Perhaps this explains why users of Walter tool grinding and erosion machines, as well as its tool measurement machines, are keen adopters of automation, applying various aspects of pallet systems, auto loading/unloading by robotics and automatic wheel changers ‘within’ their machines and, as result, increase output without additional human intervention.
The use of such automation has effectively created standalone cells of sophisticated tool manufacturing and regrinding units where output is limited only by the tool storage capacity of the machines’ integral pallet systems.
An analysis of recent years’ sales by Walter Ewag UK, a member of the United Grinding Group, has revealed that from 2015 to 2019, inclusive: over 90% of its Walter Helitronic grinding machines were supplied with automatic loading systems and around a third had automatic wheel changers; all of its ‘two-in-one’ Helitronic Diamond grinding and erosion machines were supplied with automatic loading systems and two-thirds were equipped with automatic wheel changers; and 20% of the company’s Helicheck tool measurement machines incorporated robot loading.
Says Neil Whittingham, Walter Ewag UK’s sales director: “Such figures illustrate how Walter users have embraced technology for the past 15 years or so, not only to obtain increased output with fewer machine operators tending multiple machines, but also to use these automation aids to run the machines unmanned and often in lights-out mode at night.
“Additionally, they are finding that the increased production rewards far outweigh the added cost of investing in automation, in many cases achieving payback on the cost of the robots, loaders and wheel changers within months.”
A variety of loaders can be supplied as options with Walter tool grinders/erosion machines, to meet varying demands:
The Fanuc LR Mate Robot Loader can accommodate up to 7,500 tools (cylindrical) depending on diameter/type and up to seven pallets enable the ‘chaotic’ loading of a variety of tools when the optional automatic diameter detection functionality is employed.
Latest developments include a Robot Loader 25 model, capable of loading tools of up to 315mm diameter and weighing a total of up to 20kg into an HSK holder. An optional five-pallet system accommodates up to 70 tools.
The Top Loader has a pneumatic swivel arm with gripper (that integrates with Walter’s standard robot pallet system for tools up to 32mm diameter and up to 250mm long) and the two-pallet system, one each for blanks and finished tools, can each accommodate up to 500 tools (depending on size).
Based on HSK 50 interface, the automatic wheel changer can store four or eight wheels, as standard (depending on machine type), and up to 12 and 24 optional.
When used on the Walter Helicheck tool measurement machines, the Robot Loader will accommodate up to 7,500 tools and each tool is measured, recorded and separated on pallets (four as standard, optionally up to 16).
Also for use on the Helicheck PRO and PLUS machines, integrated laser marking on tool shank and end positions – coupled with cleaning via integrated air jets – also adds to the rewards and eliminates the need for a separate marking machine/handling process.
Pointing out that Walter robot technology can be integrated into manufacturing cells incorporating say, finishing stations, Mr Whittingham also highlights a plethora of Walter ‘add-on’ technology that can further improve the benefits of automation – including automatic collet changing and tool cleaning, as well as a camera vision system that automatically finds ‘veins’ and/or coolant holes on tool blanks, for highly-accurate tool positioning.
Walter Ewag UK www.walter-machines.com