A dream comes true
HENKEL+ROTH have developed a versatile, compact and user-friendly five-axis automatic assembly machine
Joining, screwing, riveting, gluing, testing or measuring - all in a single clamping operation, in five-sided machining, with a single flexible, compact and user-friendly system: the newly developed five-axis automatic assembly machine from system manufacturer HENKEL+ROTH GmbH from the Thuringian technology region of Ilmenau makes this workshop dream come true. The machine works faster, more precisely and takes up less space than a robot with comparable capabilities, can be intuitively "taught" new machining programs without much programming effort and is therefore particularly suitable for the production of various medium-sized components in small batches.
The machine performs different assembly tasks from five sides in a single clamping operation. This enables greater precision and speed thanks to fewer reclamping operations and more freedom in the design. "We are rethinking - from 'design for assembly', which is often almost impossible to achieve perfectly in practice, to assembly for design," says Matthias Roth, one of the two managing directors of the company based in the Thuringian technology triangle.
Because the workpiece is firmly clamped on a movable table for machining, higher machining forces are also possible without sacrificing precision - a decisive advantage over an assembly robot, which also requires more joints for a higher number of machining axes and therefore inevitably becomes more elastic and less precise: "We turn the workpiece, not the tool arm," says Matthias Roth.
Flexibility of the assembly process
The automatic assembly machine was developed in response to numerous customer requests from the Thuringian plant manufacturer's five-axis hot-insertion machine, which has already proven itself on the market since its premiere at Automatica 2010. HENKEL+ROTH's five-axis automatic assembly machine has also inherited the capability for de facto six-axis machining using an additional Z-axis. One possible application is to equip the second Z-axis with a gripper that, for example, feeds and fits parts that are assembled using the tool on the other axis.
The first examples of the five-axis automatic assembly machine are already being used successfully in various workshops. There are virtually no limits to the flexibility of the applications. The automatic assembly machine can be used for joining processes such as clipping or pressing in, for screwing, gluing, ultrasonic or spot welding, for attaching rivets and hollow rivets, for inserting and sealing and, of course, for cold insertion (pressing in bushes). A measuring function for tolerance and tightness tests can also be integrated, using cameras, tactile sensors and test adapters.
Retooling flexibility - intuitive operation
Workpieces with changing configurations and different part positions, for example supplier parts for different car manufacturers, can be assembled precisely in quick succession. Changeover to the next workpiece type is possible by changing the type-coded clamping fixtures, whereby the control system loads the new data set. After a few minutes, production can begin with the next task.
Machining programs for new workpieces can be taught in easily and without specific programming knowledge and time-consuming reprogramming, similar to an industrial robot - "the machining position is approached by 'joystick' control and saved at the touch of a button," Matthias Roth explains the principle. Process parameters can also be saved.
In terms of user-friendliness, HENKEL+ROTH's five-axis automatic assembly machine scores just as highly as the hot insertion machine presented two years ago thanks to its convenient and user-friendly menu navigation via touchscreen. Users can define and modify the sequence programs themselves; path curves, for example for gluing tasks, are also possible. Type-dependent process parameters can be stored in a database.
Workshop-friendly and space-saving
The HENKEL+ROTH five-axis assembly machine also demonstrates workshop-oriented flexibility when it comes to loading. The workpieces can be loaded and unloaded manually or fully automatically, either with a permanently installed gantry robot or with HENKEL+ROTH's "mobile robot".
Finally, another advantage that should not be underestimated is the small space requirement: the machine has a footprint of 2 x 2 meters and can be easily moved by forklift truck if it is needed at a different location in the workshop. The processing area, which is clearly enclosed by glass walls, ensures operator safety even in a small space. A conventional assembly robot can hardly keep up with the five-axis automatic assembly machine from HENKEL+ROTH in these respects either.
Our services
We develop customer-specific automation solutions with the aim of making production more efficient and reducing costs in the long term.