Precision in the µm range is required in the production of punched sheets. The thin sheets have a residual height of just 0.12 mm and are very sensitive. Even the smallest handling errors lead to damage. Wink Stanzwerkzeuge has automated its processes to minimize the error rate, increase availability and reduce the workload of its employees - and has once again relied on the proven successful team consisting of the linear technology specialist Rollon and the system integrator INperfektion, which was already responsible for automating the packaging feed in 2019.

Automation of punched sheet metal production

Wink is a manufacturer of die-cutting tools for the graphics and processing industry with headquarters in Neuenhaus, Lower Saxony. The high-precision die-cutting plates, rotary cylinders, steel rule dies and other machine components are used all over the world and ensure the optimum cut for manufacturers of labels, packaging and many other die-cut products.

Previously, the process of loading, controlling and removing the existing laser systems as well as the post-treatment and packaging of the punched sheets produced was carried out manually. A completely new system including conveyor technology, robot gantry, deburring gantry and intermediate sheet storage was developed for automation. Linear technology plays a decisive role here. "Thanks to the Rollon linear technology solution, including a seventh axis, we were able to dispense with the use of several robots. This has made the project much cheaper and less complex," says Frank Neumann, Production Manager Punching Sheets/Labels at Wink.

INperfektion, a full-service provider for automation solutions, acted as the general contractor. "The original contact was between Rollon and Wink, but due to the requested scope of the project, Rollon brought us on board as a system integrator," says Carsten Finke, Managing Director of INperfektion, adding: "We greatly appreciate the trusting and respectful partnership with Rollon. Our collaboration results in valuable synergies for the customer - after all, every axis requires integration and engineering."

In addition to high demands on system safety, quality and process reliability in 24/7 operation, the automation of punched sheet metal production in the linear technology sector focused in particular on criteria such as precision, dynamics, compactness and robustness. "The aim was to achieve the shortest possible cycle times. High acceleration was therefore important. A high level of accuracy was also required - and that with a total system length of over 14 m," says Frank Neumann. The limited space and the fact that the installation had to be carried out during ongoing production added to the difficulties.

The new process is designed as follows: The punched sheets to be processed are fed to the automation system via a conveyor line. An intermediate sheet storage unit ensures replenishment and enables a uniform process. The sheets are then removed from a transfer station by a robot gripper system suspended upside down from a Rollon traversing axis and transported to the lasers. After the laser process, the sheets are transported to the deburring station.

Rollon supplied the right linear technology solution for the various motion requirements in the Wink system - from a single vertical axis to a 3-axis gantry and a traversing axis for the Fanuc M-710 robot. The basis for this was the broad portfolio of modular linear units. Rollon offers a comprehensive range of linear guides, telescopic slides and linear axes with a huge selection of designs, types and options. Users also benefit from the wide range of variants in the area of the 7th axis. The traversing axis used at Wink has an overall length of 11.5 m and consists of two segments that are assembled and mounted end to end. The compact, robust and durable Robot Transfer Unit (RTU) has a rack and pinion drive and moves the robot gripper system at a speed of 0.7 m/s and an acceleration of 1 m/s². The modular system allowed Rollon to use the Plus version of the SEV170P-2. Although this is actually a smaller size, thanks to the Plus version it offers the same performance data as the SEV220-2: ideal for limited installation space.

Dynamic, resilient and cost-efficient linear axes

Two parallel synchronized linear axes from the E-Smart series and an R-Smart as a transverse axis are used in the deburring portal. Thanks to its rectangular profile, the R-Smart axis has a high inherent rigidity and therefore low deflection, which leads to higher overall accuracy. The series is particularly suitable for applications with high load ratings where the carriage is exposed to high forces. It can even withstand high travel speeds. An R-Smart can also be found in the intermediate sheet storage system with automatic feed - this time as a vertical axis. Thanks to its 40 mm wide toothed belt, it can optimally accommodate loads in the axial direction. Another advantage is the 2-rail system, which can absorb any off-center moments better than a 1-rail system. The repeat accuracy is 0.05 mm, the speed is 1 m/s and the acceleration is 4 m/s2.

The automated punched sheet metal production line went into operation at the beginning of 2022 and everyone involved is completely satisfied. "This was our second project with Rollon and INperfektion. Cooperation and delivery reliability were once again excellent, the system runs perfectly, is reliable and low-maintenance. Further projects are already being planned," says Frank Neumann. Carsten Finke adds: "The entire project ran very smoothly and on schedule. Rollon was able to offer us the right products in a targeted manner and delivered the axes in a complete package. We only had to use the previously determined stops and everything fitted right away. We want to expand the partnership further in the future."