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IPR
23.10.2018

Production is More than Making a Product: Quality Work Made in Germany

The special feature of the cell: It is firmly bolted to a steel frame.

Modern production for more quality of life – so the idea of a company in the gastronomy sector. This idea is based on a quiet production environment with an aesthetically functional design. Only nine months later, the project has been implemented and the system captivates with its clear lines and a quiet production process. Peter Beike, owner of LASO tech Systems in Suhl, Thuringia, specializes in the production of such automation cells. His work is based on state-of-the-art technologies and so the OEM also uses the new composite concrete 7th axis from IPR. Since the movements of industrial robots are loud, he has avoided 7th axes until now whenever possible. Not so with the composite concrete 7th axis: It is not only quiet, but also low-vibration, torsion-resistant, sustainable, cost-effective, has a classic design, and takes up little space. The result of this development is a product suitable for mass production, which is at least as efficient as the metal variants previously exclusively available on the market, but with many other advantages.

The production of workpieces for the gastronomy sector consists of a multitude of complex processes. The industrial robot is used for handling, production and assembly. The OTC industrial robot FD-V210 travels through a total of seven cells along the 15 meter long composite concrete 7th axis. It takes five minutes to complete the production process for a fully functional product. The main process within the automation cell is the gas welding of stainless steel without filler materials. LASO tech Systems has advanced the process so perfectly that the usual blue imperfections do not occur. Manual finishing - polishing or etching - is therefore not necessary. From the initial idea to the finished product, this requires a large number of specialized experts, who make sure that the product can later be manufactured efficiently. In Suhl, the experts develop new processes and machines for production, procure and install the necessary technology.
IPR's RC-1500 composite concrete 7th axis as the most powerful 7th axis of the company forms the core of the automation cell. It offers a maximum bending moment of more than 72,000 Newton meters. The successful tests at the independent materials testing center in Kaiserslautern confirm the performance: The composite concrete 7th axis was subjected to a continuous load test with 2.5 million cycles – this corresponds to an operating time of about ten years. IPR’s design calculations have been confirmed in the endurance test and show the same reliability as models made of aluminum or steel.
The customer of the automation cell virtually had no alternative to the solution from LASO tech Systems. Space and cycle times were given. The principle decision was made with the change to a new product line. The special feature of the cell: It is firmly bolted to a steel frame. A design that minimizes installation time at the customer site, because everything can already be programmed with millimeter precision in the test situation of the automation unit. Once the cell has been delivered and set up, it can be put into operation very quickly, since the positions and distances for the robot are already correct. Second advantage – the system does not have to be disassembled in small parts, but in large units: 2 meters 40 wide and 7 meters long at a height of 3 meters. These are the transport units of steel pallets. The functional design is the third advantage of the modular steel frame. All cables fit under the steel plates. So no extra cable channels must be routed, which could also be tripping hazards. In terms of a Clean Factory, a large part of the accessible areas is covered with anti-slip plates, which protect against dirt and are easy to clean.
“We have immense product knowledge around the topic of 7th axes,” explains Thomas Kollmar, Managing Director of IPR - Intelligente Peripherien für Roboter GmbH. “And IPR understands the specific problems of our customers on site – and what is required in the future. With this knowledge and partners like LASO tech Systems, we create great potential. Overall, the collaboration is characterized by mutual respect based on the performance of the partner,” says Peter Beike from LASO tech Systems GmbH. “Plus, we think alike,” adds Kollmar. “What else can we do for the customer? How do we create added value?” These are the questions that determine the actions of both companies: “This is the only way to keep our customers permanently.”
IPR built the first 7th axis made of aluminum in 2006 and is an innovative expert in this field. Overall, the composite concrete 7th axis offers more options than the metal variants. For example, two guide principles exist now: a flat or profiled rail guide. Energy can now also be supplied in the middle of the base body – a space-saving method. 7th axes made by IPR are always modular and can be flexibly extended. This also applies to composite concrete 7th axes. Starting from a base module with a length of three meters and a travel of two meters, the 7th axis can be extended in virtually any way. The developers at IPR placed great value on material sustainability. Here, the figures speak for the innovation as well: Approx. 75 percent less CO2 and 90 percent less energy required compared to a 7th axis base body made of steel. Typical areas of application are machine loading, laser applications, and paint applications.