FormControl X measurement and automation software from Blum-Novotest
When visiting the halls of Schubert Fertigungstechnik GmbH, the large number of robots and automation solutions on the machines immediately catches the eye. The company is not a series manufacturer; typical batch sizes range from three to ten units and are sometimes fewer than 100 pieces. ‘We have been working for a long time to get 18 to 22 hours of autonomous machine time. This means we can run the machines around the clock without having to ask our employees to work night shifts,’ explains Jens Grieser, the managing director responsible for the technical division. ‘Ideally, we would make early and late shifts as unnecessary as possible. But we need to ensure the same high level of quality at all times.’
With this in mind, Erhard Strobel, sales engineer at Blum-Novotest, found a receptive audience in Bartholomä with FormControl X. Schubert was very interested in the BLUM software, a client server-based solution for the automated measurement and evaluation of machining processes. Ultimately four variants of a part are manufactured on one machine, with around 60 parts per variant and a cycle time of between 10 and 40 minutes per part – but only if the machines are running at full capacity. This means it is very important to keep an eye on quality, also during unmanned shifts. Thanks to FormControl X, specialists can be sure that all measured values are upheld. The advantage of measurement being performed during the process is that it is clear when a measured value begins to drift. Action can be taken long before the tolerance range is exceeded. It goes without saying that this is especially true for broken tool edges.
FormControl X is a client server-based software solution for the automated measurement and evaluation of machining processes. BLUM developed the software from scratch based on the tried-and-test FormControl software with a particular focus on the automation of measurement processes. A major advantage of the client server architecture is that the data in the FormControl X database can be accessed from multiple workstations or machines. This allows users to easily create complex measuring programs at their office workstations or review the measured values taken during the previous night. The operator can monitor the tolerance fluctuations of all measured values on a laptop near the machine. The display is generally very simple and can be viewed on a PC, laptop or tablet in a standard web browser.
The flexible options that can be used to influence the machine with FormControl X are very interesting: In one case, for instance, the manufacturing process is only stopped when the same deviation is measured on two parts in a row. This rules out the possibility of a chip adhering to the measuring point during the first measurement. ‘For example, it is possible to measure every fifth part. In the event of an outlier, instead of waiting to measure the next five parts, the machine immediately starts measuring again during the next machining process to rule out a chip at the measuring point,’ explains Erhard Strobel. ‘Only then does the program decide, based on the specifications, whether the next part will be machined, whether the machine will interrupt machining or whether it will switch to the production of another part using different tools.’
The Fanuc Robodrill machining centres are mainly used to manufacture components for tool changers for Schubert packaging machines. For instance, these tools can hold boxes into which a robot places chocolates. If a different package size or shape is required, the tool can be changed and the packaging line automatically switched over. Several pneumatically operated pistons with an H7 fit work in parallel in these tool changers. The bore holes in which the pistons run must be made very precisely and have to parallel to each other with the correct diameter. Measuring every part produced is necessary to ensure reliable operation later on. This is because a stoppage in a packaging machine can be extremely expensive, for instance with the chocolate production processes mentioned above: If the packaging line stops, the production of the sweets must also be shut down because the liquid chocolate and other ingredients will solidify and go bad. In addition, the pre-assembly processes at Schubert are synchronised, which means that deliveries must be made at very short notice. So a problem on the machine also affects processes at the parent company, which accounts for around 70 percent of orders. That is why the accuracy of the measurements in the machine was checked continuously during the beta test prior to the purchase of FormControl X – the deviations were in the range of a few thousandths of a millimetre.
The designers of the packaging machines specify dimensions that are crucial for proper functionality and have to be checked during production. The NC programs are then created in Bartholomä, and the measurement subroutines are incorporated at the appropriate points. ‘We work together here: We, the employees working on the machine, are responsible for quality, which is why we decide together with the NC programmers which dimensions are recorded with the BLUM measurement cycles and stored in FormControl X,’ explains Markus Maier, who supervises the RobodrillPlus Big K systems. ‘This also gives us the knowledge we need to understand the measurements and make improvements.’
During the introduction phase of FormControl X, we stayed in very close contact with the BLUM specialists: In addition to the dedicated support of the programmers during beta testing, Schubert was also impressed by the excellent training. Currently, a new part only needs to be programmed every two or three weeks in Bartholomä, but the employees still have a good experience with the software because it is very intuitive. FormControl X also helps them focus more on their actual work. For instance, in the past, time had to be spent in the morning checking the dimensional accuracy of the components manufactured overnight. Now a glance at the screen is all it takes: The graphical display of the FormControl X web client shows whether the tolerances have been upheld. This allows employees to react immediately or continue production straight away.
All dimensions with tolerances of less than a tenth of a millimetre are now measured automatically, as are shape and position tolerances. These are important because many parts are machined in two clamping operations, which means the position of the second machining process depends on the surfaces produced in the first clamping operation. This is another reason why FormControl X brings major improvements to everyday work processes: ‘The software takes care of the measuring tasks for me because they are automated. This means I can concentrate more on my actual work,’ reports Markus Maier. ‘Working on the machine is also more relaxed because the process is transparent and we always know where we are in terms of quality – that’s very reassuring. What’s more, I no longer have to work in shifts since I can finish my work during normal hours – that’s a huge advantage for me!’
The number of employees at Schubert Fertigungstechnik who are being ‘freed’ from shift work could rise soon: Thanks to the positive experiences at the Fanuc centres, there are plans to use FormControl X on many other machines with the aim of increasing productivity. After all, BLUM software is an important part of the automation of machining processes and is playing a decisive role in achieving a very high level of automation in Bartholomä.
FormControl X has proven its worth and entrenched itself at Schubert Fertigungstechnik: ‘For each production batch, the first and last measurement logs are printed out and filed, and apart from that, all measurements are available in the FormControl database. ‘This is useful for assessing the tool service life,‘ summarises Jens Grieser. ’And it’s also reassuring for me to be able to see where we are in terms of quality at any time. Of course, the machines and the range of parts have to be just right so we can get the most out of the software – and that’s the case for us.’
