Two machine tools linked with a high degree of autonomy
Concatenated magnesium machining reliably automated
Magnesium is the lightweight metal with the lowest density: about one quarter of the density of steel and 35% less than aluminium. Anyone caring to consult the technical literature will learn that low cutting forces are required for machining, resulting in reduced tool wear. In the context of automation of a machining process, this means rigid requirements in terms of the reliability and technical availability of automation and workpiece autonomy.
Put in a nutshell: the system must operate smoothly and reliably for long periods, and offer a sizeable workpiece buffer for raw and finished parts that can be replenished and emptied at any time, while providing adequate capacity to operate at night or over a weekend without operator intervention.
In the specific case, the machining of the two faces of the workpiece takes place consecutively on two machines, fourfold on the first machining centre and singly on the second machine. In the course of machining, the area should be accessible for manual setup processes. The additional marking of workpieces with a data matrix code after machining should be integrated into the automation process.
Schwab CNC Metallbearbeitung has been producing high-quality milled and turned parts for a variety of industries since 2010. In line with the company philosophy “Professional support over the entire product life-cycle – from prototype development and series production to the spare part”, single prototypes and larger series are produced by aluminium and magnesium pressure die casting.
The performance spectrum of the company, whose head office is at Rot am See (District of Schwäbisch Hall) in the Franconian north-east of Baden-Württemberg, also includes in-depth technical consultation of the customer prior to and during a project. The family-owned enterprise with 14 employees is managed by father Reiner and son Markus Schwab.
The automation was developed and implemented as a turnkey system by EGS Automatisierungstechnik GmbH from Donaueschingen in the Schwarzwald-Baar district. The company has been actively involved in the field of industrial automation since 1996, and has employed industrial robots for the purpose since 1999. Its customers benefit from the company’s expertise: over 1,750 robots had been installed by the time the described system was started up in 2019.
The ‘actuator housing’ workpiece is a magnesium housing component for the steering gear of motor vehicles that Schwab has been producing for some time. The main impetus for automating the machining of parts resulted from a substantial increase in demand, requiring an annual production of up to 250,000 parts. Because it also has to contend with a shortage of skilled workers, this move enabled the company to release many employees who were hitherto manually involved in the process for other activities where they were urgently needed.