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库卡机器人(上海)有限公司


1 项目介绍


Possehl电子公司为汽车行业开发并生产高度复杂的电子-机械零部件,对准确度的要求非常高,其加工工艺包括冲压、表面电镀和注塑成型以及相关的自动化解决方案。从2013年起,Possehl公司就使用自动化解决方案在三条生产线上为一些著名的汽车厂商生产不同类型的电动助力转向系统中结构复杂的控制箱。在该集团首要的生产工厂尼分工厂里,有25台KUKA机器人使用特殊设计的抓手以0.1mm水平的精度将冲压件插入到注塑成型机中,且该生产循环时间特别短。

fpt集团自从1982年组建以来始终坚持“将未来理念融入技术当中”的核心理念。其核心业务之一是规模化生产中注塑成型领域和金属切削领域的自动化解决方案。为满足Possehl电子公司的高精度要求,其选择将KUKA机器人整合到fpt开发的使用者界面。

fpt集团的总经理Harald Glass谈到:“KUKA作为我们的系统合作商,始终致力于为客户开发以机器人为基础的解决方案。机器人抓手的相关技术完全是在机构内部开发的,由于控制平台上整合了由fpt开发的使用者界面,Glass坚信KUKA不仅仅能为系统使用者提供先进的控制理念,而且还能够根据不同的系统实施量身定制的修改。”他表示,这些标准对于复杂系统的实践极其重要。


2 解决方案


2.1 单个加工循环时间短

Possehl公司的目标是,不仅要能够以可靠稳定的方式加工各式各样的部件,还要协调众多的生产过程,将单个加工的生产循环时间降到最低。要达成这后两项目标,对于可靠性和质量的要求都是非常高的。“对于机器人运动学来说,我们对灵活性的要求意味着只有多关节型的机器人才能纳入我们的考虑范围。”Glass说。此外,要想与注塑成型机的操作和编程界面能够兼容的唯一方法就是将KUKA机器人整合到fpt公司的操作者界面中。“当时,我们的任务是将机器人的操作精度控制在0.1mm之内,这才能达到我们的精确度要求。”Glass回忆说。


2.2 多个机器人之间完美配合

在Possehl的尼分工厂里,一共有25台机器人在3条生产线上以稳定且精确的方式工作。包括KRAGILUS系列的一些小型机器人,一台KR5电弧焊机器人和KUKA的另外几台中等载重量型号的机器人。这三条生产线的工作内容是相似的。“托盘叠摞在导线架上,通过传送带被运送到机器人单元当中。”该公司主管冲压、注塑成型和自动化技术的工业工程负责人Robert Tesch对我们介绍说。

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一台KUKA KR5型电弧焊机器人将最顶端的托盘拿掉并将其放入特制的框架中。该机器人会将空托盘收起并放置在向外传送的传送带上。之后,一台KUKA KR6 R900型机器人会将导线架放置到旋转工作台上的冲压模具中,该工作台有四个冲压工具,用该工具将导线架上的小车连接销解开。四台属于KRAGILUS系列的KUKA KR6 R900型机器人开始工作,每一台移除五个小车连接器,三个传感器销,并从冲压工具上移除2个电池连接销并将它们放在两个移动滑块上,这就是准备过程与注塑成型过程的分界点。一台属于KUKA中等负载型号的机器人承担装载注塑成型机的任务。“这台机器人和KR6 R900型的机器人是这套系统的核心。”Tesch解释说。

这些机器人工作的同步性非常优越,也极其精确,这样才能保证52个冲压件都能在最短的生产循环时间内被放置到注塑成型机中,而且达到0.1 mm水平的动作精度。一台KUKA中等负载型号的机器人使用其特殊设计的抓手将准备好的原材料从移动滑块上抓出,一次抓取四个,并将其放置到模具中,在模具中将其加工成所需的具有技术含量的塑料部件。这时,该机器人将已完成的铸件拿下放到传送站内,这里有一个小型的KUKA机器人将这些铸件集中起来放置到一个圆型工作台上的托盘中,以便进行分拣工序前的最终检验。

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3 效益分析

“这套解决方案非常显著地增加了产能。”Tesch兴奋地说。在Possehl电子公司位于尼分的工厂里,大家正使用这些系统和生产理念指导工作,努力将高标准要求和可靠的自动化理念落实到系列生产实践中,由此降低系统成本并缩短生产时间,只有如此才能够为顾客开发出有竞争力的生产理念,并使得德国工厂成为在全球范围内具备盈利能力的生产现场。“因为我们已经有了成功的经验,我们将要引入KUKA的六轴机器人,并充分利用现有的机器人的能力为下一代生产线服务。” Tesch解释说。

摘自《自动化博览》2017年8月刊


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< id='layer5F87F64435FAEE683CF1E5C90F6ADEF1' type='media' inbuttom='1' class='cstlayer' style='left: 973px; top: 27px; position: absolute; z-index: 104; width: 111px; height: 111px;' mid="" deg='0'> < class="wp-media_content" style="overflow: hidden; width: 111px; height: 111px; border-width: 0px; border-style: solid; padding: 0px;" type="0"> < class="img_over" style='overflow: hidden; border-color: transparent; border-width: 0px; width: 111px; height: 111px; position: relative;'> < class="imgloading" style="z-index:100;"> < id='layerCEEB74EABD58D67063A9254DE26BAA88' type='title' inbuttom='1' class='cstlayer' style='left: 0px; top: 109px; width: 412px; height: 21px; position: absolute; z-index: 110;' mid="" deg='0'>< class="wp-title_content" style="padding: 0px; border: 0px solid transparent; width: 412px; height: 21px; display: block;word-wrap:break-word;">Copyright 2016 (上海)机械设备有限公司 版权所有
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