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Case History


DENSO

GIMATIC & DENSO : GMP “A” CLEANROOM GRIPPING SOLUTION

Gimatic in cooperation with Denso, leading company in 6 axis robots and SCARA, has created a solution to enlarge the application of our products to HIGHLY clean manufacturing areas thanks to high cleanliness level (ISO04) and GMP assessment (Grade A/B). To reach the highest level of certification MPPM1606-GMP-KIT has been tested by the IPA Fraunhofer Institute in Stuttgart in every condition also together with the Denso Robot. The hand is composed by our electric parallel gripper (MPPM1606), silicon cover, special stainless steel fingers and ISO flange to be fix directly on Denso Robot. The hygienic design cover is made by SILPURAN 6000 silicon form Wacker FDA/ EHEDG approved especially for Medical application.External fingers have a special and hygienic design to let customer remove end fingers and wash the solution by VHP or UV procedure.All the system is fixed to the robot flange by our special Aluminum interface with 40 µm oxidation and ISO standard (ISO9409-1).

MPPM1606-KIT-GMP can be washed by VHP procedure (H2O2 Peroxide Hydrogen) or Ultraviolet (UV) thanks to special and smooth design that keep closed the system up to IP65 degree.

 

 

 

TECMES

 

GIMATIC & TECMES : FAST ASSEMBLY OF CAPSULE AND COFFEE

Tecmes is an Autorotor Group company specialising in the design and production of special machines. Tecmes systems are used in various industrial sectors: automotive components, cosmetics, electrical, medical and pharmaceutical components, plastic components and food. A distinctive feature of the machines is the kinematics of the mechanical movements, driven by a single electric motor.

Because of their cam and leverage mechanical function, Tecmes machine movements are extremely fast. The pneumatic operation alone is left to the workpiece grippers. These are hi-tech pneumatic products specially developed for a single application. In collaboration with the Tecmes technical department, Gimatic has developed extremely fast grippers. But that’s not all. These are components suitable for contact with food.

Tecmes supplies numerous food and cosmetics companies. In the food industry, it specialises in the assembly of coffee capsules. Lavazza, Segafredo, Kimbo, Mokador, Espresso Cap, Co.Ind. and To.Da. are just some of the companies that rely on the productivity of Tecmes mechanical systems for capsule assembly. These machines can operate 24 hours a day, seven days a week, unsupervised.  The numbers are impressive. Over 1.3 million coffee capsules are produced in a working week.

The concept of quality is one of the key variables that companies must consider today. For this reason, the company – based in Vaiano Cremasco (Cremona) – turned to Gimatic for the supply of pneumatic grippers for the positioning and handling of capsules.  This is mainly the XP20-A model, a gripper designed to meet some of the needs of the food industry. The XP20-As are equipped with stainless steel jaws and an acetal resin guide. The latter is essential for a proper seal to prevent coffee powder (or other food residues) from reducing the gripper efficiency. In addition to food applications, Gimatic supplies Tecmes with high-efficiency compact grippers (the SGPs have a 95% energy efficiency) and high speed grippers (the HSs work with frequencies from 5 to 6 Hz).

The Gimatic choice was also weighted for energy certification needs of Tecmes machines. Users are increasingly demanding reduced electrical and pneumatic consumption. Suppliers of PLCs, as well as electro-pneumatic and electromechanical components, were also chosen based on the energy-saving performances of their products.

 

 

 

AGROBOT

 

GENTLE HARVEST AND FRUIT HANDLING

Innovative Spanish company of mechatronic engineering, develops automated harvesting solutions, using an autonomous vehicle that is provided with up to 24 robotic arms which work as a team, incorporating artificial vision with which to locate and select the fruit, as well as Gimatic's mechatronic grippers for a careful and painstaking pickup without coming into contact with it.

The Customer selected this mechatronic gripper for its high performance, simplicity of control and big life expectancy. The gripper is controlled by a simple digital signal of 24VDC through a M8 3-wire connector, has integrated driver and controller and does not consume power at rest.

www.agrobot.com

 

 
 

 

BOWLER PLASTICS

GRIPPERS AND LID CLOSING SYSTEM FOR BOWLER PLASTICS IN SOUTH AFRICA

The Company, founded in 1972, started the production of plastic parts with an Arburg machine. Today, Bowler Metcalf, a group with approximately 800 employees, produces more than 500 million parts a year in four individual facilities, where injection moulding, silk screen printing, digital printing or tube extrusion are performed for more than 200 customers. One of the group’s main product areas is the Bowler Injection Moulding Division, which manufactures 320 million moulded plastic parts on 54 injection-moulding machines.

Up to recently, an operator would close the caps (fliptops) ejected by the injection moulding machine by hand. Four caps come out of the machine at the same time with a cycle time of 13 seconds. Six different cap variants are possible. This approach was economical until labour costs saw a recent increase and production processes became longer. So Bowler decided to automate this process. At the same time, the quality risk from human error is eliminated. The challenge was to maintain the machine operator’s flexibility, improve quality and lower costs.
With the automation solution from Gimatic, they should be able to use their existing 3D negative mouldings. In addition, the process should be simple and reliable. The sealing process can now be automated with relatively little loss in cycle time, which is usually about one second. That's a small price compared to the big benefit each cap delivers. At the same time, thermal stability is improved and scrap is reduced. Now, the machine is much more efficient than an employee, considering that it can work 24 hours a day, 7 days a week. Based on labour cost savings, Bowler estimates that the investment will pay for itself in about seven to twelve months - without taking into account the savings resulting from fewer rejects and greater customer satisfaction.
So far they have had little experience with these lid closing systems. In addition, the challenge for Gimatic in this application was that Bowler wanted to handle six different types of caps.
Each of the different caps must be removed from the injection moulding machine as soon as they are produced so that their hinges do not break during cooling and the plastic does not shrink. Otherwise, the caps do not keep a tight seal in the application later. 
The removal unit is equipped with four vacuum grippers adapted to the shape of the lid. It removes the identically aligned plastic lids from the injection moulding machine and places them on four corresponding 3D negative mouldings in the lid closing system, which consists of two synchronously running linear axes, each closing two lids. For structural reasons, the linear axes were built mirror-inverted. Therefore, the removal unit must rotate the two lower components during the removal process in order to keep them in the correct position. The linear axis then moves over the removed lids. To avoid damaging the lids, they are first folded 90 degrees by a so-called flock, before they are firmly pressed by a pneumatic cylinder. As the removal gripper extends again to pick up the next components, the closed lids are successively rotated by 180 degrees and ejected by air blast into a container.
Adapted to three lids, two different lid-closing machines with three grippers each were developed. The two systems were built almost exclusively with Gimatic components. Thus, the removal gripper components such as vacuum cups, spring suspensions and the quick-change system were attached to the internal profile rail system.
The lid closure system is based on a steel frame, bolted to strong adjustable feet on the floor. The compressed air connection comes from the injection moulding machine or the robot handling system. For this purpose, a special interface in the form of a valve island was created. The control is also taken over by the injection moulding machine. For the linear axes, two Type LP07 linear units with two guide carriages are used, driven by a pneumatic cylinder. Small OFC cylinders fix the lids on a 3D printed negative mould.
The cylinders are equipped with a high-strength thermal rubber with high friction properties, so that components do not slip or become damaged during the closing process. An OFL cylinder presses the lids shut from above. The pressure can be adjusted depending on the component. RT 25 rotary units finally eject the lids. These rotary units have an integrated air duct and are about 20 percent smaller and cost about 30 percent less than comparable products on the market with the same power. The entire system is controlled, evaluated and monitored by magnetic sensors that communicate with the injection moulding machine.
The managers of both companies are very satisfied with the cooperation so far:

The Gimatic team, on the other hand, was promptly supported by Bowler during the design phase with all necessary information, data and samples.
Commissioning went smoothly. The team in Hechingen was prepared to travel to South Africa but that was not necessary in the end. The plant was manufactured and assembled in Hechingen. William Johnstone, from the Hestico Company, as representative for Arburg in South Africa, Colin Jacobs, machine set-up specialist at Bowler and Wayne Knutsen carried out the factory machine acceptance test, before delivery to Africa.