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It can be a challenge to find a single type of end effector to handle the full array of product characteristics – gentle enough to handle crushable items but adept enough to handle odd shapes. The key challenges to operational deployment remain: AGVs transfer tools between the production system and TSC, leaving only the insert changes to the operator.The benefits of these robots include reduced dependence on labor at pick stations, put walls, unit sorter induction stations and the shipping dock, as well as increased accuracy in pick and put processing. Tool Service Cell (TSC) automates the tool reworking process with an ergonomic tool loading station for insert changing for 4 tools, and an automated tool wash, dry and presetting. Customer wanted to enable predictive tool reworking where the operators are not needed all the time just to rework tools. This means there are multiple people tied in tool reworking at all times. Since the customer uses hard metals and the production mix is high, tools wear fast – and demand for tool reworking is constant. Step 3: Automate tool cleaning and presetting when tools wear fast Automated tool life monitoring and deliveries of tools needing a rework.Tools shared between machines just-in-time.
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Reduced tool investment with less sister tools needed.Over 90% machine tool utilization in high mix low volume production environment.In this system everything else except for the tool reworking is automated. With GTS tools are delivered just-in-time to the machine tool, meaning that every single tool needed in a certain NC program do not need to be in the tool magazine when the program starts – it is enough to have them available when they are actually needed.ĪGVs are used for transferring the tools from and back the tool room to a robot that loads the tools further to GTS. Customer took centralized tool automation, Fastems Gantry Tool Storage, into use to share the tools between machines and to speed up the tool loading process. Tool investment would have been extremely high, and manual tool loading started to form a bottleneck in production. The demand for a large variety of tools was increasing with lot of product variants. Step 2: Add Gantry Tool Storage for unmanned high mix production Faster and more timely tool transfers, less machine idle time.Tool IDs allow for monitoring the tool wear and have worn-out tools delivered to the tool room automatically.Timely tool reworking with a real time visibility on what is needed next.Safer work with less repetitive, manual transfers of heavy and sharp tools.MMS also commands the AGV fleet manager to perform the tool transfers timely, based on the tool wear and upcoming needs. To ensure timely tool loading, Manufacturing Management Software (MMS) schedules the tool use for each production order and machine tool – basically informing the operators in advance on which tool to prepare by when. Capacity increased without adding more personnelĪGV delivers tools to tool stations where the operator then loads the tools in the magazine.Ability to produce high mix and low volumes unmanned.Extremely high part precision with robotized setups.Reduced amount of different fixture setups.Improved ergonomics through automatic heavy part robotic handling.Unmanned production capacity increased for full weekends.If needed in the future, customer is able to expand the system even further with more AGVs, a larger storage or more machine tools. ALDs help in reducing manual work from part load and unload operations, and offer an easy access for many AGV types. When the customer wanted to increase unmanned production capacity for high mix of products to the maximum level, Fastems Auto Loading Cells (ALDs) were added for the FMS. Step 2: Adding automated loading robots to allow for longer unmanned production No need to re-arrange machines and devices while increasing the automation level.Well organized and optimized material flow through manufacturing operations.MMS schedules the production and sends required AGV transportation tasks to fleet management software to execute required material transfers between different systems and the storage. Manufacturing Management Software (MMS) is used manage material inventory also in new buffer storage. The storage was placed space efficiently on the corner of the hall and it acts as an inventory and buffer storage for incoming raw materials, semi-finished and finished parts, as well as parts going to surface treatments or dispatching. The existing FMS remains on its original position and AGVs with a new centralized material storage were added.