Automated production of precision tools

35 product families, each with different parameters, initially made the task difficult for the KR Agilus. "The exact accuracy of the gripping technology is crucial for this work. Programming this presented us with internal challenges," admits Rommel. There were also external constraints such as a lack of space and short cycle times. Horn decided to bring Kuka's expertise in the field of application engineering on board in order to bring the project to a successful conclusion. After all, the software and its documentation is a crucial component in automation.

One software package and four system types

This is how Kuka became the Tübingen-based company's programming partner. Sven Göckes, a robot programmer at Kuka for many years, was introduced to the ideas and then planned and defined a standardized programming and software structure. "The aim was to program the solution so generically that we could expand the product variety at any time. That wasn't easy and it also awakened my ambition," says Göckes. Two years, many joint discussions and more than 4,000 hours of programming later, the systems for the various product families were fully developed and put into operation. A key success factor was the Kuka.AppTech software package, which fits perfectly with Paul Horn's production concept thanks to its modular structure. The individual modules of Kuka.AppTech can be ideally adapted to the various product groups, enabling the reproducibility of repetitive programming sequences with little effort.

Automatically position the indexable inserts

The solution was created thanks to the interaction of the lean, precise KR Agilus and various Kuka software packages. © Kuka

The KR Agilus hangs upside down from the cell ceiling in Horn's systems, from where it can carry out all movements. An employee can load the cell with a pallet from the outside and enter the relevant parameters for the workpieces on it at the control panel. The KR Agilus then aligns the indexable inserts on the workpiece carrier and grips it. The robot arm guides the workpiece to a camera station, which determines the cutting position. Using this information, the KR Agilus positions the indexable insert on the carrier, which is brought to the CNC machine for grinding in the next step. The fully ground indexable insert is returned to the robot, which places it back in its original position on the pallet. No time is lost in the process: While one workpiece is being ground, the robot is already mounting the next one on a new carrier.

"We are primarily concerned with a long-term perspective. With the new systems, we expect to be more flexible in the future and to be able to implement new product families ourselves. By working together with Kuka, we have created the basis," says Managing Director Rommel.

Jonas Micheler, Global Content Marketing Manager Division Robotics, Kuka

Kuka, www.kuka.com/amb-2024

Carbide tool factory Paul Horn, http://www.horn-group.com