Automation

Gantry Automatic Part Loader

Monorail gantry style loader with a special end tool specifically designed for loading/unloading of Gleason Phoenix machines, capable of handling a wide range of parts and used in conjunction with a customer/Gleason supplied conveyor. The loader includes all equipment and software to exchange parts between a fixed position conveyor nest and the machine except for workpiece specific tooling.

Detailed Gantry Loader Description

Two-axis gantry-style mechanism. Each axis is a linear, motor-driven motion element. The vertical axis is used to pick and place parts on a conveyor. The horizontal axis is used to transport parts between the conveyor and the machine. A special end-effector (sometimes called end tool or end-of-arm tooling) is used to grip the parts, orient parts between axis horizontal and axis vertical orientations and to present either the blank or the finished part to the machine. This equipment is supported by a floor-mounted structure which extends over the machine.

The loader is located over the machine and the actions are from within its guard confines and within the rear portion of the machine, extending through the area opened by the rear door. Since the loader does not extend through the front door, it remains closed to protect the operator.

Limitations:

Workpiece weight: 23 kg
Gear outside diameter: 320 mm
Pinion shank length: 300 mm

The loader is designed to pick and place parts from a specific location relative the machine with the part axis vertical. The reference surface of the part (pinion back of head or back of gear) must be presented by the conveyor at a consistent height and within range for pickup. This elevation is for gears 750-960 mm and for pinions 750-1000 (overall length) mm.

This loader does not:
Perform any automatic tool changing functions
Align parts for slotted nosepiece arbors
Manipulate or locate parts for stock division
Interface to any other equipment other than the part conveyance

Speed

The loader is capable of exchanging parts in 25 seconds for the pinion and 29 seconds for the gear. Part-to-part tooling changeover is limited to changing the work piece specific tooling on the gripper. Within a geometrically defined part family (e.g. pinions), the changeover procedure can be accomplished in five (5) minutes by a skilled and motivated operator.

Control System

The loader is controlled by a Modicon 984 PLC control system built to the NFPA-79 specifications. The control system resides in an air-conditioned control enclosure mounted between the upright tubes of the outside leg. Operator control functions are mounted into the enclosure door. This console also includes a fault message display.

Options

To accommodate the loader the Phoenix machine must be arranged with the following options:
1. Pre-arrangement option for automatic loading of the machine (including control hardware interface & support software, workspindle flushing, documentation)
2. Rear door loader access arrangement
3. Rectangular floor plan arrangement

Conveyor Application

The loader bridges over an area behind the rear access door reserved for the conveyor. The user can use virtually any conveyor type or means desired but must conform to the pick-off position and height specified above.

Conveyor Interface

Any conveyor used in conjunction with the loader must be interfaced electrically through a pre-defined arrangement. No other standard or optional arrangement is offered by Gleason. The standard software to support the interface defines the exchange of information between the loader and the conveyor.

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