Retrofitted automation for flexible form measurement

The solution presented particular challenges: More than 20 different workpiece types needed to be inspected for their form characteristics, such as flatness, roundness or coaxiality, and this needed to be automated in quantities of up to 100 parts per batch. To achieve this, MES firstly installed a collaborative robot with an XL-Mahr feeder as an upgrade to a MarForm MMQ 400 already in use by the customer. Secondly, a framework program available in MarWin for such an extensive range of parts in terms of robots and software allows the customer to integrate new components very easily. The robot has now been programmed to load and unload the measuring station automatically. Doubly economical: the degree of utilization of the measuring device increases considerably, while the costs per part drop significantly – an investment that quickly pays for itself.

Variable three-finger gripper

The MahrFeeder is a workpiece storage system with drawers from which the robot automatically picks. A three-finger gripper picks up the workpieces from the inside or outside, depending on their properties. One by one, the robot places the workpieces on the centering and tilting table of the form measuring device. An operator is now only required to reload the drawers, which contain blue foam inserts specially tailored to the customer's workpieces. The special feature: the recesses in the foam are designed to fit different workpieces – at several levels in depth as well as at the front and back. This saves the customer space and means they don't have to change the inserts when they want to switch between components.

Measure – evaluate – sort

MES also adapted the measuring process itself to the customer's requirements and programmed special commands for the robot in MarWin. As soon as the workpiece is placed on the centering and tilting table of the MarForm MMQ 400, it aligns it and the measuring process starts. A DMC camera then reads the code with all the workpiece information, which is transferred to the measurement report. This provides the customer with complete traceability of the measurement results. The robot stores the parts that are not in order separately so that they can be inspected and reworked again if necessary.

The most important advantages of the customer solution at a glance

• Economical: device retrofitted to existing equipment; service life increases – costs decrease
• Productive: automated loading and measuring without tying up personnel
• Flexible: gripping technology and foams are customized for high part variance
• Space-saving: designed for the measuring room, no complex safety technology required
• Individual: customer requirements regarding software and workpiece portfolio taken into account

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