Industry Examples

Robotics

Industry Example

Schleicher provides the complete package for innovative RL Robotic systems: Drive technology, control and operation. The special features of RL Robotic systems: All drive units can be immovably arranged outside the workspace - this reduces the frequency of errors and wear. Above all, runs can be achieved at an extremely high speed, payload and throughput – compared to standard systems, this increases speed by 50 percent. Target parameters: An acceleration of 4 g and a speed of 4 m/s at a payload of 40 kg and more.
  • Continuous optimal relationship between acceleration and deceleration, speed and positioning through runs that are dynamically regulated on the control side
  • Harmonious tailoring of electric motors with control configurations in hardware and software as well as using the touch-screen operating terminal
  • The drive technology is linked to the control using Sercos III.

Car Manufacture

Industry Example

Schleicher's CNC control is used in IPC systems, such as in pressing plants in the automotive industry. The calculation of CNC data and simulation of the motional sequences takes place in advance. Then, using Schleicher's NERTHUS procedure (data reduction for free-form contours), the intermediate points for the paths are reduced and an optimised NC program is generated. Through the graphic simulation of all the components involved (press, tool, workpiece and feeders), a safe press cycle is achieved using rapid and accurate motional sequences. The executable programs are passed via the network to the ProNumeric controls, which then interpolate the motional sequence. In the press cycle, the CNC control minimises the dwell time of the feeders in the press. The motions are tailored to each other, resulting in a lift time close to the machine's gross output. Schleicher's NERTHUS procedure reduces the number of intermediate points and thus NC blocks in any free-form contours under a freely-selectable contour tolerance. The motional sequence can be simulated on a standard PC. From these few NC blocks, the CNC control re-generates the free form using the Online Curve Interpolator (OCI). This achieves a continuous and smooth path with optimised axis velocity. The program links the three axes of the charging feeder, the three of the discharging feeders and the two of the loading feeder to the vertical shaft of the press. To this end, the command value encoder is read in the interpolation cycle through the CANopen fieldbus and the axes are synchronised to each other dependent on the position and velocity of the press. The five individual presses can also be grouped together as a press line. Here it is possible to couple the group in turn to a higher-level virtual master sensor in order to achieve an optimal total production velocity.

Properties:
  • The linear axes of the feeder driven by servomotors achieve accelerations of up to 2.5 m/s², at velocities of 150 m/min
  • The motion of the already fast feeder is optimised through path control
  • The motion is controlled by an IPC-based CNC, which interpolates nine NC axes (eight servoaxes and the leading axis) for each feeder – a task for which CNC control is naturally much better suited than a PLC
  • The CNC runs free outside the press.
  • The press only has to stop in the case of particularly complicated charging procedures, if at all. The master sensor, feeder and I/O modules are networked with the control using CANopen

Milling

Industry Example

The Schleicher XCx 400 and XCx 1200 controls are used in high-performance dental milling machines, amongst other things: Dental prostheses are milled from the solid material using the utmost precision. The materials used here include ceramics, steels and types of glass. The resultant quality must meet the highest demands regarding precision:
  • µm-accurate dimensional conversion
  • The highest surface quality at very high processing velocity
  • The XCx 400, 800 and XCx 1200 controls allow the processing of very large CNC programs and data volumes.
  • Smooth communication with the CAD/ CAM system. In addition, it is very easy to combine various machines - for example, a dental mill with an optional workpiece changer.
  • Individual operating and visualisation concepts
  • Individual drive design through close collaboration with various partners
  • The integral combination of PLC and CNC guarantees (real-time) synchronous coordination of motion and secondary-unit control.
  • Interpolating axes: 5+1 or 5+2 (production & tool change)
  • Safety & accuracy of fit in the production process thanks to
  • swivel and rotary axis (360°)

Packaging

Industry Example

Package robots allow fully-automated unloading of standardised, loose packages from containers and transfer platforms. Autonomous unloading is achieved through a 3D laser scanner, which records the package locations in the interior of the container. This scanner data is transferred to the Schleicher XCA 1100 control; imaging software evaluates the data under Windows XP. The software assesses potential grab points and an associated trajectory (path curve of the robot arm). The target coordinates for the robot determined in this way are transferred to the CNC part of the same XCA 1100. Controlled by the CNC, the grabber picks up loose, cuboid packages - even from directly below the container ceiling - of various sizes and up to a weight of 31.5 kg, and places them on a conveyor belt.

If all of the packages are outside the robot's working range, the robot system, controlled by the PLC part of the XCA 1100, moves on a steerable chassis to the optimal location and continues to unload from there. The robot system uses a telescopic belt conveyor to position and transport away the packages. The system can unload 20ft and 40ft containers.

The kinematics of the package robot:
  • Definition through translatory and five rotary axes
  • The Tool Center Point (TCP) has six degrees of freedom
  • The arrangement of the main axes is comparable to a turned jointed-arm robot
  • Two rotation axes and the wrist axis, also designed to be rotatory, are mounted on a horizontally manoeuvrable translatory axis in a kinematic chain.

Handling

Industry Example

Schleicher controls guarantee smooth handling in all types of handling facilities. For example, they are used in the production of smoke alarms and fire-extinguishing units, cans for the fishing industry and by well-known packaging manufacturers.

Features:
  • Multi-axis and channel systems
  • Entire production sequences using CNC programs
  • Using this control it is possible to process, assemble, inspect and package workpieces

Advantages:
  • No manipulation of current project in the PLC
  • Easy tailoring and modification of CNC programs
  • Wide range of handling functions
  • Flexible in use

Electronics

Industry Example

Due to their thermal stability, some components cannot be subjected to wave soldering processes (displays). Due to their SMD layout, other printed boards cannot be soldered conventionally using a wave. In addition, the cost of masks for the further soldering of boards is generally too high. THT components are therefore soldered by hand. To automate this process, Schleicher relies on innovative selective soldering. (Source: www.ebso.com)
A machine was developed for this that also allows producers of small and medium-sized series with small budgets to start using this technology. The Schleicher customer thus obtained the status of world market leader.

Laser Industry

Industry Example

Schleicher is one of the most innovative suppliers of laser-control systems in the market. Our solutions can be used in many ways, such as in cutting, welding, drilling, polishing, sticking and in the labelling of materials

Features:
  • Interfaces to all the important radiation sources Trumpf©, Rofin© or IPG©
  • Flexible functions for parametrisation
  • Control of laser power synchronous with feed regulation
  • Laser pulse control with synchronous frequency to path velocity
  • Accurate power and pulse control
  • Set accurate start and end points of cuts in full servoaxis motion

Advantages:
  • Fail-safe
  • Flexible (even in the case of technical developments)
  • Accurate weld seams
  • Precise and repeatable accuracy even with fluctuating path velocity
  • Even cross-section/grid
  • Processing of very complex programs

Control-compatible interface card guarantees best performance, for example:
  • Accurate control of the widest variety of laser radiation sources
  • Highly accurate feedback from the sensor technology to the laser control
  • Laser power control synchronous with the velocity of the laser head
  • Pulse control/time measurement
  • Monitoring function for PWM signals
  • Individual configuration of location function using XSL
  • Implementation of further customer-specific features using XSL

CNC control system

The modular CNC control system effectively counteracts tolerance times in laser installations.   

Features:
  • Extremely high resolution of 1 µs at outputs to laser control
  • Very accurate positioning of switching point on the contour
  • Dynamic control of the laser: Power dependent on the course of the contours or shapes

Advantages:
  • Faster processing time
  • Shorter cycle time
  • Highly accurate space-time coordination
  • Better quality of processed surfaces and cut edges
  • High repeat accuracy

Medical Technology

Industry Example

Schleicher controls are predestined for use in medical technology: They are very precise and meet the high demands required for the production of medical devices. Adjustments are possible to meet even the most stringent clean-room classifications.

Example: Vacuum disinfection installation
Schleicher controls are used in a vacuum disinfection installation with interior disinfection. These are used in clinics, care facilities and childcare facilities. The procedure for sealing contaminated waste in PE/PA film bags is controlled. The 90-second process is started automatically on closing the lid and includes the disinfection using controlled vacuuming and welding.

Features:
  • Tested and certified to DIN EN ISO 15883-3:2006
  • High-performance touch operating terminal
  • Program display

Advantages:
  • Prevents the emergence and spreading around of germs
  • Reduced waste volume
  • Simple visual user guide
  • Display of individual program steps
 
Example: Dental mill

The milling machines with Schleicher controls are ideal for dry and wet processing of all millable materials and are therefore used worldwide in dental laboratories, milling centres and clinics.

Features:
  • Up to eight interpolating axes
  • Swivel and rotary axis turns through up to 360°
  • Fully-automated workpiece changer can be integrated

Advantage:
  • Smooth production sequence and tool change
  • Safe
  • Accurate
  • Includes implementation and adjustment services

Environmental Technolgy

Industry Example

High demands are placed on biological waste-water treatment systems. They create clean water wherever a connection to the sewer is not possible, for example in holiday complexes and in conservation areas and water reserves. The high demands placed on such small sewage treatment plants comply with Schleicher's innovative control technology.

Features:
  • Pump procedures using wear-free air lifts
  • Whisper-quiet air compressors
  • Water-level monitoring
  • Acoustic warning signals (power failure, strong water inflow)
  • Alarms via SMS possible on several saved numbers
  • Battery back-up
  • Service stations can be linked using control
  • Volumes: from single-family homes to districts

Advantages:
  • Technically reliable
  • Retains biologically-active micro-organisms
  • Can be switched remotely

Construction Machines

Industry Example

Schleicher controls meet all of the performance requirements of modern crane controls, and also include all safety functions. They are used in the construction of mobile cranes, amongst other things.

Features:
  • Automatic assembly/dismantling (within 13 minutes)
  • Monitoring of crane and safety functions
  • Control of crane and safety functions
  • Steerable vehicle axes
  • Preselectable crane configuration (assembly direction, hook height, boom position)
  • Hydraulically extendable sliding outrigger posts
  • Hydraulically controlled support cylinder
  • Automatic levelling
  • Sealed PCBs

Advantages:
  • Works independently
  • Long range
  • Quick assembly
  • Protected against tipping
  • Robust (down to -10°C, against condensation and vibration)

Marine and Offshore

Industry Example

The control is used for separators. Separators are centrifuges used for separating liquids from each other, primarily fats and oils, such as in the treatment of fuels on ships before combustion.
 
Features:
  • Compact structure in an enclosed casing
  • PLC, I/O, simple HMI
  • Extensive obsolescence management

Advantages:
  • Robust (against extended temperature range, shock loads and vibration)
  • Simple handling and installation, even in places of use that are difficult to access
  • Individual developments possible
  • Long-term availability
  • Comprehensive hardware and software maintenance