Transforming Your AWEA VMC into a High Productivity, Unmanned, Lights-Out Manufacturing Powerhouse

AWEA and TDT bring you the 15 pallet Auto Changer for Vertical Machining Centres 

The manufacturing industry is continually evolving towards greater productivity, precision, and efficiency, with automation playing an increasingly pivotal role. While collaborative robots (Cobots) have generated considerable excitement, they’re often limited to high-volume, repetitive tasks. For vertical machining centres (VMCs), particularly where production involves numerous different part numbers or smaller batch sizes, Cobots aren’t always practical. Instead, a comprehensive automation system can provide unmatched flexibility, efficiency, and reliability for truly lights-out operation.

Why Automation is Critical for Modern Machining:

The increasing demand for precision, speed, and efficiency in manufacturing highlights automation as not just an advantage but a necessity. A robust automation solution transforms your existing VMC into a fully autonomous machining system, enabling significant enhancements to productivity and profitability.

Key Advantages of VMC Automation:

1. Resolve Labour Shortages: Automation effectively mitigates the impact of workforce scarcity by replacing manual intervention with automated processes. It ensures consistent productivity even during challenging hiring conditions.
2. Enhanced Production Efficiency and Reliability: Unmanned operations mean continuous production without breaks, significantly increasing productivity and reducing downtime. This can result in substantial cost savings and improved delivery timelines.
3. Eliminate Hazardous and Tedious Tasks: Automation systems handle dangerous or monotonous tasks, enhancing workplace safety, reducing employee fatigue, and contributing to overall morale and productivity.
4. Lights-Out Manufacturing: Achieve around-the-clock operation without the need for constant human oversight, maximizing your machinery’s utilization, output, and profitability.
5. High Flexibility: Systems designed for versatility accommodate both mass production and small-batch production efficiently, ensuring maximum adaptability to various job requirements. This flexibility allows companies to quickly respond to changing market demands without major equipment changes.

 

Multi-Pallet Coordinator (MPC):

• Integrates a quick-change pallet system and a robust drawbar mechanism to streamline transitions between jobs.
• Provides storage modularity with customizable levels and trays, ensuring adaptability to specific production demands.
• Lightweight fork-type carriers securely handle pallets, optimizing loading and unloading speeds (X-axis at 35m/min, Z-axis at 20m/min, and C-axis rotation at 120°/s).
• Supports a maximum workpiece size of 500 x 500 x 350 mm, weighing up to 200 kg—ideal for aerospace alloys and various high-precision industries.

 

Essential Components for Effective VMC Automation:

Zero-Point Clamping System:

• Employs the SCHUNK zero-point system, renowned for rapid and precise gripping and positioning of workpieces.
• Pneumatically driven, it’s cost-effective and environmentally friendly.
• Offers exceptional repeatability (accuracy of 5 µm) and impressive clamping force (800kg per clamp).

 

 

Intelligent Management:

• Optional RFID-equipped trays track and manage each workpiece’s processing status, enhancing traceability and production control.
• Integrates seamlessly with the overall workflow system, enabling real-time monitoring and reporting to the control centre.
• (An image or schematic demonstrating RFID tracking and intelligent management integration could be valuable.)

 

Advanced Tool Management:

• Features a spacious 120-tool magazine to accommodate complex machining tasks without frequent manual tool changes, further supporting lights-out capability.
• (Include an image of the extensive tool magazine for visual emphasis.)

User-Friendly Interface & Enhanced Control:

• Equipped with a 15” Delta touchscreen interface, providing straightforward and intuitive control.
• Monitoring pages clearly indicate machine status with color-coded signals, simplifying operational oversight and management.
• Offers secure door lock switches for safe workpiece loading and unloading, enhancing operator safety during manual interventions.
• Includes manual control options via jog mode or absolute (ABS) positioning, along with configurable permission management for precise control of machine operations.

 

 

Compact and Comprehensive Automation Solution:

The AF-800II MPC system’s footprint, at just 6,663 x 4,578 x 2,843 mm, efficiently integrates into existing manufacturing spaces, bringing substantial operational benefits without extensive facility modifications. Its compact design ensures minimal disruption and quick integration into your current production line.

 

 

Modularity Across the Awea Range:

This advanced modular automation system isn’t exclusive to just AWEA VMCs; it is also fully compatible with Awea’s AU and FCV ranges of advanced 5-axis machining centres. This enables manufacturers to leverage automation technology seamlessly across multiple machine platforms, optimizing productivity and flexibility in diverse manufacturing environments.

 

Summary:

Investing in a robust, versatile automation system transforms your vertical machining centre into a highly productive, flexible, and autonomous manufacturing solution.

It bridges the gap where Cobots fall short, especially in scenarios involving diverse, lower-volume part production, offering significant competitive advantages through lights-out manufacturing capabilities. Leveraging automation ensures sustained growth, enhanced operational efficiency, and future-proofing of your manufacturing processes.