Mobility in 24 servo axes

Profile

• What was needed:E2 energy chains, E4 energy chain, e-tubes
• Requirements: Robust and compact energy chains were required to supply the tensioning beams. A reliable guidance solution for a high cable weight over a length of 18m had to be found for the entire linear robot. And to supply the milling head should use a flexible cable guidance for 3D movements.
• Industry: Machine tools
• Success for the customer: Compact E2 energy chains, a particularly robust and reliable E4 energy chain, and an e-tube on the milling head provide a safe and reliable solution for the high-performance CNC system. From the user's point of view, the machine represents a real milestone.

The new CNC machining system for aluminium profiles up to 18 metres long is highly automated and at the same time extremely flexible.

Problem

The medium-sized manufacturer auratronic is considered a specialist for sophisticated CNC machining systems. The systems for precise machining of plastic, wood or aluminium are individually projected for each customer and each task. This was also the case with the construction of a CNC mechanism for a manufacturer of aluminium balconies. The basic task for this project was clearly outlined: thick-walled aluminium profiles with a length of up to 18m are to be clamped and flexibly machined by a linear robot. To minimise setups, 16 profiles can be clamped simultaneously and controlled in one setup. One of the design challenges was to equip the linear robot as well as the 16 CNC-controlled clamping beams with a moving energy supply system.
The special features of the machine include high travel speeds (up to 60m/min and 24m/min for the clamping bars in the feed) and the 24 powerful servo axes. Safety laser scanners monitor the environment of the CNC system. To ensure optimum machining processes, the system is integrated into the end customer's CAD/CAM system. With the corresponding software package, the designers can simulate the respective processes in advance. The software also determines the position of the clamping bars and, under certain circumstances, causes the bar to be "re-gripped" in the process: after all, it must be possible to machine the profile at all points.

Solution

auratronic regularly cooperates with us in the project planning of new machines. And the specialist also relied on our product portfolio in the area of energy supply systems for the newly designed AT 520 SBZ CNC machine. In the machine tool, 24 completely assembled energy supply systems from our company are used.
First, the 16 tensioning beams had to be supplied with energy and signals over a length of 12,500mm. The E2 energy chains used here are robust and particularly compact, so that the linear robot could be kept as narrow as possible.
A safe feed for energy, data, hydraulic and pneumatic cables also had to be found for the entire linear robot. Today, an 18m long chain from the E4 series safely guides the heavy cable weight and ensures the fail-safe process even in continuous operation.
Finally, a particularly flexible energy supply had to be found for the three-dimensional milling head. An e-tube not only fulfils this requirement, but also guides the cables in a particularly compact manner and allows the tight bend radii required in the application.
The commissioning of the plant, designated AT 520 SBZ, was immediately followed by trial operation. Then the machine - which has an impressive weight of 29 tons due to the high demands on the precision of the machining - was disassembled and reassembled at the customer's site. At auratronic, this plant is considered a pilot project. From the user's point of view, the CNC machining system is a real milestone and at the same time a good example of the implementation of Industry 4.0 in a medium-sized metalworking company.

The 16 clamping beams are each supplied with energy and signals via an igus energy chain with a travel of 12.5 metres.

The energy and media supply of the machining linear robot (with cutters, drills, saw and tool magazine) is provided by an energy chain from the E4 product range.