The automation of manufacturing processes by robots or by means of gantry systems is on the rise and has become a significant topic for our customers - also in the SME sector.
The right automation solution for your company brings great advantages.
Lower production costs, reduced throughput times, consistently high quality and better planning of production, to name just a few of the advantages of automation.
GEISS AG offers a wide range of automation solutions for vacuum forming and CNC finishing, whether through the use of robot technology or the integration of gantry systems between individual processing steps.
In order to automate vacuum forming and subsequent finishing, it is essential to carry out the finishing without cutting, or to completely extract the chips produced during the machining.
GEISS AG also has the necessary solutions for this.
Increase your competitiveness with GEISS AG as an experienced partner at your side.
GEISS automation by means of robots.
Add a robot to your new thermoforming or milling machine. Combine several machines into one production line. A wide variety of line concepts can be realised here, tailored to your needs. Parts handling, waste disposal or additional tasks such as parts printing can be handled fully automatically by the robot system.
A current view into our production hall: A thermoforming machine is combined with a shuttle table milling machine by a seven-axis robot system.
The robot itself has six axes and travels on a linear axis behind the two main machines.
The thermoformed parts are automatically placed on the milling tables, machined and removed again. The finished plastic components are stacked on a conveyor belt and conveyed out of the plant area. The advantages are clear from this practical example. During production, the plant operator only has to take care of feeding the sheet blanks and removing the finished parts.
The whole thing is realised by the Siemens Sinumerik function Run MyRobot. Separate robot controls are thus a thing of the past.
Controlling the robot by means of G-code in the Cartesian coordinate system makes programming much easier.
We go one step further here.
The robot movements are carried out completely on a parametric basis. In the end, the end user has no contact whatsoever with the robot programming.
Even for the approach of new products, only a component-specific parameter set has to be stored in the controller and the robot movements are automatically adapted to it.
The GEISS Automation system concept offers an unprecedented opportunity for simple automation.
Talk to us about it and together we will design your concept for the future.
The most important aspects at a glance:
- Extension of a thermoforming or milling machine by a robot system
- Combination of several machines by a robot system
- A wide variety of automation concepts can be realised according to customer specifications
- Robot control by Siemens Sinumerik function Run MyRobot
- G-code as the basis for robot programming
- Parametric structure of the control system enables easy adaptation of the robot movements
Parts handling
A wide variety of gripper frames can be attached to the robot for parts handling - whether universally adjustable or tailored to a specific product. Vacuum suction cups form the interface between the thermoformed part and the robot. In addition, the gripper frames can be changed fully automatically or in a manual process, depending on the frequency of the set-up processes.
Plant concepts
With GEISS automation a wide variety of line concepts can be realised. Depending on the cycle times of the individual machines and the required number of pieces, the line concept can be designed according to your needs. Two vacuum forming machines in combination with two milling machines. A centrally positioned robot that interacts with its environment. There are almost no limits to the possible combinations.
If the vacuum forming machine, loading machine and CNC finishing machine are linked with a gantry system for parts handling, we speak of the TT-IN-ONE series.
TT-IN-ONE stands for thermoforming and trimming in one system.
The TT-IN-ONE concept offers advantages over the integration of a robot for large components.
The concept is particularly suitable for...
...components in large quantities, when the machine only needs to be retooled infrequently.
...for product families where all different components can be clamped and transported with automatically adjustable workpiece holders and grippers.
The first TT-in-one has already been in operation since 2003 - CHANGEOVER EFFORT STRIVES TOWARDS ZERO!
Experiences with the first TT-in-one machine:
The machine has been running since 2003, much to the satisfaction of our Danish customer.; Staal & Plast Danemark, 5740 Ringe on the Island Fünen; satisfaction for some months. The customer decided upon this machine, as it is offering the highest flexibility. For the manufacturing of planting tables for market gardens a machine was needed, which could process a big number of different components. Due to different international standards, the table shapes are similar but different however, in their exact measurements.
The customer has approximately 300 different external dimensions of components in its range. It must also be possible to process two plates simultaneously. The flexibility of the TT-in-one convinced the customer. To solve this task specific combination tools have been developed for the vacuum mould. In addition, there is a combination tool, which functions as a universal milling fixture. For retrofitting only the moulding die has to be changed.
Both transfer machines as well as the turning machine have been designed in such a way that only programmatic changes have to be made at the CNC trimming machine – there are no retrofitting costs.
The success of the system proves to our company how forward-looking the idea of the TT-in-one machine really is.
Customer feedback:
Mr. Hennig Sörensen, former CEO of https://staal-plast.dk/about-us/ : “Our range comprises planting tables for greenhouses of big dimensions. We wanted these planting tables – made of plastics that beats metal in this area of application – in a size that worldwide was not available: 6250 x 1800mm. We were planning to buy the vacuumforming machine and to care for the automation by ourselves. But the offer of GEISS company surpassed all expectations. Hence we handed the complete project over to GEISS. We trusted that GEISS would find a solution. The result shows that we made the right decision!
The latest TT-IN-ONE system from the production of GEISS-AG combines a T10 vacuum forming machine of the latest design with a milling machine of the CNC10 series.
Geometrically similar, differently sized skylight domes are produced fully automatically on the system.
After the dome lights have been formed, a handling portal transports the deep-drawn parts from the trolley of the loading machine to the machining table of the CNC machine. There, the part is clamped for machining by means of a programme-adjustable universal milling fixture. During the subsequent milling process, all milling chips are extracted directly at the milling tool. After machining, a second handling gantry removes the finished machined part and the cut-off clamping edge of the part and stacks both separately on pallets at the end of the production line.
Both handling gantries and the main axes of the CNC machine are driven by linear motors. Due to the speeds that can be achieved with this, the system is so fast that handling and finishing are completed before the next vacuum formed part has to be removed. The cycle time thus depends exclusively on the vacuum forming.
The positions of the suction pads of both handling gantries are programmable, just like the positions of the universal milling fixture. All axes of the system, including the vertical axes of the gantries, are designed as NC axes. The speeds, accelerations and positions of the axes can therefore be easily changed and optimised in the machine's NC programme.
Experts have long known it: automated processes are optimizing work processes and are saving time and money. To realize a fully automatic production we are offering an addition to the step less adjustable window plate system.
The automation is rounded off by the GEISS produced automated tool changer. Instead of 30 to 180 minutes retooling time, with this system only needs a few minutes.
The profitability check proofs: With approx. 500 tool changes per year, annual savings of 76,000 euros can be achieved at investment costs from 44,000 euros.