Optimization & Re-Engineering > Two significant Pillars of ... · Benefits of IO-Link:...

S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation

Optimization:

Expertise to augment the functionality of a system by

maximizing the efficiency of solutions and sincere efforts to

minimize the cost

Re-Engineering:

Existing Applications demanding improved performance in

terms of flexibility, cycle-time, precision, image-

enhancement, etc. through alternative-solutions or

upgradation of technology

1

Optimization & Re-Engineering > Two significant Pillars of Automation

Ashwin Vanikar

Cluster-Head South Asia: Application Engineering

S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 2

Optimization & Re-Engineering through Application Engineering?1/2

Different Approaches towards working-out sol’ns for the Applications:

Based on the rule of Thumb:

Some people have certain ideas or concepts, which have been derived from some previous applied procedures

& are mostly approximated. This approach is not intended to be very accurate or reliable for every situation.

Result of such approach: a) If things work well, we don’t know, why & how

b) If things don’t work well, we still don’t know, why & how

Based on “Gut-feeling”:

Some people have an immediate or basic-feeling without a logical reasoning. There is no methodical-scientific

approach to reach a sol’n. They like to involve a lot of trial & error methods.

The approach is: just do it with your “gut feeling”

Result of such approach: a) same as for “rule of thumb” &

b) time wasted with huge cost involved


Optimization & Re-Engineering through Application Engineering?2/2

Different Approaches towards working-out sol’ns for the Applications:

Based on methodical & scientific approach (the Application-Engineering-approach):

Very few people may consider certain ideas or concepts, which have been derived from some previous

applied procedures or experiences, but always have a fresh approach, using scientific methods &

procedures to arrive at a technically reliable & competent sol’n.

Result of such approach: a) If things work well, we know, why & how

b) If things don’t work well, we still know, why & how > immediate corrective

measures

S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation

Various opportunities for Automation?

4

.... there are many possibilities and many applications

1.

Conveying

2. Rotating 3. Gripping 4. Clamping 5. Stacking 6. Pick & Place

7.Transporting 8. Lifting 9. Inserting 10. Holding 11. Placing 12. Feeding


Convenience in Optimization & Re-Engineering using Engineering Tools

Secured selection & assured

performance

No room for any error:

• support tools guarantee the optimum

selection

• Saves lot of time

• Saves energy

• Saves cost


Optimization 1/3

Case-study-1:

Application: Hand-shake mechanism in CNC for machining of bearing cages

Operation requirement:

• The bearing cages (weight = 3.5 kg.) are to be machined from both the

sides

• Previously, the change of side was done either manually or with a pick &

place arrangement.

Technology challenge & need for optimization:

• In manual operation, monotonous work & fatigue to the operator

• The pick & place-sol’n occupied extra foot-print on the machine

• The cycle time was higher


Optimization 2/3

Case-study-1:

Application: Hand-shake mechanism in CNC for machining of bearing cages

Principles to be understood:

• Necessity of a mechanism, which has inherent features to do the hand-

shake with side change

• An axis, which can do pitching operation by moving apart & coming closer

with synchronization

• Requirement of Electrical actuator for flexibility in stroke-lengths for various

sizes

Suggested sol’n.:

A timer-belt-axis with two opposing slides, servo-motor, pneumatic-rotary

cylinders & 3-jaw-grippers

Advantage: 1) Operator relieved from monotony & fatigue

2) reduction of cycle-time


3/3


Optimization 1/2

Case-study-2:

Application: Pneumatic circuit optimization of a vertical-tooling-head system for

Engine block assembly


• The tooling-head, working in vertical orientation has to be lowered-down

by pneumatic cylinder & before it approaches the engine block, has to be

inched with position-control, so the tool engages with component without

impacting


• The existing circuit was able to lower the cylinder, but not able to inch with

proper position-control & used to dash against the engine-block &

damage the tool & block


Optimization 2/2

Case-study-2:

Application: Pneumatic circuit optimization of a vertical-tooling-head system for

Engine block assembly


This problem needed a solution, which can counter the basic

dead-load of the tooling-head with reverse-pressure principle

Suggested sol’n.:

A counter-balance circuit with Precision-pressure regulator

with a 3/2-valve

Advantage: Operator has full control over the motion of the

tooling-head


Re-Engineering 1/2

Case-study-1:

Application: Seam welding of fuel-tanks for automobiles


Different components, especially sheet-metal or sometime even connecting-

rods to be seam-welded by vertical movement of the wheel-electrodes


• Existing application was done with pneumatic-cylinder

• The biggest challenges were position-control & force-control, due to which

components used to get damaged

• Time was wasted in trying to control three parameters > position, force &

speed

Welding schematic

principle


Re-Engineering 2/2

Case-study-1:

Application: Seam welding of fuel-tanks for automobiles


• This needed a different approach from technology point-of-view

• A complete re-engineered sol’n >> from pneumatics to Electrical cylinder,

driven by a servo-motor

Suggested sol’n.:

Electrical-ball-screw-cylinder with servo-motor

Advantage:

Improved end-product quality via better control over all process

parameters >> position, speed & force with added advantage of

Electrode-wear compensation

Electrical-Cylinder

with Servo-motor


Re-Engineering1/2

Case-study-2:

Application: Re-engineered solution for twin-spindle CNC >> part-loading/unloading


• Bearing components to be loaded & unloaded in a twin-spindle CNC-

machine

• Previous solution with a horizontal-axis & a single axis-vertical-axis & that

too pneumatically-actuated. Thus, a single vertical axis had to cater for two

spindles with loading & unloading


• The vertical-axis, being single & pneumatic, could not fulfill the cycle-time

demand of the appl’n. The total cycle-time was around 52 sec for one

component, including machining.

• Thus, a re-engineered sol’n. was a dire need of this application

Previous-sol’n

Single-Z-axis-Pneumatic


Re-Engineering2/2

Case-study-2:

Application: Re-engineered solution for twin-spindle CNC >> part-loading/unloading


• The first thing, which was needed was to have two vertical Z-axis

• Another necessity was to change the pneumatic-Z-axis to Electrical-Z-axis

Suggested sol’n.

Two Electrical-Boom-axis, individually servo-driven with grippers & to take the

increased load, the horizontal also was converted to twin axis

Advantage:

Drastic reduction of cycle-time from 52 sec to 34 sec with better control over

process parameters

Previous-sol’n

Re-engineered-sol’n

Single-Z-axis-Pneumatic

Twin-Z-axis >

Electrical-Boom axis


Emerging Technologies


• No wastage of compressed air during downtime• Automatic leak detection• Online process monitoring, remote maintenance and parameters regulation via PROFIBUS

Energy efficiency module

Goal: Reduction of Carbon-footprint

Reducing energy and regulating central operating parameters

Fieldbus nodes with

fieldbus interface for online

data transmission

2/2-way shut-off valve

permits auto-stop function

Flow sensor and pressure

sensor for process

monitoring


All set for automation with IO-Link >>> Point-to-Point

Benefits of IO-Link:

Parameterisation made simple

• Software-supported parameterisation of intelligent sensors

and actuators via the IO-Link master

• Automatic parameterisation in case of device replacement

Safe investment thanks to standardisation

• International, open and fieldbus-independent IO-Link standard

Less downtime, higher productivity

• Exchange of diagnostic and operational data between device

and master systems, accelerates troubleshooting

Simpler to install

• Uncomplicated wiring of the sensor-actuator combinations

with standardised, unscreened lines reduces material costs,

simplifies logistics, and saves time

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