AGV Lifting System

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Challenge:

A Tier 1 automotive supplier was experiencing performance issues with premature failure and high maintenance with their existing Electro-Mechanical – Roller Screw type actuators used in an axle damper / wheel bearing press. The repeated load cycle was causing accelerated wear of the roller screw. In addition, the variation in friction between damper bushings and driveshaft tube components was causing force spikes and shock loads further damaging the roller screw actuators.

To replace the existing Roller Screw type actuator, the supplier would need high force and precision control in a compact space envelope. A traditional hydraulic cylinder bearing press system approach and a larger electro-mechanical actuator were considered to replace the system. However, the hydraulic system would have occupied too much floor space and did not provide accurate control. If the assembly press used a larger electro-mechanical actuator, the footprint would grow considerably in size and cost would become prohibitive.

Solution:

A Kyntronics SMART Electro-Hydraulic Actuator (SHA) with 40-inch stroke was selected based on force and speed requirements. The solution was an all-in-one system with servo motor, drive, and actuator that was drop-in ready.

In addition, the unit was provided with an internal feedback device to provide accurate positioning without possible interference when pressing into long axle tubes.

Results:

• The SHA provided the high force required in a compact footprint which fit into the available space on the machine easily.
• The SHA combines power and precision resulting in a more-reliable solution for this Tier 1 customer while providing the position and force accuracy for repeatable quality for this assembly process.
• Due to the SHA’s tolerance of “shock loads” and “load spikes” it will provide long, maintenance-free operation compared with the Electro-Mechanical Roller Screw actuator it replaced.

Challenge:

An Appliance manufacturer ordered a new press line from a machine builder to produce precision sheet metal panels for a new product launch. The manufacturer wanted to eliminate the use of hydraulics due to the advantages of being environmentally cleaner, providing significant energy savings, reducing floor space required and quieter operation.

The new product had stringent process quality requirements for the metal forming presses that would require precise control of force and position during the servo press stroke.

The “no hydraulics” mandate created unique challenges for the Machine Builder due to the high forces required of up to 170,000 Lbs (756 kN) in the metal forming stations.

In addition, the system would need to seamlessly integrate with Rockwell Automation motors and servo drives.

Solution:

The Machine Builder considered using electro-mechanical actuators (EMA) on the metal forming press but found that the large size and high cost of EMA technology was prohibitively expensive and would not meet their project requirements. In addition, there were concerns about EMA screw life due to the “spike loads” the actuators would be subject to during production.

After careful consideration, the Machine Builder selected Kyntronics SMART Electro-Hydraulic Actuator (SHA) for the servo press stations on the new machine. The SHAs were rated for 85,000 Lbf (358kN) of force and were provided in an in-line configuration mounted to the top of the press.

For the primary servo press station, two 85,000 Lb SHAs were synchronized together providing 170,000 Lbs of force. The SHA provides precise and repeatable control of applied force and position which was critical for the quality required from the new machine.

The SHAs incorporated Rockwell Automation (Allen Bradley) Servo Motors and Drives that met the customers’ control specifications to produce precision sheet metal panels.

Results:

• The SHAs eliminated the need for an HPU and hydraulic infrastructure on the new machine resulting in a clean working environment, quieter operation, and substantial energy savings.
• Part quality exceeded the new product’s stringent requirements, even at the high forces required for the metal forming operations.
• The SHA provided very reliable, maintenance-free operation despite the 'shock loads' that were present in the metal forming operations.

Challenge:

An appliance manufacturer had to re-tool a production line for a new product launch. The manufacturer had several key objectives required for this new line including:

• Eliminating the use of HPUs, hydraulic cylinders and related hoses and components
• Reduced energy consumption (“Going Green”) with an improved working environment: cleaner, quieter, safer with less maintenance.
• Improved process control and quality.

These objectives presented some difficult challenges for the Manufacturing team and the Machine Builder chosen to design and build a new line. On previous lines, HPUs and hydraulic cylinders had been used due to the large forces required (> 40,000 LBs) in the metal forming operations. In addition, the new line required more precision in the material clamping stations to achieve the quality and productivity required.

Finally, the manufacturer required the new line utilize Rockwell Automation servo motors/drives to integrate into their Rockwell controls platform.

Solution:

The Machine Builder considered using electro-mechanical actuators (EMAs) but found the large size and high cost of EMA technology would not meet their project goals. They also had concerns about EMA screw life and reliability due to the shock loads that would occur in the metal punch/pierce operations during production. The team selected Kyntronics SMART Electro-Hydraulic Actuators (SHA) for the new line. The totally self-contained, sealed design of the SHA removed the need for HPUs, hoses, valves, hydraulic cylinders and other components eliminating the potential for leaks and minimizing maintenance. Kyntronics assisted the Machine Builder with sizing the correct Rockwell Automation motors for the 14 SHAs used for this project.

Unlike HPUs that run continuously and consume significant energy, the SHAs “power-on-demand” feature only consumes energy when in cycle. Its modular design allows the SHA to be configured to fit the limited space available.

Another unique benefit to the Machine Builder was the availability of an Add-On-Instruction (AOI) developed by Kyntronics for Rockwell Automation Servo Drives/PLC enabling faster integration of the SHA with Rockwell controls.

Results:

The Kyntronics SHAs utilized on the new metal forming line allowed the manufacturer to achieve their targeted objectives including the following:

• The SHAs eliminated the need for HPUs and related components resulting in
• Substantial energy savings
• A smaller machine footprint
• A quieter, and cleaner working environment
• Significantly less maintenance and safer (no oil spills)
• The precision servo control of the SHAs improved the quality and repeatability of the clamping and metal forming operations
• The Rockwell AOI developed and supported by Kyntronics included a software template that provided precision force and position control and the AOI significantly reduced the Machine Builder’s integration time and streamlined commissioning of the line

The Kyntronics all-in-one SHA combines the power of hydraulics with the precision of servo control resulting in an innovative solution for this appliance manufacturer’s new production line.

Challenge:

A Tier-1 Automotive Chassis System manufacturer had to re-tool a Hydroforming line to accommodate a new model design change. The new line required the flexibility to produce both the current OEM product and the new product at higher volumes.

As a requirement for the new machine design, the manufacturer wanted to eliminate the messy and inefficient hydraulic system used in the old machine and implement new technology that provided better process control, was cleaner, quieter, saved energy and had the flexibility to handle the part variability.

In addition, the new system would need to seamlessly integrate with Rockwell Automation controls and drives.

Solution:

The manufacturer considered using electro-mechanical actuators, but found that the large size and high cost of EMA technology would not meet their project requirements.

16 Kyntronics SMART Electro-Hydraulic Actuator (SHA) were selected for the new machine. The SHAs were rated from 6,000 lbf (27 kN) to 23,000 lbf (103 kN) of force and were provided in both in-line and right-angle configurations to optimally fit the available space envelope.

The SHAs incorporated Rockwell Automation (Allen Bradley) Servo Motors and Drives that met the customers’ control specifications.

Results:

The Kyntronics SHAs implemented on the new Hydroform Tube Processing Machine exceeded the requirements of the machine builder and end customer, including the following highlights:

• The SHAs eliminated the space-consuming HPU, manifolds, valves and hoses which helped contribute to the machine footprint being 50% smaller than the previous production line
• The ability of the SHAs to operate independently with cycle overlap allowed the new machine to produce 25% more parts per shift vs. the previous machine
• The programmability of the SHAs provides flexibility to handle multiple part variations with improved process control – using position and force control ensuring optimal cycle times
• Elimination of the hydraulics on the new machine results in an environment that is cleaner, less noisy and more energy efficient

The Kyntronics SHA combines the power of hydraulics with the precision of servo control resulting in an ideal solution for the Hydroform Tube Processing Machine.