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Flexible Manufacturing Systems

Flexible Manufacturing System (FMS) is a system in which Method of producing goods is readily adaptable to the changes in the product being manufactured. A flexible manufacturing system (FMS) gives manufacturing firms an advantage in a quickly changing manufacturing environment.

Hytech Flexible Manufacturing System (FMS) is a prototype of FMS which are currently being used in the industry. It consists of following equipment:

  • CNC Lathe with Servo Motors
  • CNC Mill with Servo Motors
  • Gantry for Loading and Unloading from CNC Lathe Machine
  • Three Axes Robotic Arm for Loading and Unloading in CNC Mill Machine
  • Pallet Conveyor / Automated Guided Vehicle
  • Automatic Storage and Retrieval System

SCADA Based Central Control Unit:

Complete Flexible Manufacturing System is controlled through a Central Control Unit which is based on SCADA. Touchscreen is provided where user can decide the machining operation to be performed on respective machine along with a quantity.

Alarms as well as safety features are also displayed on the screen to avoid any accidents

CNC Lathe Machine (Model: HPL 100):

CNC Lathe machine is a PLC Based machine with Servo Feed motors. It is equipped with slant bed and linear motion guideways. Hydraulic chuck is used for automatic clamping of workpiece

Key Features of CNC Lathe:

  • Slant Bed with Linear Motion Guideways
  • Hydraulic Chuck with Hydraulic Powerpack
  • 8 Station automatic Turret
  • Servo Motors with Position Feedback for maximum accuracy

Detailed Specifications of CNC Lathe:

Parameter Specifications
Controller Siemens Industrial Controller
Centre Height 150 mm minimum
Chuck Size 150 mm
Chuck Type Hydraulic with Hydraulic Powerpack
Swing Over Cross Slide 80 mm
Distance Between Centre 300 mm
Spindle Taper MT3
Traverse X Axis 80mm
Traverse Z Axis 270mm
Tool Changer Automatic tool changer
No. of Tools 8
Maximum Turning Diameter 62 mm
Spindle Motor Power 3 HP AC Motor
Resolution 0.001 mm
Rapid Traverse 5,000 mm/min
Positioning 10 micron
Repeatability 20 micron
Tailstock Manual Tailstock
Lubrication system for Main Spindle, Guideways and other areas Automatic Lubrication system to be operated through controller
Safety devices Fully enclosed workspace
Electrically operated automatic opening door
Door close sensor
Central emergency switch
COMPLETE TRAINING MODULE 1) 3D Model & 2D facility
2) CAM program from Industry
CAD Software  Linking facility CAD Model  linking facilty from Autocad, Unigraphics, Creo, Catia  and automatic NC  code generation facility
Machine Link RS-485 and  USB cable from PC to machine
Coolant Flood coolant system of capacity of 40 liters
 Guard Totally enclosed high visibility guard
SAFETY  SYSTEM Emergency stop button
Axes limit switches  and Software Limit switch
Programming facilities MDI Programming facilities
Interpolation Full circular and linear interpolation
Programming units Inch/ metric programming
Subprogram Subprogram with repeat facility / program call, Canned Cycles, Parametric Programming
Machine Stop Manual and programmable machine stops
Mode of Operations FMS Mode, Individual Mode
Communication with other machines and Central Control Wireless Communication / ProfinetCommunication

CNC Mill Machine (Model: SPM 250 Servo):

CNC Mill machine is a PLC Based machine with Servo Feed motors. It is equipped with Pneumatic Vice for automatic clamping and declamping of work pieces. 8 Station automatic tool changer is provided with pneumatic actuation

Key Features of CNC Mill:

  • Linear Motion Guideways
  • Servo Motors with Position Feedback for maximum accuracy
  • 8 Station Automatic Tool Changer
  • Pneumatic Vice for auto clamp and declamp

Detailed Specifications of CNC Mill

Parameter Specifications
Controller Siemens Industrial Controller
Travel X, axis 300 mm
Travel  Y axis 200 mm
Travel  Z axis 250 mm
Travel A Axis (4th Mill Axis) 360 Degrees
Table Size, (Length x Width) 600 x 225 mm minimum
Axis Control Simultaneous Three axis control
Job  Load on Table 60  Kg. min.
Tool changer Automatic Tool Changer through Software  as per Industrial Controller
Tool Holder As per ISO 30 standard
Automatic Tool Changer Automatic  8 Station Tool Changer
ATC Actuation Pneumatic
Main Spindle  motor – Power 3 Horse Power (AC) with VFD
Spindle Motor Type AC Motor
Spindle Speed Variation Through Controller with Feedback
Spindle Speed Range 300 RPM to 3,000 RPM
Resolution X axis 1 micron
Resolution Y axis 1 micron
Resolution Z axis 1 micron
X/Y/Z Cutting Feed Rate 2,000 mm/min
X/Y/Z Rapid Feed Rate 5,000 mm/min
Cutting force  X / Y / Z 900 / 900/ 1200 N
Position Accuracy X / Y / Z *  10 micron maximum
A axis 0.05 Degree
Lubrication system for Main Spindle, Guideways and other areas Automatic Lubrication operated through Software
Safety devices Fully enclosed working area. Limit switches for X and Z axes,  Emergency Off, Door Closure switch
COMPLETE TRAINING MODULE Complete CAD-CAM Solution & DNC Facility namely;
1) 3D Model & 2D facility
2) CAM program from Industry  should be  machined  on Trainer
Vice Pneumatic Vice with Pneumatic Compressor (1HP) should be provided
Pneumatic Vice which can hold Flat plate as well as Round job up to 25mm Dia
Main Supply Three Phase, 415 V
X/Y/Z Axes Motors AC Servo Motors
X/Y/Z Axes Drives AC Servo Drives with Position Loop , Velocity loop  and Torque Loop  make
Machine Link RS-485 and  USB cable from PC to machine
Coolant Flood coolant system of capacity of 40 liters
 Guard Totally enclosed high visibility guard
SAFETY  SYSTEM Emergency stop button
Axes limit switches  and Software Limit switch
Programming facilities MDI Programming facilities
Interpolation Full circular, linear interpolation, Parabolic and Elliptical Programming
Programming units Inch / metric programming
Subprogram Subprogram with repeat facility / program call, Canned Cycles, Parametric Programming
Machine Stop Manual and programmable machine stops
Mode of Operations FMS Mode, Individual Mode
Communication with other machines and Central Control Wireless Communication / ProfinetCommunication

Gantry for Loading and Unloading from CNC Lathe Machine

Gantry with Linear motion guideways is provided for loading and unloading from CNC Lathe Machine. It can pick up a round job from Pallet conveyor or AGC and load it into the CNC Lathe Machine.

Pneumatic Gripper is provided which can be modified to pick up a job of up to 35mm.

Brake motor is provided for Z Axis.

Key Features of Gantry:

  • Brake motor for Z Axis
  • Linear Motion Guideways for horizontal as well as vertical axes
  • Pneumatic Gripper with a payload capacity of 2.5 Kg
  • Position Accuracy of up to 0.020mm

Detailed Specifications of Gantry

Parameter Specifications
Horizontal Travel 3,000 mm
Vertical Travel 1,200 mm
Feed Motors Stepper Motors
Position Accuracy 0.020 mm
Gripper Actuation Pneumatic
Gripper Payload Capacity 2.5 Kg
JOG Facility Provided
Programming Standard G and M Codes
Rapid Rate 2,000 mm/min

Robotic Arm for Loading and Unloading from CNC Mill Machine

Robotic Arm is provided for loading and unloading from Mill machine. It is a Three / Four axes robotic arm with stepper motors used as feed motors. Linear motion guideways are provided on each linear axis.

Key Features of Robotic Arm

  • Brake motor for Z Axis
  • Linear Motion Guideways for all linear axes
  • Pneumatic Gripper with a payload capacity of 2.5 Kg
  • Position Accuracy of up to 0.020mm
  • Can be operated individually without complete FMS operation

Detailed Specifications of Robotic Arm

Parameter Specifications
X Axis Travel 1,500 mm
Y Axis Travel 1,000 mm
Z Axis Travel 1,000 mm
C Axis (Optional) 270 Degree
Feed Motors Stepper Motors
Position Accuracy 0.020 mm
Gripper Actuation Pneumatic
Gripper Payload Capacity 2.5 Kg
JOG Facility Provided
Programming Standard G and M Codes
Rapid Rate 2,000 mm/min

Automatic Storage and Retrieval System

Automatic storage and Retrieval system is a storage unit with a robotic arm. It is actuated pneumatically. Workpiece along with a fixture is loaded on pallet conveyor which is then transported to individual machining centers with the help of either conveyor or an Automated Guided Vehicle

Key Features of Automatic Storage and Retrieval System

  • Brake motor for Z Axis
  • Operation through standard G codes and M Codes
  • Position accuracy of 0.020 mm
  • Three axes are provided with a feed rate of 2,000 mm/min
  • Homing facility is provide for all axes

Detailed Specifications of Automatic Storage and Retrieval System

Parameter Specifications
X Axis Travel 1,500 mm
Y Axis Travel 600 mm
Z Axis Travel 1,000 mm
Feed Motors Stepper Motors
Position Accuracy 0.020 mm
Gripper Actuation Pneumatic
Gripper Payload Capacity 2.5 Kg
JOG Facility Provided
Programming Standard G and M Codes
Rapid Rate 2,000 mm/min

Conveyor

Conveyor is used to transport raw materials from ASRS to machining centers. Conveyor is constructed in a C shape with ASRS in the middle and Machining centers (CNC Lathe and CNC Mill) on either sides. User can manually control the speed of the conveyor either through Central controller or manually through VFD. Raw workpieces are transferred through a fixture which can hold a round bar of up to 35mm diameter or a flat square plate of 130mm.

Key Features of Conveyor

  • Flex Belt with link mechanism which can take a turn in 180 degrees
  • Speed of the conveyor can be controlled through controller as well as through Variable Frequency Drive
  • Can be operated through standard G codes and M codes through central controller
  • Can be operated individually without complete FMS operation

Detailed Specifications of Conveyor

Parameter Specifications
Conveyor Travel 5 meter (C Shape)
Motor Type AC Motor
Motor Capacity 1 HP
Speed Control of Conveyor Through VFD
Programming Standard G and M Codes
Payload Capacity 20 Kg

Automated Guided Vehicle (AGV)

‘Hytech’ has developed an AGV which originally works on Program Guided principal but at the same time color guiding principal is used to maintain the accuracy below 10mm.

Step Servo Motors are used in Hytech AGV for each driving wheel. Feedback of these motors is taken to achieve highest position accuracy. AGV programming is done in the same way it is done for any two dimensional CNC machine. Coordinates of each point of the track can be easily found out with the help of autocad drawing (Explained in detail in section 5.0).

Red Colored strips are provided in track for each point. These color strips act as an additional measure to maintain position accuracy of AGV.  Two photo sensors are provided for each wheel of AGV. These sensors are preprogrammed in such a way that they sense only red colored strips.  Motion of each wheel will stop as soon as its corresponding color sensor is activated (Senses Red colored strip). That means AGV motion will stop completely as soon as both sensors sense red colored strips.

Key Features of Automated Guided Vehicle

  • Path can be easily changed / modified
  • Various coordinates of the path can be easily generated from autocad drawing
  • Color sensors are provided on both wheels which will work as an additional measure to increase the accuracy and compensate for the missing pulses if there are any.
  • Reference band is provided which will allow the user to reference the AGV in just two seconds
  • Can be moved in JOG
  • HMI display is provided to display actual coordinates
  • Encoder feedback is provided for each motor which increases the position accuracy
  • Number of stops / stations can be added without any extra expenditure

Detailed Specifications of Automated Guided Vehicle

Parameter Specifications
Operating Principal Programming of two driving wheels in simple coordinates.
Battery 75 Amps x Qty. 02
Data Entry Through HMI (Touch Screen) or through Central Controller
Path Programming Directly through HMI
Conveyor Length (Mounted on AGV Top) 400 mm
Maximum AGV Run 60 meters
Maximum Speed 5,000 mm/min
Speed Variation Can be changeable directly through HMI
Mode of Operations FMS Mode, Individual Mode
Communication with other machines and Central Control Wireless Communication