The Machining Industry

Geoff Dawson

The Best Integrators! Creating the Best Solutions!

FANUC ASIs are the CATALYST(s) which combined with FANUC Products are………..

….with the Best Products!

Topics• Machine Tool Market • FANUC/ASI Performance• IMTS • Machine Analytics• FANUC Collaborative Robots • +HMI for CNC and Robot• Power Motion +• OneFANUC Continuous Machining Cell• OneFANUC and Rebuild/Retrofit

Machine Tool Market

Looking at 2016……….

Sales began to stabilize at a higher level starting in August prior to IMTS – Strong Nov/Dec.

Overall a slight Decline in 2016 but less than the sharp

decline of 2015.

Erratic Sales in early 2016.

Shops with 1-19 employees will spend 50% of shops with 250+ employees But, there are six times as many small shops as large shops

Per the Gardner Business Media Survey - Job Shop (1-19

employee) spending is 50% of the Large Shop (250+ employee)

spending

HMC’s and VMC’s are Forecast up.

HMC’s are typically easier machines for automation

HMC’s are the main driver of the projected increase in core machine tool spending but VMCs and EDM are also up

HMC VMC

EDM

Turning Grinders

ScrewMachines

Automotive is Forecast down after a strong 2016.

Other sectors are significantly up after being flat or negative in 2016.

October Forecast (2017) was 2.6%

+2.6+4.1 January revised to 4.1%

-17.6

2015 Oxford Forecast was 5% growth while actual was a retraction of 17.6%

-5.6

Another Successful IMTS ………………………

IMTS Robot ASI Participation

THANK YOU

Machine Analytics

Connectivity – Machine Analytics

FOCAS

Understanding Efficiency • Machine Shop had limited data on actual machine

utilization but was optimistic that the machines operate 70-90% utilization.

• Customer installs MachineMetrics, and finds out that utilization is actually 40-50%, sometimes as low as 15%.

• Customer uses this knowledge and makes the decision to purchase FANUC Robots to tend existing machines as well as additional machines.

• With the combination of transparency through the implementation of MachineMetrics and the added productivity with Robotic Machine Tending, The customer realized an increase of Utilization upwards of 80-90% thus realizing a 40% increase in efficiency.

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FANUC Collaborative Robots

CR35iA - Assist

Cooperate or……………..Collaborate?

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The robot is safe…..what now?

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+HMI for CNC and Robot

New +HMI – Robot and FA

Coming Soon – R30+B Plus New CNCAvailable on 30+-B, 31+-B5, 31+-B, 32+-B

Ease of Use - Interface (+HMI)ROBOT CNC

• Higher Speed

• High Resolution

• New Touch Screen

+HMI – Hardware

New CNC Hardware New R-30+B Plus (A cabinet)

Remote iPendant – Available Now!

View on iPad / Android Tablet CNC and Robot

in One Display via Remote iPendant

Power Motion +

Russ Jones Kyle Thornley

CNC/Robot Common Components - Robot Aux. Axis• Common Control of Single and Dual Axis FANUC Positioners• Motors and Drives can be used with Robot or Power Motion i• Simplified Mechanical Design• Single Source for Critical Components• Common Spares and Maintenance Support

FANUC RobotSingle and Dual Axis Positioners

OR

Robot Aux. Axis Package(s)

Stand Alone Aux Axis System• Dual Station Servo Controlled Robotic Welding Positioner• Rockwell Supervisory PLC w/Soft safe interlocking• Same Motors and Drives for use with Robot or Power Motion i• Commanded Positions from PLC• Modular Design allows for removal of either robot and still run system

Panel Type C

Portable iPendant

Ethernet/IP

Supervisory PLC

Cell & I/O

I/O

Work Station 1 Work Station 2Path 1 – 3 axesPath 2 – 3 axes

Stand Alone Aux Axis System – Example

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Gantry Packages• Pre-Engineered Gantry Solution• Rack & Pinion, Belt Drive, Ballscrew Drive Mechanisms• Canned PLC and iPendant Teach SW Templates• Customization available if needed• Standard Electrical Enclosure available

One FANUC Continuous Machining Cell

NEWFANUC ROBODRILL

Model α-D14MiB5

Overview

one FANUC Machining SystemNEW

FANUC ROBODRILLModel α-D14MiB5

FANUC RobotModel M10iA-12

Workpiece ProducedFANUC Robot

Model M10iA-12FANUC LR Mate

RobotModel 200iD/7WP

FANUC Power Motion iA System

one FANUC System HighlightsHigh Productivity

• Continuous Running: Robot within CNC exchanges a part while machining of other part is performed

• Tool Change: PMiA and Robot exchange tools from ROBODRILL tool turret automatically

SYSTEMCONTROLLER

PMiA

PMiA loads raw parts or tools for robot

Robot includes custom tracking software to monitor machine positions for parts exchange

ROBODRILL Custom PMC provides table X and Y positions to Robot

Main system controller provides interlock and sequence data to each FANUC unit’s controller

Robot includes two I/O connections:PLC (Adapter)ROBODRILL (Scanner)

PMiA provides motion control for the part feeder and the tool length setter.

Components include:• 3-axis gantry• 3-axis part feeder• 2-axis tool length setter• 1-axis exit conveyor

Overview

Continuous Machining Cell

Continuous Machining Cell

Continuous Machining Cell

Continuous Machining Cell

Continuous Machining Cell

Continuous Machining Cell

One FANUC Rebuild/Retrofit

Machine Tool Retrofit and Rebuilders

New FANUC CNC Controls = Like New Machine = Opportunity to Automate with Robots

Robot features available now were not available at original deployment. • Robot Model and Payloads• Vision• DCS • Ethernet I/P• Motion Products

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Success Story - Gantry Mill Project Scope: Rebuild and Retrofit the Controls and Drives on (2) 5-Axis Cincinnati Milacron Gantry Mills and replace the existing machine mounted tool changers with (2) Robotics

UPGRADES INCLUDE:

• Replace Siemens/Milacron Acramatic 950 with FANUC 31+-B5

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• Upgraded Servo System• (3) Servo Motors were added in synchronous to control

each spindle vs. the single motor and (3) gearbox mechanical solution.

• The Z axis was also upgraded with a 2nd servo and now runs synchronous.

• Allowed CNC to double the feed rates.

• The existing Tool Changer was a maintenance issue and limited to 20 tools per spindle.

• Robot cells will be more reliable• Increased capacity to 40 tools per spindle• Allowed for heavier 12” cutters removing the hazard of

manual loading

• Custom Screens for CNC and Robot operation were created.

NEW FANUC CNC Hardware(x2)• FANUC 31+-B5• (11) aiS 30/4000 HV Servo Motors• (1) aiS 40/4000 HV Servo Motor

Robotic Tool Changer (x2)• M710iC/50• R30iB Robot Controller

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Gantry Mill Project – Concept

Gantry Mill Project – As Installed

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Gantry Mill Project – As Installed

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FANUC has an extremely strong position in the CNC and Robotics industries making FANUC Products the ideal solution.

Work with your FANUC Sales Team to win competititive situations.

As FANUC ASI’s, get to know your Robotics and CNC Account Managers to identify and leverage opportunities based on your companies capabilities.

Work with your esxisting and new customers to identify FANUC controlled Machine Tools both new and existing which are good candidates for Robotic Automation.

Thank You!