Linear Motion Technology
Robot and servo press: Frit pressing in a flash
For the automated assembly of frits for the chemical industry, the Swiss special machine manufacturer Cerasus GmbH has implemented a flexible robot cell. The servo press from Bosch Rexroth integrated into the cell increases productivity, process quality and flexibility in frit assembly.
There is nothing off the shelf in special machine construction. And yet, standardized solution packages are a great help to save valuable time in engineering and implementation. Cerasus, which is based in the Swiss municipality of Steinen, simplifies complex assembly tasks with a mechatronic subsystem from Bosch Rexroth for pressing and joining applications. It is supplied ready for installation and can also map measurement functions with the integrated force sensor.
The complete mechatronic package from Bosch Rexroth is used in a cell for the assembly of frits and is developed on behalf of Cerasus. These are small, cylindrical throttle elements made of metal that are pressed into a sleeve to produce flow limiters for medical and chemical technology.
Flexible robot cell with a six-axis robot and the Smart Function Kit Pressing
The CERAFLEX assembly cell consists of a six-axis robot from Fruitcore Robotics and the Smart Function Kit Pressing, a ready-to-install servo press from Bosch Rexroth, with which different joining and measurement functions can be implemented quickly and easily. The special feature of the Rexroth solution: The mechatronic subsystem is composed of optimally coordinated, preconfigured individual components and is supplied with pre-installed operating software.
In addition, users have the choice of configuring, designing and ordering the Smart Function Kit for pressing and joining applications online using intelligent eTools or – like Cerasus – having it tailored to specific applications in coordination with Bosch Rexroth. Both options reduce engineering times. CAD data and documentation can then be downloaded via the online configurator.“For our customer-specific solutions, we value the dedicated and competent engineering support of Bosch Rexroth,” says Gabriel Bösch, Managing Director of Cerasus.“This is not a matter of course in the industry and makes the difference for us.”
Precision work: The servo press based on the Smart Function Kit from Bosch Rexroth (left) presses millimeter-small throttle elements, known as frits, into metal sleeves. (Image: Cerasus GmbH)
Servo presses in no time at all
With the Smart Function Kit Pressing, system integrators and end users can quickly implement servo presses for a wide range of standardized joining tasks with nominal forces of up to 70 kN (maximum forces of up to 72 kN). The modular and ready-to-install complete solution combines optimally matched mechanical and electrical components from Bosch Rexroth into a subsystem with pre-installed operating software. The guided commissioning and convenient graphical process creation take only a few minutes. The integrated force sensor can also map measurement functions for quality assurance. The process data can be easily visualized via the HMI and transmitted via open interfaces.
The compact CERAFLEX assembly cell with a modular servo press from Bosch Rexroth works autonomously for up to 10 hours. (Image source: Cerasus GmbH)
Smart Function Kit: Time-saving and flexible
With the help of the commissioned CERAFLEX assembly cell, Cerasus has automated the previously manual, monotonous frit assembly for its customers. As a result, larger quantities can be produced in less time. In addition to the insertion, pressing and measurement, the categorization of the manufactured throttle elements is now also fully automatic. After measuring the flow resistance, an axis robot places the products in different tanks to separate rejects from OK parts and temporarily store throttle elements with specific measured values for other applications.
Precise, reproducible processes with the modular servo press
Compared to manual frit assembly, the modular servo press from Bosch Rexroth works with significantly higher accuracy and process stability.“The pressing process therefore requires exact values for movement and force,” explains Bösch. Thanks to the integrated function for quality monitoring with force-displacement measurement, Cerasus can analyze the process and continuously improve it. Already, excessively large tolerances can be recognized by the starting force to be applied. Faulty parts are thus detected at an early stage and tool damage is avoided.
Annual production in three months of automation
The CERAFLEX cell can work autonomously for up to ten hours and in two-shift operation around the clock. With a cycle time of about one minute, the robot and servo press can now handle the previous annual production in a very short time. In view of this time saving, the manufacturer added a second task to the CERAFLEX cell. For this, Cerasus uses another Smart Function Kit with 12 kN nominal force and a correspondingly larger electromechanical cylinder. The rest of the equipment remains unchanged, so that the cell can be converted in half a day. The second press application has an integrated length control. The necessary distance measurement is carried out by means of the force-displacement recording, including the press height.
In use: millimeter-small throttle elements, known as frits, are pressed into metal sleeves by the servo press based on the Smart Function Kit from Bosch Rexroth (left). (Image: Cerasus GmbH)
High flexibility due to open control platform ctrlX CORE
The robot cell owes its high degree of automation and productivity both to the control software developed by Cerasus and to the combination of a flexible servo press and the open control platform ctrlX CORE from Bosch Rexroth.“We opted for the Smart Function Kit Pressing not only due to its high-cost efficiency, but also because of the simple and quick adjustment of the pressing process,” explains Bösch.“The control platform ctrlX CORE impressed us with an extremely short delivery time and its large range of open interfaces and flexible expansion options through apps, which provides us with a sustainable basis for various projects.”
Efficient pressing, forming and testing: The Smart Function Kit Pressing is a complete mechatronic package for nominal forces up to 70 kN (maximum force up to 72kN). The pre-installed operating software allows quick and easy commissioning, setup and process monitoring. (Image source: Bosch Rexroth AG)
Easy setup of web HMIs
Cerasus programmed modular software for the robot cell, including an HMI interface.“The two-in-one solution is well received by our customer, as it saves space for a separate machine and makes production more flexible,” reports Bösch. In both cases, the complete system is controlled via the ctrlX CORE control platform and matching ctrlX I/O modules. The CERAFLEX software programmed in CODESYS takes over the interaction of the individual components. The WebIQ HMI also integrates the platform-independent operating software of the Smart Function Kit into the machine overview. With the help of WebIQ, web HMIs for ctrlX AUTOMATION can be created even without extensive programming knowledge – this includes simple process controls with few displays. The WebIQ app of the ctrlX World Partner Smart HMI runs directly on the ctrlX CORE. The partner network, ctrlX World, extends the automation toolkit ctrlX AUTOMATION with hardware and new apps and thus offers maximum flexibility.
Basis for future assembly cells
Cerasus now uses the proven CERAFLEX concept with its standardized, force-adjustable pressing process as a flexible basis for the efficient creation of further turnkey solutions.“Our Solution Kit for Pressing and Measuring is equipped with everything that is needed for joining with distance and press force monitoring,” says Bösch.“Further process steps such as marking, output or testing of the components can be easily integrated. The operating software is very intuitive and allows simple and fast commissioning. In addition, the automation platform ctrlX AUTOMATION offers us a high level of integration and future viability.”
Looking back, Bösch is very satisfied with the Smart Function Kit and the control platform ctrlX CORE from Bosch Rexroth:“Hardware and software solutions meet the promised performance characteristics. The local support in Switzerland and the programming support from Germany worked well, and everything was delivered on time. With the Smart Function Kit and ctrlX AUTOMATION, we can develop particularly economical, reliable and flexible solutions for our customers.”
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Author: Markus Geiger
Position: Channel Development Manager Factory Automation in Switzerland