Maximum edge quality

Fully integrated, fully automated batch-size-1 manufacturing cell for cabinet fronts

At the LIGNA, IMA Schelling will show a fully integrated, fully automated batch-size-1 production that has been designed specifically for a big European fronts manufacturer. The highlight of the production cell is a Performance.cut machining centre that also cuts out free-form parts such as nested desktops. Another specific feature is the edge banding process on a Combima Systems running in a production environment that enables formation of pairs for efficient panel arrangement in the circular edge processing installation. The whole manufacturing cell is equipped with two 4-axis robots and one 6-axis robot.

Since the middle of 2016, the fronts manufacturer for which the batch-size-1 production cell has been developed has been fabricating components on two very similar workcells, each consisting of two parallel edge banding lines served from an area storage system. The production capacity of these workcells is more than 2000 parts per shift. The parts are, however, fed manually to the circular edge processing installation allowing incoming parts to be inspected for edge quality. But experience today has shown that this step can be omitted as the edge quality is constantly at an extremely high level. As a consequence, the new batch-size-1 production has been designed as a fully integrated fully automated manufacturing cell consisting of two production lines with an output of at least 3000 parts per shift. The fronts manufacturer has already taken an option on a third line.

At the trade show, IMA Schelling will show panel cutting on a Performance.cut and edge processing on a Combima Systems single-side edgebander with a return conveyor system. In the manufacturing cell eventually installed at the customer’s site, a panel storage system and large buffers between panel cutting and edge banding make the batch-size-1 cell complete. For the trade show, the processing plant has been completed with a Robot.sort V sorting cell. In this way, also the robotics modules of the IMA Schelling Group can be presented in a production environment.

Panel cutting on the Performance.cut

Panel cutting is performed in a fully automatic process on a Performance.cut panel cutting centre.  The machine offers the advantages of real batch-size-1 panel cutting, independently of the required cutting plans. It ensures effective panel cutting, maximizing capacity while minimizing floor space requirements. Specific feature: the panel cutting centre also cuts free-form parts such as nested desktops. Moreover, it offers the possibility of processing panels with “finger pull profiles”. The workcell installed at the customer’s site will also be able to detect damaged spots on the raw panels and bypass them during the panel cutting process so that faultless components are produced and the number of reject parts is minimized. A 4-axis robot, equipped with a 2200 mm long vacuum pick-up device with surface grippers, feeds the single panels to the panel cutting centre. Another 4-axis robot, also equipped with a vacuum pick-up device with surface grippers, takes the pre-sized components away from the panel cutting centre. It repositions the components taken out and stacks them next to it.

Formation of pairs for efficient panel arrangement in the edge processing loop

Closed-loop edge processing on two Combima Systems single-side edgebanders is at the heart of the new work cell. Each of the panel sizing and edge processing combination machines is equipped with an IMA PU gluing unit and a Nordson pre-melter unit. The fine finishing operations have been designed to meet the specific requirements of high-gloss lacquered fronts with protective surface films. Hence, maximum quality and durability of the high-gloss fronts are guaranteed. A conveyor system for pairwise return allows for efficient panel arrangement, ensuring an optimal filling level of the workcell.

Robot.sort V sorting cell

At the LIGNA, IMA Schelling will show the batch-size-1 manufacturing cell in combination with a sorting cell. It is comprised of trolley filling in tight grids and an ABB 6-axis robot.  In its final stage of construction, it consists of four storage racks, each with 60 stock positions, and has a storage capacity of approx. 1200 parts. The vacuum pick-up device (scissor lift) is fitted with surface grippers and can be set to meet the requirements of the panel range. The sorting robot is capable of handling components sizes between 200 mm x 100 mm x 10 mm and 3200 mm x 1300 mm x 50 mm and maximum weights of 50 kg. The sorting cell is integrated in the IPC.NET manufacturing execution system.

IPC.NET manufacturing execution system

Both the batch-size-1 manufacturing cell shown at the LIGNA and the work cell to be delivered to the customer are controlled by the IPC.NET plant control system. It performs planning tasks and the subsequent workflow control from panel storage, through panel cutting and edge processing, to component sorting. The panel optimisation also considers the data for the positions of the damaged spots on the raw panels as determined by the quality control. In addition to that, the plant control system visualizes all manufacturing cells in real time.

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