GROB exhibits the latest hardware and software technologies at the AMB
In addition to the presentations of a newly-developed motor spindle with a cross-feed device and the innovative swivel axis calibration for universal machines, GROB-WERKE will be exhibiting its latest technologies in the fields of energy efficiency and production control systems at the AMB. Der GROB-WERKE trade fair stand is in Hall 5, stand C38.
Since the construction of the new exhibition center, the International Metalworking Trade Fair (AMB) in Stuttgart has been an excellent platform for GROB-WERKE to present its latest developments in the universal machine sector. Six years ago when GROB first demonstrated a universal machine at the AMB, trade fair visitors were able to gain an impression of what it means for the GROB engineers to incorporate and implement concentrated know-how from systems business in the universal machine business. Another example of such a “development” can be seen at the AMB in the newly-developed motor spindle with an integrated cross-feed device for contour turning of complex work pieces. This can be used in the future, for example, to produce the contour of a high-temperature resistant turbocharger housing directly in the GROB universal machine in one clamping operation and therefore much more economically.
GROB will be demonstrating such a process with the universal machine G550 NEW at its trade fair stand C38 in Hall 5. It is equipped with the new motor spindle with an integrated cross-feed device as well as HSK-A100 and a Siemens control unit. It is used at the fair to demonstrate contour turning of a turbocharger made of high-temperature resistant steel and a demonstration work piece made of aluminum. The second GROB machine on display will be the G350 NEW universal machine with the 28,000 motor spindle and Heidenhain control unit. The machine will be processing an aerospace aluminum structural component live in operation with a high cutting rate and tremendous 5-axis dynamics. Finishing is possible with the large swivel range of the axis (225°) in one clamping operation.
Chip-in-spindle detection system (SiS) for universal machines.
GROB will also be demonstrating another technology that can be used for system and universal machine business with its SiS detection system. This system permits peak time neutral detection of tool clamping errors caused by chip inlays between the face of the hollow shank taper and the spindle nose. The special feature of the GROB SiS system is safe and independent detection of very small chips between the tool taper and the spindle taper as well as between the faces of the spindle and the tool holder of 10µm and more. As the detection of tool clamping errors caused by chip inlays is not only a topic in large-scale automotive production, but especially for safety-relevant components, GROB also supplies its motor spindles with chip-in-spindle detection system for its universal machines. This is a system that is integrated into the motor spindle and that inspects the tool interface for possible errors after automatic tool changes. Sensors in the spindle nose detect and evaluate the asymmetric deformation of the tool clamping point caused by chips. Energy and signal communication between the stator and rotor is wireless. The chip-in-spindle detection system is not tied to cycle times and does not require any preparation in the working area of the machine. It is therefore an ideal supplement for enhancing process reliability during automatic tool changes in the machining centers.
New GROB production control system G-Net
The fourth industrial revolution “Industry 4.0” is currently a frequently discussed topic. The “G-Net” Manufacturing Execution System creates cross-work transparency throughout the entire production process by means of web technology. The “G-Net” permits machine feedback for the CIP process and lets the machine “talk” to its environment. Visitors to the fair will be able to see for themselves how G-Net can be used practically by users at the GROB trade fair stand. GROB customers can in future be supported in production with GROB software solutions from CAD models through to the finished component. Customized solutions can be shown with modular applications for topics such as production data acquisition (PDA) and machine data acquisition (MDA) or web-based, mobile reporting. With the G-Net app it is possible to exchange all production-specific data from the ERP und PLM systems directly from the machine. The new G-Net interface permits real-time access to the ERP system from the machine or from the ERP systems to the machine. The perfect interaction between the robust and high-precision G-module range and the intelligent G-Net generates tremendous productivity advantages. GROB has been thoroughly testing G-Net at its own production works for more than a year. G-Net is currently generating more than 60,000 messages per week in the GROB production works – without stress. Machine operators quickly become accustomed to using the intuitive and easy-to-use G-Net user interface with minimal training. The practical findings are directly incorporated into the development cycle. GROB customers therefore benefit from practical solutions for practical applications.
A new dimension of 5-axis accuracy with GROB Swivel Axis Calibration (GSC)
The rotational axes of all machine tools have slight systematic geometric deviations that add up to a total volumetric deviation in the working area. Measuring methods to detect these errors have been developed to cope with this phenomenon. These include the “CYCLE996” and the “CYCLE800” measuring cycles that take the measured values during swiveling into account. With the GROB Swivel Axis Calibration (GSC) GROB engineers have revolutionized this measuring process – another GROB trade fair innovation. With the GSC technology it is possible to almost double the accuracy of the work processes in comparison with existing technologies. This is a tremendous advantage over classic technologies, especially for customers who have to produce very precise parts (individual components), for example in the aviation industry.
This high accuracy is achieved by a more exact description of the kinematics. While conventional methods describe the kinematics with four figures, the GSC typically uses 30. The GSC technology practically replaces the “CYCLE996” or quick-check, as GSC works considerably more accurately and is always active – not only when the “CYCLE800” swivel cycle is programmed. As a result GSC can also be used in automotive applications in which no “CYCLE800” but predetermined zero values are used. In addition measurement is simpler and more flexible. GSC not only enables high-precision work piece machining, but also minimizes the number of necessary run-in parts.
GROB energy efficiency – complex and comprehensive
GROB development engineers have been focusing intensively on the topic of energy efficiency for many years. With their holistic approach they are able to enhance energy efficiency and therefore increase output. The entire complexity of this key issue will be shown at the GROB trade fair stand and an entire range of measures for improving energy efficiency in complex production systems and universal machining centers will be explained. GROB specialists will be explaining the effects on energy efficiency when a system can look into the future with the MES (Manufacturing Execution System) and knows exactly which job is coming next and when the system can “sleep” because there is nothing to do or when it has to “wake up” so that it can prepare “just-in-time” for production of the next part. There is hardly a field of research that is so complex and comprehensive, as it has to deal with the technology, i.e. the product, the optimum production of the components and also the entire manufacturing strategy.
