With several die changes a day, a system of removable rails with ATI couplers results in more uptime for Tier 1 automotive supplier.

Güdel, Inc. and ATI Industrial Automation announce collaboration on transfer press systems where exchangeable transfer rails are secured by specially engineered couplers. This coupler upgrade mitigates common issues that cause other exchangeable rails to get stuck between die changes. With numerous production runs and die changes per day, this is a major productivity breakthrough for the customer.
New ATI Coupler Averts Maintenance Problems
It took collaboration between two industry leaders, Güdel and ATI, to solve one of the biggest problems with automatic die change for a world-class supplier plagued by sticking, “quick change” transfer rails. Now, with Güdel and ATI technology, changeover of the rails is a smooth operation for continuous production to avoid millions of lost dollars in downtime.

“Normally, one batch of parts runs while another is loaded for a die change,” said Joe Campbell, Vice President, Güdel. “If the rails fail to decouple properly then the machine goes down. Now, with ATI Tool Changers, changeover is fast and reliable.”

ATI is known for rigid, secure, and reliable coupling devices such as industry-leading robotic tool changers. They designed custom tool changers for Güdel transfer lines that can thoroughly withstand the high speed, high inertia loading environment that is typical with this process.

What was needed was an extremely strong coupling device that could handle the stress of the rail and die set during the exchange.” said Robert Little, CEO, ATI. The simplicity of the tool changer design was also a clear benefit over the hydraulic system previously used that required lots of preventive maintenance and caused downtime.

ATI worked closely with Güdel to make sure they designed a tool changer with an appropriate locking mechanism, alignment pins, and sensors all contained in a package that met the required space constraints, while meeting all of the loading requirements. The press rail development with Güdel is just another example of ATI’s willingness to work with the customer to make sure they create a custom solution that meets their needs.

Güdel provides the ETR (Electronic Transfer Rail) and the BDS (Blank De-stack System). All servo motions are linked with parallel operating encoders synchronized to the angle of the press. Fast and rugged, the system uses proven Güdel guideways with maintenance-free bearings and standardized parts. This eliminates service and maintenance costs for a more sustainable, cost-effective solution.

“Güdel offers many ways to optimize cycle time for press lines, and we are proud to partner with world-class suppliers like ATI to solve difficult problems like this,” said Joe Campbell, Güdel Vice President.

Güdel’s TrackMotion technology, now in its third generation, supports the new Agilus robot from KUKA. The smaller footprint of today’s TrackMotion design allows the compact KUKA Agilus robot to fit in tight spaces even while extending the robot work envelope. Midwest Engineered Systems (MWES) recently highlighted this with a machine tending application in highly restricted space. “Güdel made this easy for us,” said Vincent Panzarella, Project Manager, Midwest Engineered Systems Inc. “We were able to download 3D models of their new TMO-1-C for immediate inclusion in the system layout. We determined in advance the carriage on the rail had to be lengthened to give us enough reach.”

Güdel supports integrators with engineering services for the latest robots such as the KUKA KR AGILUS: KR 10 R100 sixx, and upon request provides robot installation with switches and support brackets, cables, energy chain, pneumatics and testing. “Gudel offers four (4) sizes of standard robot tracks, both overhead and floor mount, that cover 98% of the robot models available on the market,” noted Joe Campbell, Gudel Vice President. “When innovators like KUKA bring new robot models to market, we can quickly support them with our standard TMF and TMO product lines.”

Güdel TrackMotion TMO is the latest generation in overhead robot tracks from the world’s leader in auxiliary robot
motion. TMO innovations include higher performance and reliability, configurable and scalable designs and reduced lead times.

TrackMotion TMO is a family of overhead robot tracks built with the latest linear motion components from Güdel. There are three types of TMOs designed specifically for elevated (E), wall (W) and inverted ceiling (C) robot orientations. TMOs come in four sizes to accommodate the smallest robot up to models in the 2,500 pound range or static loads up to 5,000 pounds. TMO is rated for speeds up to 2.5 meters per second with acceleration of 2.5 m/s2. Güdel floor and overhead tracks can be used with virtually any robot brand, and can be configured in virtually any length, with multiple carriages and straight, cantilevered and bridged leg options. TrackMotion Floor (TMF) is another standard module.

Standard routing and protection solutions for cable management from TrackMotion cable carrier to robot base.

Cables for robot workcells are in constant motion and fail quickly if not properly managed which is why Güdel developed Base-RAP for TrackMotion© floor and overhead modules. If dress packs for robots are an afterthought, especially at the base of a robot, premature cable failure is virtually certain. Güdel’s Base-RAP (Routing and Protection) solution provides cable management and protection features to prevent cable problems between the energy chain of TrackMotion modules and the base of the robot.

“When considering a linear motion provider, it pays to investigate the level of support offered for cable management,” said Joe Campbell, Vice President, Sales and Marketing. “At Güdel we go the extra distance. Base-RAP is protection all the way from the cable carrier to termination points on the TrackMotion carriage and robot base.”

Key components of Base-RAP include protective cable conduit, brackets, and quick access mounting clips. Conduits are two piece split loom construction and available in several sizes to protect cables from tangling, flapping and interference with robot motion. All brackets are designed and configured to safeguard against stress and unnecessary motion, and appropriate bend radii are maintained to prevent premature cable failure. Quick access clips are designed for easy replacement of cables without special tools.

“Eighty-percent of the time, robot downtime is caused by cable failure,” said Campbell. “Base-RAP is the first standard dress-out solution to address cable management from the e-chain to the TrackMotion carriage and robot base.”

Integrators use their expertise to determine what cables and hoses are needed to fill cable carriers on TrackMotion modules. Now, with Base-RAP, integrators have the first standardized cable dress-out protection system explicitly for cable management around the robot base of linear motion devices.

For faster and very efficient handling of green tires.

Güdel’s latest innovation saves money. It enables green tires to be handled with greater speed and care by using a specially-designed tray. Due to its ingenious technology, Güdel’s new system has successfully overcome the twin problems of adhesion and rejects. Not only can the sticky green tires be offloaded more easily and without incurring any damage, the conveyor can also be operated at higher speeds.

Güdel’s new Green Tire Trays can be integrated directly into existing conveyor systems irrespective of type (i.e. roller, wide-belt or narrow-belt conveyors). These trays are distinguished by their low unladen weight, yet, at the same time, are impressively rigid and can handle tires weighing up to 30 kg and with an external diameter of up to 900 mm.

The Green Tire Trays’ integrated stiffening ribs keep distortion to an absolute minimum. In addition, these injection-moulded trays contain no impurities at all, which, on conventional conveyor systems, can sometimes have a negative impact on the quality of the tires.

The tray is tilted at 45°, which provides optimum storage with no loss of quality. The tires can be deposited very precisely indeed, thanks to the positioning accuracy of a mere 1 mm. The trays can be fitted with RFID chips, which enable individual analysis and facilitate data tracking. It goes almost without saying that the empty trays are easily stackable.

In order to make them more distinguishable when used in visual identification systems, Güdel’s Green Tire Trays are available in any colour.

Trumpf produces its own machine uprights with particularly rigid Güdel gantry axes.

At its Pasching site in Austria, Trumpf, a leading manufacturer of production engineering and medical technology, is setting up a new production complex for laser hybrid welding. Machine frames with large surface areas are produced in the machine. Güdel is providing the roboMover gantry system with dimensions of 7 x 10 x 5.6 meters.

Laser hybrid welding is a combined welding process offering the advantages of good gap bridging, simple weld preparation and concentrated heat input, deep welding penetration and high speed. The laser beam heats the surface of the workpiece in question to vaporization temperature. Thanks to the deep penetration of the vapor column, it is possible to achieve the desired welding results in the form of deep and narrow weld penetration.

The special aspect of the gantry travel path concerns the special, high rigidity of the axes. This is the only way that the laser beam can be accurately controlled. There are no vibrations in the system that might result in the laser beam being deflected. Also, the rapid change of position during the machining process and the associated vibrations have no effect on the overall system or the laser process. To achieve this, Güdel has implemented the required natural frequency of the gantry system of at least 15 Hz.

The floor axes and vertical axes work in master/slave mode. In this unidirectional operating principle, there is no mechanical connection of the drive units by a transmission shaft in which the first drive (master) controls the second (slave). High-precision planetary gearboxes from Güdel are used in all axes. The planetary gearboxes are characterized by high rigidity and power density, and ensure there is additional reliability in the application results. Güdel’s roboMover gantry system permits effective strokes of 4.6 x 6.1 and 1.85 meters.

Both the integrator Yaskawa and the end-user Trumpf were highly satisfied with the execution and installation by Güdel. The highly demanding technical requirements that had been committed to were met in full measure. In particular, the plant managers at Trumpf praised the rapid setup installation during the inauguration ceremony. In particular, Güdel’s professional approach to setting up and aligning the axes proved to be a winning formula, as well as the fact that everything worked correctly right from the first.

Following this success, Yaskawa is also planning to offer this solution to other customers. Potential applications have been identified in process applications for large workpieces in particular. In this case, Güdel systems are not restricted to welding applications. The gantry travel path is independent from the application and can also be used for milling, polishing or even gluing, to name only a few examples.

Higher speed and greater capacity for large-scale press lines.

With the launch of its second generation of roboSpeed single-arm feeders, Güdel makes the automation of industrial-scale press lines even more efficient. Used in conjunction with the intelligent GMotion control system, it increases production capacity, reduces the time spent on setting up the machinery and simplifies jig making.

The press lines have a capacity of twenty-one parts per minute. “This makes the roboSpeed the transfer system of the future for our customers. It is a very robust and compact machine that provides great flexibility in the tool room and meets every demand with regard to ease of operation”, explains Kurt Haldi, General Sales Manager for Press Automation.

The roboSpeed is used for loading the first press, unloading the last press and handling the transfer of parts from one press to another. Because the roboSpeed is particularly compact, it exploits the confined spaces of the tool room to the full. The machine is very user-friendly and designed for payloads of up to 100 kg.

At an in-house exhibition earlier this year, Güdel demonstrated the roboSpeed to a hand-picked selection of representatives from various renowned car makers and press manufacturers from Europe and Asia. Because the new transfer system was so well received, Güdel will be presenting roboSpeed to a global clientele at Euroblech, the sheet metal working exhibition, which will be held from 21st to 25th October in Hanover.

Apart from the automation of parts transfers between the presses, Güdel is also highly proficient in the other associated sub-processes and provides customised solutions for every part of the production process – from the destacking of blanks, via the press linking, through to the removal and final stacking of the finished parts.

Güdel, a leading supplier of linear, drive and system technology, has acquired Sumer, a French manufacturer of high-performance planetary gearboxes. The deal allows Güdel to extend its range of products for high-precision production processes and dynamic automation processes. The new company will operate under the name of Güdel Sumer.

For Güdel, the acquisition constitutes the perfect strategic expansion: coupled with the existing drive components, it will now be possible to provide complete function packages from a single source. From Sumer’s point of view, the take-over represents the chance to sustain the company’s development, while Güdel, using its worldwide network of companies, will be able to access new markets and create additional growth opportunities.

It is planned to increase the volume of commercial operations and expand the size of the workforce at the company’s French site in Sarlat-la-Canéda. Mr Nicolas Laval, a employee of many years’ standing, has been appointed CEO of the new subsidiary.

This acquisition sees the merger of two family-run companies that share common values, such as individual responsibility, sustainability, innovation and quality.