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 |