75 metres across to the return line, where it is deposited onto another powered roller conveyor mounted on a hydraulic scissor-lift table. The table lowers the body to the floor before moving it to a transfer car that runs on twin steel running tracks cast into the concrete floor. Incidentally, there is no physical link between the car and its power source – it is all done through an induction cable system, again cast into the concrete floor.
 
Increasingly innovative conveyors 
While conveyors can be considered mature technology, there is clearly plenty of scope for additional innovation. This is demonstrated by Intralox, which says that as automotive plants work towards improving output, flexibility, employee ergonomics and safety, many are turning to modular plastic belts for conveying fully assembled vehicles. Intralox has partnered with several global automotive manufacturers to apply modular plastic belting technology to assembly lines. Compared with traditional steel conveyors, the company says that modular plastic belts offer more flexibility, with reduced pit requirements, and do not need lubrication.
Intralox has recently developed its strongest and stiffest modular plastic belt yet. Intended specifically for moving vehicles, the design allows plastic to be used on longer, heavier and tougher applications. For instance, with a belt three metres across it is possible to safely pull 30-35 vehicles, says the company. The belt features a high-strength, electrically conductive acetyl material, as well as a wear-resistant material for concentrated load points.

In future, Intralox predicts that more vehicle-moving conveyors will be built above the floor using a low-profile design. By eliminating pits, automotive plants can reduce capital costs and construction time significantly on new lines. This also means that lines can be reconfigured with ease for new model changes.
 
Of course, there are plenty of applications for innovative conveyors around the automotive plant which do not involve vehicle assembly. UK-based Conveyor Systems, for example, recently completed a project to design and supply a conveying system incorporating both twin and single trolley cars that transports cages of flat steel sheets weighing up to four tonnes to and from a hydraulic press producing body panels.

AGVs hold the key

MGV/AGV, HSM
HSM’s MGV can easily be transformed into an AGV

Among recent automatic guided vehicle (AGV) innovations from Handling Specialty Manufacturing (HSM) is the MGV/AGV, a manually guided vehicle that can be quickly and easily automated as growth or throughput dictates. 
 
Rather than high-volume plants, the MGV/AGV is aimed at facilities where output is more modest, such as plants for luxury, sports, electric and recreational vehicles.
 
“Our goal in developing this piece of equipment is to provide small to medium sized vehicle plants with the means to easily move from their current manual assembly line process to a manually guided, then fully automated line without having to make significant infrastructure change and investment,” says Thomas Beach, president at Handling Specialty.
 
The MGV is a heavy-duty, self-propelled cart with a hydraulically powered scissor lift mounted in the centre of the frame. It can be fully customised with regard to lifting capacity and deck size. Furthermore, the MGV allows companies to establish an assembly line with minimal installation costs, as the cart does not require overhead or underfloor power, towline systems, conveyor belts or lines.
 
“The modular design of the MGV means it can be retrofitted with a control package that allows end users to evolve into AGVs as they continue down the path of lean manufacturing,” says Beach. “Our simple migration path from MGV to AGV eases the financial risk for end users.”
Greater demand & throughput 
The automotive plant assisted by Conveyor Systems was looking to replace an existing AGV system with a more advanced transportation system to meet the increased demands and throughputs which coincided with the launch of a new vehicle being built alongside existing models. The trolley cars were designed to accommodate a range of heavy-duty cages, either one large or two small, in six sizes ranging from one metre up to 1.9m wide.

The cages holding the flat steel sheets are taken from the destacker and positioned on a heavy-duty roller conveyor integrated into the twin cage trolley cars. These then feed to either side of the press with an interconnecting single cage car oscillating between them, thus forming a layout in the shape of the letter ‘h’. Pressed body parts are then returned to the stacker and the process continues.
 
The cycle time from loading cages to offloading and return is only 4.5 minutes, which is well within the original time allotted. However, aside from speed, the customer specified that the system had to be flexible and reliable, allowing clear access to the press for maintenance purposes and also offering the capability to bypass the conveyors should the system for any reason break down.
 
As the press requires cages to be fed from two sides, due to the need for left- and right-hand components, the twin cage cars have to be capable of stopping in five different positions. This necessitates ramping up the speed for accurate interfacing of the different sizes, a function that uses lasers for positional accuracy and operator safety. Control panels are integrated into the individual cars, which also include a purpose-built, heavy-duty pallet roller conveyor with 89mm diameter rollers fitted with twin sprockets, pitched at 158mm. The chain drive, which is facilitated by geared motors, is direct driven for easy adjustment and maintenance.

Stacking up the benefits
One step earlier in the process, destacker technology is also moving forward apace. Here, AP&T says it has produced a new destacker that meets automotive industry demand for increasingly rapid production. The unit can work twice as quickly as a conventional destacker, according to its maker, and is intended for large vehicle blanks such as doors, roof panels and sides.

Adapted for careful management of materials that include aluminium, the DST-DH destacker is based on AP&T's standard modules and is equipped with double Gantry 200 feeders. Moreover, the centring tables have brushes to ensure scratch-free handling, while picking is performed with the assistance of a vacuum. Capacity is up to 20/40 blanks per minute (single/double blanks measuring up to 3,500 x 2,000mm).
 

Lightweight end effector, De-Sta-Co
Production line speed can be improved by swapping traditional steel end effectors for lightweight, aluminium versions

Remaining in the same area of the plant, Rob Pitera, De-Sta-Co’s global product director for end effectors, says the biggest trend right now for stamping press operators is retooling production lines to gain speed. This makes it possible to move more parts through the line and increase production without having to expand the facility. “Moving parts faster is not as simple as just ramping up the speed of the line’s automated components,” says Pitera. “Carelessly trying to boost speed can stress tooling, thereby accelerating wear and tear on the machines and increasing the risk of downtime.”
 
Pitera adds that to properly increase production line speed, manufacturing engineers should start by switching traditional steel end effectors – the tools that pick and place the material being stamped – with new lightweight tooling. “High-strength aluminium end effectors can be used to increase production line speed by up to 30% without overworking other automation components,” he says. “Lightweight end effectors also allow for the installation of smaller robots that are faster and more efficient than the high-payload machines designed for heavy tooling.”
 
Since each vehicle production line is unique, it is important that the end effector tooling selected for the upgrade is modular or can be customised. This enables manufacturing engineers to tailor the production line for a specific application, instead of trying to modify standard tooling.
 
De-Sta-Co has just added more than 150 parts to its Accelerate Collection of lightweight tooling, which includes: crossbar and tri-axis transfer press components; clamp blocks, T-clamps and parallel clamps; sheet metal gripper mounting brackets; and sensor-mounting components.
“When building new workholding tools, car manufacturers can take advantage of the latest products designed to save energy and space,” concludes Pitera. “For instance, modern vacuum cups, which are used as end effector contact points in the majority of stamping facilities, can now be equipped with state-of-the-art, single line Venturis that offer instantaneous release and cut air use by half.”

Gains from cranes

KBK Aluline manipulator crane
The KBK Aluline manipulator crane assists assembly workers

International studies prove that ergonomic workplace design has an immediate impact on productivity – so says crane manufacturer Demag, which is inviting automotive plants to benefit from the productivity opportunities that its latest KBK Aluline has to offer.
The KBK Aluline is said to be one of the smoothest-running systems on the market, even for loads of up to 2,000kg. Providing fast and simple installation and conversion, Demag says that the system offers low noise levels and is virtually maintenance-free.

The modular system features six different aluminium profile sections in four sizes, and an integrated conductor line for two profile sizes. As a result, unique combinations can be created with steel profile sections for maximum distances between suspensions.

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        • ■ DESTACO ●美國最大自動化、工件夾持元件製造商
        • ■ CAMCO、FERGUSON ●凸輪分割器的發明者 ●全球最大的凸輪分割器製造商
        • ■ Robohand ●美國最領先的高精度夾持器
        • ■ CRL,Central Research Laboratories® ●世界級安全隔離操作系統
        • ■ Accelerate Collection® ●加速輕量化機器手臂工具 EOAT
        • ■ DIRECTCONNECT™ ●模塊化直接安裝系統
        • ■ Toggle Lock Plus™ 双重鎖夾具
      • ■ 美國 VLIER : 彈簧鎖銷 Spring Lock Pin 創始者
    • ■ 歐洲品牌 >
      • ■ ​德國 THYRACONT Vacuum​​ Instruments GmbH : 最精制的真空計
      • ■ 德國 BÄCKER GmbH & Co. KG​​ 最高水平塑料元件
      • ■ 德國 HEINRICH KIPP WERK GmbH & Co. KG 百年專業小型緊固件
      • ■ 德國 Rudolph Tietzsch GmbH - 超高電壓測試儀和電阻測試設備
      • ■ ​ABB防爆馬達 Explosion-proof Motor
      • ■ 瑞典 PRECIMETER 液態金屬檢測流量控制
      • ■ 德國 HVP High Voltage Products GmbH 高壓高頻電源電子元件
      • ■ 德國 ERS electronic GmbH 全自動溫度校準先進測量設備
    • ■ 芯片設計與晶圓代工 IC Design, Turnkey & Foundry >
      • ■ 中科同志科技 Torch - ​中小型真空焊接Vacuum Brazing、SMT設備領頭羊
      • ■ 泰姆瑞 TERMWAY 高精密全自動CCD視覺貼片機
      • ■ 天譽創新科技有限公司-電動六軸自由度平台並聯機器人
      • ■ 外延片、晶圓代工、半導體設備耗材 Epi wafer、Turnkey、Foundry Service
      • ■ ​高壓功率器件 IC 設計 MOSFET/GaN Design、Turnkey
    • ■ 湯森儀器 Tempsens Instruments GmbH >
      • ■ ​AST 紅外線高溫計熱像儀夜視儀 Pyrometer, Imager and Nigh Vision
      • ■ 印度 馬拉松加熱器 Marathon Heater (India) PVT Ltd
    • ■ 專利庫倫力型靜電吸盤 Patent Coulomb-Force E-Chuck
    • ■ 日本 VANTECH 金屬網
  • 產品介紹
    • ■ 半導體電子相關設備 >
      • ■什麼是真空回流焊 What is Vacuum Brazing?
      • ■ 自動化波峰焊電磁圓泵 Wave Soldering Electromagnetic pump
      • ■ ​什麼是人工智能服務機器人 What is (AI) Artificial Intelligence Service Robot?
      • ■ ​SRT北京軟體機器人 ①EOAT柔性氣囊夾爪②機器視覺智能辨識檢測機
      • ■ ​什麼是防爆馬達 What is Explosion-proof motor?
    • ■ 靜電吸盤 E-Chuck (Electrostatic Chuck) >
      • ■ 什麼是靜電吸盤 What is Electrostatic Chuck?
      • ■ 專利庫倫力型靜電吸盤 Patent Coulomb-Force Electrostatic Chuck
      • ■ 無線薄化硅片吸盤 Move-Free ​Thin Wafer Carrier Supporter E-Chuck
      • ■ 陶瓷靜電吸盤 Ceramic E-Chuck
    • ■ Robohand 夾爪 Grippers >
      • ■ ROBOHAND 滑軌滑台、旋轉器 SLIDES, ROTARIES >
        • ■ 最新精密導軌和升降機 Newest Line of Precision Guides and Lifters
        • ■ 滑軌滑台、擒縱器、推卸器 Slides, Escapements, Thrusters
        • ■ 氣動旋轉台 Pneumatic Rotary Actuators
      • ■ 袋爪 DBG Bag Grippers
      • ■ Robohand ●美國最領先的高精度夾持器
      • ■ Robohand 選用軟體
      • ■ 無塵室夾爪、滑軌、旋轉器 Clean Room Grippers, Slides, Rotaries
      • ■ 迷你夾爪 Micro Miniature Grippers
      • ■ 微型滑軌滑台 Miniature Slide
      • ■ 不銹鋼食品夾爪 FUA Food Handling Grippers
      • ■ 電動夾爪 Electric Grippers
      • ■ 氣動夾爪 Pneumatic Grippers
      • ■ 重型夾爪 Heavy Duty Grippers
      • ■ 熱成形溫度傳感器夾爪 Hot Forming Sensor Grippers
    • ■ DESTACO 機器人手臂工具集 EOAT >
      • ■ 快速輕量化機器人手臂工具集 ACCELERATE® LightWeight EOAT
      • ■ 袋爪 DBG Bag Grippers
      • ■ 鈑金夾爪 Sheet Metal Grippers
      • ■ 工具快換電子接頭 Tool Changers
      • ■ 終端效應器 End Effectors
      • ■ 新型加速真空杯 New Accelerate® Vacuum Cups
      • ■ 電子真空杯 Ecocup™
      • ■ 專利文丘里真空管 Patent ARV® Venturi Vacuum Generator
    • ■ DESTACO 夾具夾鉗 Clamps >
      • ■ 最新精密導軌和升降機 Newest Line of Precision Guides and Lifters
      • ■ 航太夾具 Aerospace Clamps
      • ■ 手動快速夾鉗夾具 Manual Clamps
      • ■ 氣動夾具 Pneumatic Clamps
      • ■ 迷你氣動夾具 Mini Pneumatic Power Clamps
      • ■ 重型氣動夾具 Power Clamps
      • ■ 液壓夾具汽缸 Hydraulic Clamps, Air Hydraulic Pump
    • ■ CAMCO 分割器、減速器、過載保護離合器 Indexer, Reducer, Clutch >
      • ■ CAMCO 零件裝卸器 Linear / Rotary Parts Handlers >
        • ■ CAMCO、FERGUSON
        • ■ CAMCO 線性&旋轉零件裝卸器 Linear / Rotary Parts Handlers
      • ■ CAMCO 精密輸送機 Precision Conveyors >
        • ■ CAMCO、FERGUSON
        • ■ CAMCO 精密輸送帶 Precision Conveyors
      • ■ CAMCO GTB 伺服定位旋轉器 SERVO POSITIONING ROTARY TABLES
      • ■ CAMCO、FERGUSON
      • ■ CAMCO 分割器、過載保護離合器 Indexers, Overload Clutch
      • ■ CAMCO 定位器、減速器 Positioners, Reducers
    • ■ CRL 世界級安全隔離操作設備 >
      • ■ 世界級安全隔離操作系統 CRL,Central Research Laboratories®
      • ■ CRL 遠距隔離操作機械手 Telemanipulator
      • ■ CRL 手套箱 快速輸送端口 GloveGox RTP, Rapid Transfer Ports
      • ■ CRL 廢物桶傳輸系統 ​WASTE DRUM TRANSFER SYSTEM (WDTS)
    • ■ ACCUOPT 紅外線熱像儀監控儀,夜視儀 Infrared Imager, Surveillance & Night Vision >
      • ■ ACCUOPT 紅外線熱像儀 Infrared Imager FeverSENS
  • 產品新聞
    • ■ DESTACO 產品市場 : 航空航天 Aerospace >
      • ■ Assembly雜誌 : 你的機器人需要快換工具嗎?
      • ■ PRweb : DESTACO新型GTB定位旋轉台,提供比競爭者型號更小更輕和更卓越的扭矩
    • ■ DESTACO 產品市場 : 汽車 Automotive >
      • ■ ASSEMBLY雜誌 : 分割器加速SUV車門組裝
      • ■ PRweb : DESTACO推出Accelerate®Vision虛擬現實VR數位設計解決方案工具,以提高生產力
      • ■ MA雜誌 : DESTACO終端效應器Effector的設計使用虛擬現實VR增添加速的視覺虛擬
    • ■ DESTACO 產品市場 : 生命科學 Life Sciences >
      • ■ PR Newswire : 新型一次性Beta袋 Single-Use Beta Bags
      • ■ 自動化在生命科學的應用 Automating life sciences applications
      • ■ Today's Medical Developments 封面故事 : 自動化在生命科學的應用
      • ■ IMD : CRL® 新型VERSA®遠距操控機械手
      • ■ PR Newswire : 新的 CRL CleanRTP 快速傳輸端口友善且可客制
    • ■ DESTACO 產品市場 : 消費品 Consumer Goods >
      • ■ PR Newswire : DFS ①燃油加油机②POS系统③​ATG控制台
      • ■ PRweb : DESTACO利用滑軌平台擴展Robohand™ OEM解決方案,用於機器管理和零件傳輸
      • ■ PRweb : DESTACO新型深碟型真空杯顯著提高輪廓面或油性面板的抓握性能
    • ■ DESTACO 產品市場 : 食品加工/包装 Food Processing and Packaging >
      • ■ AMS雜誌 : 傳送自動化的好處,更高的生產力始於高效的物料處理
      • ■ Destaco TCC公差補償夾具大大簡化焊接裝配製程
      • ■ CAMCO GTB 伺服定位減速器 SERVO POSITIONING ROTARY TABLES
    • ■ DESTACO 產品市場 : 核能 Neclear Remote Handling Solutions >
      • ■ PR Newswire : 新型 CRL G-LDR 遙控操作器以更緊湊的安裝方式提供久經考驗的可靠性
      • ■ PR Newswire : DESTACO將在WM專題討論會上展示創新的CRL廢物處理產品
    • ■ THYRACONT 產品新聞 >
      • ■ THYRACONT Smartline™現在也可以與PROFINET工業乙太網通訊協定一起使用!
      • ■ 德國 Thyracont : 智能真空測量儀、真空開關 Vacuum Instruments
  • 特色產品
    • ■ NEW Vendors >
      • ■ ACCUOPT 熱像儀 FeverSENS mini (紅外線,可見光,即時双視頻)
      • ■ FERGUSON
    • ■ 快速輕量化 終端效應器 ACCELERATE® Effectors
    • ■ CAMCO GTB 伺服定位減速器 SERVO POSITIONING
    • ■ Destaco TCC公差補償夾具
    • ■ DESTACO 協作快換接手TC1
    • ■ DESTACO 最新精密導軌和升降機 Precision Guides and Lifters
    • ■ DESTACO CAMCO 高速伺服可編程定位減速器 PGM40
    • ■ DESTACO 分割器 過載保護離合器 CAMCO Index Overload Clutch
    • ■ DESTACO 電控真空吸盤 EcoCup™
  • 產品影片
    • ■ 靜電吸盤 Electrostatic Chuck
    • ■ DESTACO 介紹 >
      • ■ DESTACO 應用實例
    • ■ 機器人手臂工具 EOAT End of Arm Toolings >
      • ■ 真空吸盤 Vacuum Cups
      • ■ 夾具夾鉗 Clamps
      • ■ 夾爪、滑軌、擒縱器、旋轉器 Grippers, Slides, Escapements, Rotaries
      • ■ 工具快換接頭 Tool Changers
      • ■ 終端效應器 End Effectors
      • ■ 袋物夾爪 Bag Grippers
    • ■ 分割器、過載保護離合器 Indexer, Clutch >
      • ■ 精密輸送帶 Precision Conveyors
      • ■ 零件裝卸器 Linear / Rotary Parts Handlers
    • ■ CRL遠距隔離安全操作
    • ■ Robohand
    • ■ ​THYRACONT Vacuum​​ Instruments 真空測量計
    • ■ 德國 Rudolph Tietzsch 高電壓測試儀和電阻測試設備
    • ■ AST 高精度高溫溫度計
    • ■ 湯森儀器 Tempsens Instruments
    • ■ 日本 VANTECH 金屬網過濾器和沖壓件
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