TG-12×4 Hi-Accuracy System UR5 Collaborative Robotic Loading
One of Royal Master Grinders’ standout offerings is our highly adaptable system, featuring a Universal Robotics UR5 and Schunk EOAT. We’ve crafted this collaborative platform in several variations, all of which have become customer favorites. Whether it’s paired with the TG-12×4 or TG-12×8 machine, we’ve employed not only the UR5 but also the UR10 for extended reach when needed.
Utilizing a conveyor system, this machine seamlessly transitions parts from a lathe or screw machine to the grinding process, followed by inspection and placement into shipping containers, all without requiring human intervention. With the use of Kaiser Manufacturing Kaizen foam trays, parts are meticulously separated and organized, ensuring high value items remain protected and organized, even when they cannot come into contact with each other.
- Load and grind parts down to .040” (1mm) and up to 3” Diameter (75mm)
- Automation slides out of the way for machine maintenance and set-ups. Locks back in place so there is no need to re-teach the robot
- Machine Enclosure customizable in design, color and customer’s graphics
- Load from Static Pallets or conveyor system
In recent years, collaborative robotics has emerged as a distinct automation approach. Royal Master, with a long history of designing specialized automation solutions, has greatly benefited customers with families of parts through Magazine loaders, cross-transfer loaders, and other innovative systems. Initially exploring collaborative robotics years ago, it has now become a mainstream component of our automation offerings.
Using a 24” HMI and a three-panel interface, you can easily manage multiple screens simultaneously while programming CNC Dressing. The configuration options range from over-the-wheel template dressing to comprehensive CNC dressing for both the work and regulating wheels, providing you with seven axes of CNC control.
The High-Accuracy package offers a range of options, from simple operator assist loading to fully robotic systems, including both conventional and collaborative robots.
At IMTS 2024, the system will feature a UR5 collaborative robot and a conveyor with palletized parts. This setup demonstrates the process of removing parts from a turning operation, placing them on a pallet, transporting them to the grinder, and then, after grinding, gauging and re-palletizing the parts for shipping.
Using Kaizen Shadow Foam, manufactured by Kaiser Manufacturing, the hydraulic valve parts we are grinding are well-protected from damage. The UR5 collaborative robot loads and unloads the parts in one swift motion, ensuring a highly efficient system. Additionally, the integration of a Keyence gauging system enhances process monitoring and quality assurance. This system allows information to be fed back to the machine, providing valuable data for trending and a variety of other applications.
The BEDROCK machine foundation is based on a 8” thick Starrett surface plate lapped to .0002” over its entire surface, and each component built up from there is deserving of the Hi-Accuracy name. The Ram Bed position control is our high-accuracy frictionless cross roller way with ball screw and servo motor movement. A glass scale with one tenth of a micron resolution reports the position to the machine controller. Making a diameter compensation of .00001” is easy and accurate.
The wheel spindles are supported by Class 7 ABEC angular contact ball bearings. This high-quality, rigid spindle support design ensures long life and superior size control. As a result, the system achieves sub-micron tolerances, delivering exceptional accuracy.
The machine automatically reports its functions to the Advanced Machine Optimization (AMO) system. By activating the AMO feature, the grinder transmits machine-specific information to either the machine’s control system or your in-house network. This allows you to receive real-time reports on machine performance and PM reminders based on usage. You can also check error logs, part counts, cycle times, part numbers, and more. With AMO, you stay connected to your grinding process, receiving up-to-date information to optimize your manufacturing operations.
The TG-12×4 Hi-Accuracy System UR5 Includes:
Flexible loading and unloading system for large quantities or small production lots
Low cost/flexible pallet design using Kaiser Manufacturing ridged foam inserts
Universal Robotics Collaborative Robot, ONRobot End Effectors and additive manufactured EOAT
12” Diameter Grinding Wheel, 6” diameter Regulating wheel
Variable Frequency Drive on grinding wheel spindle for super abrasives or maintaining constant surface footage when grinding
Infeed and Thrufeed Grind capability
Password protection on operator interface
Programmable Infeed Cycles can be saved and recalled with unique file names from a library
Thrufeed Grind with fine resolution positioning to 0.000,010” of an inch or 1/4 micron increments
5” of Ram Bed travel allowing for removal of Grinding Wheel
Available SBS Wheel balancing and Acoustic Emissions
Remote Connectivity using TeamViewer application
The Highlights
- Versatility for Medium to low production parts is the key to this system
- Collaborative UR5 robot with a ONRobot Electric End effector
- Pallets are easily designed by Kaiser Manufacturing with Kaizen Foam
- 3D print your end of arm tooling that is required for maximum flexibility of the system
- Move the Robot Station out of the way on two bearing slides to conveniently access the machine for wheel and set-up change overs
- Grind parts down to .002” Diameter up to 1.5”
- Other types of feeding available including step feeders and conveyors
- Integrate post process gauging
- 24” touchscreen control with three panel screens giving the most flexible control in the industry
- Starrett Surface plate granite
- Compensation in .00001” increments
- Dressing Options include
- Standard Template Tracing Over the Wheel
- Automatic and Programmable Template Tracing over the wheel Dressing
- Automatic Template Dressing
- Over the Wheel CNC
- Horizontal CNC for the Grinding wheel using either a Rotary Diamond Disk or Diamond Too
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