Minimize set-up times with tool terminal

A tool terminal with a patented drum stores several hundred tools, eliminating the need for manual retooling. The result: up to 30 % lower set-up costs.

The majority of machine tools manufactured in Germany are exported. Customers are located in highly developed industrialized countries as well as in emerging markets. Although this means a good order situation for local machine manufacturers, it also means high competitive pressure for companies in the machining sector and precision parts production. They can only set themselves apart from the competition by processing special orders, a high degree of flexibility and years of expertise. At the same time, production costs must be kept as low as possible.

Wassermann Technologie GmbH also develops tool changing systems for machine tools, among other things, and is familiar with the challenges of the machining industry thanks to its close cooperation with well-known manufacturers such as DMG Mori and Index. That is why, after years of development work and long test phases in its own factory, the company from Eichenzell in eastern Hesse is now launching a particularly flexible tool terminal with suitable software for managing the tools.

The aim was to significantly reduce set-up times. The terminal also needed to be able to be attached to existing machine tools. This was achieved by having the software take over the control. The terminal can also process RFID data. Before a tool is placed in the terminal, it is first scanned via RFID and its specific data is recorded. The software is used to manage the tools in a database. If a specific tool is requested, it is transferred to the machine in seconds using a linear axis, including the associated data. The transfer can be made to the spindle or the machine-side tool magazine. It is important that the terminal can be loaded during machining time. This avoids downtimes; search and set-up times as well as tool set-up and preparation times are drastically reduced or eliminated completely.

The standard version of the new terminal requires a footprint of around 3 m². With an installation height of less than 3 m, transportation is made easier and the often low ceiling and door heights of production halls are taken into account. The space-saving dimensions with a high tool density are made possible by the innovative drum concept: the terminal is available with one, two or three drums. A round rack magazine without a drum is also available. Depending on the size of the individual tools, the double-drum version can hold around 450 tools as standard. With a triple drum and corresponding size, up to 1200 tool positions can be realized with an HSK 63 tool holder. Wassermann Technologie’s experience shows that on average around 300 tools are required per machine today. However, the system can be expanded and adapted to the customer’s requirements. It can also be combined with industrial robots to make handling even more flexible.

In terms of software and control technology, the terminal is available in various configuration levels: for the end user with full software and hardware, for automation specialists and machine manufacturers also without control. In the version for the end user, interfaces for peripheral devices, such as tool presetters, are also possible. A third variant is the terminal with control without software. This version is for when machines are interlinked, in which case a host computer software takes over the control.

The terminal is particularly relevant for machine tool manufacturers who use it as a direct memory. The terminal provides the machine manufacturer with a very large tool store, which replaces the previous store and provides a significantly larger number of tools for the machine. Another important aspect for the machine manufacturer is the saving in design capacity, as this is provided by Wassermann Technologie. The terminal is also particularly useful in the machining sector: There, it provides the option of upgrading the existing machine tool with the number of tools required. The complete installation and integration is carried out by Wassermann Technologie. Depending on the version, the preparation time takes about a week; another week is added for integration at the customer’s site. The implementation of older machines is also possible here. In addition to short set-up times during operation, this means that the new system is quickly ready for use. It can also be used in the automation industry, where the terminal can be used as a central memory for interlinking and transfer lines. In this case too, Wassermann Technologie supports the user with its know-how during integration.