Additively manufactured robot grippers in series production
Cost optimization, flexibility and speed
BEULCO uses parallel grippers and suction pads for workpiece handling with robots, which presents us with several challenges. During metal processing, the workpieces have to pass through two steps. In the first step, the components have to be deburred and then machined in the second step. In both process steps, the systems are loaded by robots. All pressed workpieces have individual contours and there is also a variety of over 300 different designs. In addition, high tool costs led to the search for a more cost-effective alternative to the existing metal grippers. The aim was to produce cost-efficient, customized robot grippers suitable for industrial use.
Datum: 29.9.2023 | Lesezeit: 5. Min.
The origin of the idea
At EMO 2019 in Hanover, Lutz Schopen, Head of Technology, discovered the technology of industrial Markforged 3D printers. The possibility of reinforcing the components with the continuous carbon fiber during printing was the main criterion for him to invest. He quickly realized that this technology could become a game changer for BEULCO in the field of gripper technology. He hoped that it would drastically reduce costs in the area of end-of-arm tooling.
Steep learning curve
A first sample component from Mark3D GmbH quickly produced impressive results in the initial tests on its own test bench. Initial wear tests were carried out on this test bench and experience was gained. Among other things, a separate concept for connecting the gripper to the robot was developed after a rethink in the design had taken place. The grippers were now optimized for additive manufacturing during the design phase.
In the course of this, the connection of the grippers was changed from a force fit to a form fit. The groove of the gripper is pushed into a C-slot of the robot, clamped with a plate and screwed in place. This eliminated the weak points of the attachment. Thanks to the modular design, it is now possible to use the grippers in both processing steps on the robot systems.
Expectations exceeded with 3D printing
"Not a gimmick, but real means of production at BEULCO GmbH & Co. KG!", emphasizes Lutz Schopen. The new additively manufactured grippers meet the requirements in 99% of applications. Some of the suction pads have already been used for over 200,000 cycles and show no measurable wear. The high loads resulting from fast movements do not affect the durability, nor do the cooling lubricants with which the components come into contact.
Furthermore, the procurement times (external procurement) have been significantly reduced from 4-6 weeks to 1-2 days, in the best case to 24 hours. Added to this are huge savings. A total of €200,000 has already been saved on over 330 pairs of printed grippers and suction pads.
Replacement grippers and grippers in new designs are still planned for the future. There is still a regular demand for these. BEULCO GmbH & Co. KG sees additively manufactured clamping fixture jaws for the series production of workpieces on automatic lathes and machining centers as another field of application. Here, BEULCO faces challenges such as strong forces and high heat generation. A solution is being worked on together with Mark3D GmbH.
Prospetcs
Where are we today?
But that was just the beginning. We have expanded the production of replacement grippers and grippers in new designs in order to meet the constant demand. In addition, another field of application was defined: additively manufactured clamping fixture jaws for the series production of workpieces on automatic lathes and machining centers.
This is where our in-depth expertise in the field of 3D printing in production comes into play. Additive manufacturing not only enables the production of high-strength components, but also opens the door to flexible, customized solutions. Thanks to the modular design of our grippers, we can now use them in both processing steps. This not only contributes to cost efficiency, but also significantly increases the flexibility of our production.
Furthermore, we now also count our in-house design and development department among our customers. Here we produce designed components and prototypes - after all, data can be assessed much better on the "real" object. We also produce measurement documents for our measurement projectors in quality assurance in order to optimally align parts and minimize the error rate.
The use of 3D printing technology has proven to be a strategically wise decision for BEULCO.