In 2017, Simon Oreskovic set up a Zelos Zerspanung machining workshop with only three employees in Bessenbach, Germany, and also realized the key significance of automation to success. The goal of the 30-year-old management manager is to create an effective high-mix / low-volume working environment with quick-change tools for gripping and robotics. To this end, his first step was to find automation technologies that would ensure that the start-up machining shop could process a wide range of components ( Figure 1 ).

Figure 1

 German Zelos Zerspanung machining workshop adopts a flexible machine tool care robot system, which is characterized by clamping not the actual parts, but the vise of the fixed parts. In this way, only a gripper is needed. When switching to new processing content, there is no need to reprogram.

  Simon Oreskovic believes that some machine processing solutions will threaten the survival of small processing workshops. Therefore, they are reluctant to enter the stage of automated production, because they always believe that this system is bound to be more complex, high cost, the process is only applicable to some products, and must be professionally trained professionals to operate. 'That 's not the case, ' he said. ' In order to improve competitiveness, workshop automation is an inevitable trend. However, we can control the scale of automation and gradually adjust the level of automation according to future needs. '

 This is particularly important in high-paid countries such as Germany. At the start of small-scale automation, Mr. Simon Oreskovic first introduced quick-change tool clamping technology to speed up the setup process. After that, an automatic loader and a tray collection system were added to the original three-axis machine to ensure that the new work can be set up in offline mode. While the new processing content is installed into the tray collection system, the machine can continue to cut other parts to maximize the normal running time of the spindle. Next, the two machines are integrated with the robot system. After integration, the robot grabs not the component itself, but the standard vise of the fixed component above. Near each machine, a trolley is parked. In this way, only one gripper can complete the loading operation of various component types. This automation type ensures that the workshop can focus all its energy on components with a size of no more than one punch ( 80 % of its business ). At the same time, it also improves flexibility and can efficiently handle different batches of components from 10 to 1000 ( Fig.2 ).

In Fig.2, nearly 80 % of the components processed by Zelos are only the size of a fist. Therefore, the workshop needs to consider the influence of this factor when selecting the type of machine automation integration.

The first stage : Quick change tool clamping technology

  Before the establishment of this workshop, Mr.Simon Oreskovic worked for his father 's manufacturing company Automated Sewing Systems AG in Bessenbach, and accumulated rich experience in machining and manufacturing. The Zelos processing workshop he founded is mainly responsible for processing parts for his father 's company, and will also receive orders from some general engineering, machine tools, stage construction and railway industries.

  During his work at Automated Sewing Systems, Mr. Simon Oreskovic gradually became familiar with the quick change tool clamping devices produced by Lang Technik, a company based in Holzmaden, Germany (with its US branch located in Hartland, Wisconsin, named Lang Technovation). Therefore, in order to accelerate the setup process, provide process reliability and repeatability, he did not hesitate to purchase the zero point clamping system produced by Lang Company and the Makro Grip five axis vise( Figure 3) .

 Figure 3

 The first step in the automation of the workshop is the introduction of the zero point clamping system produced by Lang Technik and the Makro Grip five axis vise. The former ensures repeatability of bow and arrow positioning, while the latter only clamps a small part of the component to ensure smooth contact from all five directions of the component. After the component is formed into a bottom groove through a 20 ton stamping machine, the "teeth" of the vice jaws engage with the groove. So, even if only a small part of the component is grasped, this device can provide high clamping force

  The Makro-Grip vise clamps the blanks in an unusual way. First, a 20 t punching machine is used to squeeze from one side along the bottom of the blank, and then multiple grooves are formed on the blank through the ' teeth ' of the punching machine. Then, the blank is installed on the vise that the jaw is matched with the groove contour. It is said that even if the vise clamps only a small part of the blank, a high clamping force can be formed after this form of matching connection. At the same time, during the processing, the machine can also machine from the five directions of the components. After the processing is completed, the groove will be removed by milling.

  This is quite similar to the workpiece clamping technology. The latter is to form a wedge-shaped tenon at the bottom of the blank, and then install the blank on the vise that matches the contour of the wedge-shaped tenon. However, in order to form this wedge-shaped tenon profile, a special machine tool is required. The Makro-Grip is formed by a stamping machine.

The second stage : robot loader and tray collection system

  Lang provides assistance in selecting the type of automation process suitable for Mr.Oreskovic 's processing workshop and the main processing components. Automation is mainly suitable for large-volume production lines, but it also has certain advantages in the processing of low-volume / high-mixed components. Guiseppe Semeraro, sales manager of Lang, said, ' Once you have a better understanding of the needs of the workshop, you can choose a simple, inexpensive and transformable automation solution ( including robots ) to improve production capacity.

  The first set of automatic loading automation system selected by Zelos is the Lang Eco-Compact 20-workpiece tray transportation and handling system, which is installed on the DMG MORI Milltap 700 three-axis grinder. The system is characterized by 20 pallet stations, each of which can bear 40 kg. The tray collection system ensures that the workshop does not affect the machine movement when setting and queuing operations are carried out. Each tray has a zero clamping function, which can complete the repeated positioning operation.

The third stage : automatic loading of vise clamping parts

        The second automatic machine loading system selected by Zelos is Lang Robotrex. In fact, the workshop purchased a total of two, one for DMG MORI Ecomill 1100 three-axis machine tools, and the other for Ecomill 50 five-axis machine tools.   

        Robotrex is installed in a shell in front of the machine. Its main feature is a FANUC robot with a load-bearing capacity of 12 kg. Each part will be clamped by a Makro-Grip vise, which will then be fitted in rows by the operator to the top of a cart and transported to Robotrex by cart ( the system can receive up to 4 carts ). The vise moves in the vertical direction to form a compact structure, and a small trolley can install multiple vises. Each trolley can be loaded with 30 vise with the maximum size of 120 mm × 120 mm × 100 mm or 42 vise with the maximum size of 120 mm × 100 mm × 70 mm. The vise is installed in the zero clamping system of the machine tool ( Fig.4 ).

Fig.4

According to the size of the parts, the automatic car can stack up to 42 vise. The Robotrex system produced by Lang is equipped with four small trailers, that is, the maximum storage capacity can reach 168 vise.

        During the operation, the robot does not pick up parts of different sizes or shapes, but the conventional vise on the trolley. Therefore, only one gripper is needed, which also avoids the teaching process before the new gripper carries out the new homework. The advantage of this system is that it is superior to the robots and grippers produced by other companies. Simon Oreskovic said, ' The system that grabs parts through a robot and sends them to the machine may be a more effective solution for series production, but for a processing workshop like ours, it only needs to replace the parts without reprogramming the simplest automation system.

        In addition, automated operations allow the machine operator to concentrate on the next order, complete the vise setup according to the new job content and use the press to process the new workpiece blank. DMG MORI 's Messenger machine monitoring system can send out an alarm in time when problems are found, and in the process, the cutting tool is detected by the probe on the machine. Mr. Simon Oreskovic said that the function improves the accuracy of machining and reduces the amount of material scrap and rework time.

        Mr. Simon Oreskovic believes that the investment in workshop automation is very worthwhile, and the normal operation time of the spindle can reach 20 hours per day. We can also flexibly plan time-critical incoming orders. The machine can run continuously in the evenings and weekends, and there is no need for personnel on duty at all, leaving more time for us to reunite with our families. Although our team is still small, but the advantages of automation system is still obvious. ' He said with a smile on his face.

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