Cycle time optimized production system universal joint star<\/h1><\/div><\/div><\/div>High-precision and coolant-free production of universal joint stars \u2013 with simultaneous machining of the workpiece on both sides<\/h3><\/div><\/div><\/div><\/div><\/div>![\"HK-CON](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%271000%27%20height%3D%27800%27%20viewBox%3D%270%200%201000%20800%27%3E%3Crect%20width%3D%271000%27%20height%3D%27800%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"Kreuzgelenkstern-Anlage-HK-CON\\"")
<\/span><\/div><\/div><\/div>![\"Kreuzgelenkstern\"](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27480%27%20height%3D%27800%27%20viewBox%3D%270%200%20480%20800%27%3E%3Crect%20width%3D%27480%27%20height%3D%27800%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"Kreuzgelenkstern-Image-HK-CON\\"")
<\/span><\/div><\/div><\/div><\/div><\/div>The machine concept: Precision, speed, reliability<\/h2><\/div><\/div><\/div>During a machining cycle, two raw parts are machined simultaneously.
\nAll sides of the workpiece are machined in one system to save time.<\/p>\n<\/div>
![\"Kreuzgelenkstern\"](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27570%27%20height%3D%27478%27%20viewBox%3D%270%200%20570%20478%27%3E%3Crect%20width%3D%27570%27%20height%3D%27478%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"Kreuzgelenkstern\\"")
<\/span><\/div>Further information about workpieces<\/a><\/p>\n<\/div><\/div><\/div>![](\"https:\/\/hk-con.de\/wp-content\/uploads\/Kreuzgelenkstern-engl.webp\" "\\"Kreuzgelenkstern-engl\\"")
<\/span><\/div>PDF-Download: Cycle time optimized production system universal joint star<\/span><\/a><\/div><\/div><\/div><\/div><\/div>Suitable for<\/h3><\/div>\n- Universal Joint Stars<\/li>\n
- Threaded and offset fittings<\/li>\n
- 3- and 4-way valves<\/li>\n<\/ul>\n<\/div><\/div><\/div>
Task<\/h3><\/div>\n- Roughing the ends and tenons<\/li>\n
- Finishing the cones<\/li>\n<\/ul>\n<\/div><\/div><\/div>
Special feature<\/h3><\/div>\n- Complete cutting process in one machine<\/li>\n
- Very short processing times<\/li>\n
- Coolant-free machining process significantly increases tool life (factor\u00a02) compared to coolant-based processes<\/li>\n<\/ul>\n<\/div><\/div><\/div>
![\"HK-CON](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%272138%27%20height%3D%271509%27%20viewBox%3D%270%200%202138%201509%27%3E%3Crect%20width%3D%272138%27%20height%3D%271509%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"Anlage-Achsen\\"")
<\/span><\/div><\/div><\/div><\/div><\/div>![\"Bearbeitungsraum](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27800%27%20height%3D%27450%27%20viewBox%3D%270%200%20800%20450%27%3E%3Crect%20width%3D%27800%27%20height%3D%27450%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"HK-CON-Kreuzgelenkstern-Bearbeitungsraum\\"")
<\/span><\/div><\/div><\/div>Equipment<\/h3>\n\n- 2 horizontal swivel axes (A1, A2) one above the other<\/li>\n
- 4 facing heads (Z1-Z4, X1-X4)<\/li>\n<\/ul>\n
Tool spindle<\/h3>\n\n- Tool holder on facing head: T-Max\u00ae P cutting head for turning<\/li>\n
- Torque: 16 Nm<\/li>\n
- Power: 8,9 kW<\/li>\n<\/ul>\n
Peripherals<\/h3>\n\n- Measuring station for 100% measurement. The component length\u00a0and the journal diameter is measured.<\/li>\n
- Robot for loading and unloading the measuring station<\/li>\n
- Step conveyor, conveyor belt and loading portal to the<\/li>\n
- Loading the machine<\/li>\n
- Loading portal with three servo axes (U, V, W axis)<\/li>\n
- Suction<\/li>\n
- Chip conveyor<\/li>\n<\/ul>\n
Machine dimensions<\/h3>\n\n- Machine tool: 4800 x 2000 mm<\/li>\n
- Machine tool incl. periphery: 6500 x 3800 mm<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
Highlights<\/h2><\/div>\n- Significantly improved tool life through dry machining.<\/li>\n
- 100 % measurement with temperature compensation and automatic measured value feedback for autocorrection.<\/li>\n
- The machine has a minimum footprint including all peripheral components.<\/li>\n<\/ul>\n<\/div><\/div><\/div>
High Clocking<\/h2><\/div>\n- Two universal joint stars in 29.2\u00a0seconds each!<\/li>\n
- This results in a cycle time of 14.6\u00a0seconds per gimbal star!<\/li>\n
- Depending on the processing effort, the machine is able to achieve a cycle time of only 11.5\u00a0seconds when processing universal joint stars.\/li><\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
Experience the production line Universal Joint Star in action<\/h3><\/div>![\"YouTube-Logo\"](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27320%27%20height%3D%2772%27%20viewBox%3D%270%200%20320%2072%27%3E%3Crect%20width%3D%27320%27%20height%3D%2772%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"YouTube-Logo\\"")
<\/span><\/div><\/div><\/div> <\/div> <\/div> You are currently viewing a placeholder content from YouTube<\/strong>. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.<\/p> More Information<\/a> <\/div> Unblock content<\/a> Accept required service and unblock content<\/a> <\/div> <\/div> <\/div><\/div><\/div><\/div><\/div><\/div>Efficient loading and unloading of the machining area<\/h2><\/div>Large quantities: The assembly<\/h3><\/div><\/div><\/div>The raw parts arrive at the machine in larger quantities as bulk material<\/strong>. A lift and tilt device<\/strong> is used to load a step conveyor which places the blanks on a conveyor belt. During the infeed section on the conveyor belt, the blanks are aligned and separated at the end of the belt by two anti-cyclically operating pneumatic guide units so that they can be picked up by the robot within easy reach.<\/p>\nThrough the infeed section on the conveyor belt, the surplus workpieces are pushed onto a chain belt and guided back into the step conveyor.<\/p>\n<\/div><\/div><\/div>
![\"Fassungsverm\u00f6gen:](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27480%27%20height%3D%27300%27%20viewBox%3D%270%200%20480%20300%27%3E%3Crect%20width%3D%27480%27%20height%3D%27300%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"Stufenfoerderer\\"")
<\/span><\/div>Capacity: The step feeder<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>The conveyor belt \u2013 separation and alignment<\/p>\n<\/div><\/div><\/div><\/div><\/div>
Agile and fast: The robot arm<\/h3><\/div><\/div><\/div>A robot<\/strong> now takes over the workpiece and places it in the loading portal<\/strong>.<\/p>\nIn the system shown in the picture, a robot from ABB was used at the customer’s request: here the IRB 1200 model. This robot arm is predestined for the task with its small size and extreme maneuverability. The high speed also speaks for this model.<\/p>\n
Optionally, robots of all known manufacturers can be integrated.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Ready to be taken over by the robot<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Teamwork: robot and loading portal<\/p>\n<\/div><\/div><\/div><\/div><\/div>
No waiting times: The loading portal<\/h3><\/div><\/div><\/div>The loading and unloading process of the processing machine in combination with the measuring process of the finished workpieces is not performed by the robot<\/strong> alone. Only in combination<\/strong> with the loading gantry<\/strong> does efficient loading and unloading of the processing unit become possible: The loading gantry, which can be moved in the X, Y and Z directions, is equipped with four grippers; two parallel grippers each serve for unloading and two centric grippers for loading the machine. After the centric grippers have been loaded with the blanks, the portal moves into the machine room, where it first removes the two finished workpieces<\/strong> before inserting the blanks into the clamping devices arranged one above the other.<\/p>\n<\/div><\/div><\/div><\/span><\/div>A firm grip: centric gripper for raw parts<\/p>\n<\/div><\/div><\/div><\/div><\/div>
Quality with 100 % testing<\/h2><\/div>Double sided double pack: The 2 x 2 processing<\/h3><\/div><\/div><\/div>The machining process<\/strong> starts while the loading gantry with the two finished parts travels to the measuring station and transfers the parts there directly. The robot<\/strong> then loads the loading portal<\/strong> with two new blanks.<\/p>\nHK-CON relies on “interrupted” machining to compensate for any minimal shifts in the zero point that may occur due to the large machining forces during roughing: First, the face and diameter of pins 1 and 3 are simultaneously roughed. Then the star is rotated by 90\u00b0 to rough the face and diameter of pins 2 and 4 and then finish directly. Finally, the star is rotated by 90\u00b0 once again – cones 1 and 3 are now finished.<\/p>\n<\/div><\/div><\/div>
![\"Planschieber:](\"data:image\/svg+xml,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%27480%27%20height%3D%27545%27%20viewBox%3D%270%200%20480%20545%27%3E%3Crect%20width%3D%27480%27%20height%3D%27545%27%20fill-opacity%3D%220%22%2F%3E%3C%2Fsvg%3E\" "\\"Planschieber\\"")
<\/span><\/div>Facing slide with tool<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Finishing the rough-machined tenons<\/p>\n<\/div><\/div><\/div><\/div><\/div>
The finished workpieces: Removal and measuring station<\/h3><\/div><\/div><\/div>The robot removes the finished workpieces from the measuring device – while the next unmachined parts to be processed go into machining – and places them on the parts chute.\u00a0The measuring device is an in-house development.<\/p>\n
Measurement 1:<\/strong>
\nIn combination with a measuring computer (Marposs, Promess or other manufacturer), the two last machined journal diameters and the total length of the finished part are measured 100 percent.<\/p>\nMeasurement 2:<\/strong>
\nSince the universal joint stars are machined dry, the finished parts have an increased temperature during measurement. This is recorded by a thermocouple integrated in the measuring station in order to calculate the exact measured value via temperature compensation. In addition to the output “ok” and “n.ok”, the
\nthe measuring computer returns the data to the machine, which automatically makes the necessary tool corrections.
\nThe values on which the correction is based are regularly compared with the reference values of a setting master.<\/p>\n<\/div><\/div><\/div><\/span><\/div>Checking the dimensional accuracy<\/p>\n<\/div><\/div><\/div>
<\/span><\/div><\/div><\/div><\/div><\/div>Tested and found to be good: The withdrawal<\/h3><\/div><\/div><\/div>The robot unloads all “OK” finished parts according to the PLC command on the parts chute<\/strong> to a turntable<\/strong>.
\nAll “not OK” parts are collected separately.<\/p>\n<\/div><\/div><\/div>
High-precision and coolant-free production of universal joint stars \u2013 with simultaneous machining of the workpiece on both sides<\/h3><\/div><\/div><\/div><\/div><\/div><\/span><\/div><\/div><\/div><\/span><\/div><\/div><\/div><\/div><\/div>The machine concept: Precision, speed, reliability<\/h2><\/div><\/div><\/div>During a machining cycle, two raw parts are machined simultaneously.
\nAll sides of the workpiece are machined in one system to save time.<\/p>\n<\/div>
<\/span><\/div>Further information about workpieces<\/a><\/p>\n<\/div><\/div><\/div><\/span><\/div>PDF-Download: Cycle time optimized production system universal joint star<\/span><\/a><\/div><\/div><\/div><\/div><\/div>Suitable for<\/h3><\/div>\n- Universal Joint Stars<\/li>\n
- Threaded and offset fittings<\/li>\n
- 3- and 4-way valves<\/li>\n<\/ul>\n<\/div><\/div><\/div>
Task<\/h3><\/div>\n- Roughing the ends and tenons<\/li>\n
- Finishing the cones<\/li>\n<\/ul>\n<\/div><\/div><\/div>
Special feature<\/h3><\/div>\n- Complete cutting process in one machine<\/li>\n
- Very short processing times<\/li>\n
- Coolant-free machining process significantly increases tool life (factor\u00a02) compared to coolant-based processes<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/span><\/div><\/div><\/div><\/div><\/div><\/span><\/div><\/div><\/div>
Equipment<\/h3>\n\n- 2 horizontal swivel axes (A1, A2) one above the other<\/li>\n
- 4 facing heads (Z1-Z4, X1-X4)<\/li>\n<\/ul>\n
Tool spindle<\/h3>\n\n- Tool holder on facing head: T-Max\u00ae P cutting head for turning<\/li>\n
- Torque: 16 Nm<\/li>\n
- Power: 8,9 kW<\/li>\n<\/ul>\n
Peripherals<\/h3>\n\n- Measuring station for 100% measurement. The component length\u00a0and the journal diameter is measured.<\/li>\n
- Robot for loading and unloading the measuring station<\/li>\n
- Step conveyor, conveyor belt and loading portal to the<\/li>\n
- Loading the machine<\/li>\n
- Loading portal with three servo axes (U, V, W axis)<\/li>\n
- Suction<\/li>\n
- Chip conveyor<\/li>\n<\/ul>\n
Machine dimensions<\/h3>\n\n- Machine tool: 4800 x 2000 mm<\/li>\n
- Machine tool incl. periphery: 6500 x 3800 mm<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
Highlights<\/h2><\/div>\n- Significantly improved tool life through dry machining.<\/li>\n
- 100 % measurement with temperature compensation and automatic measured value feedback for autocorrection.<\/li>\n
- The machine has a minimum footprint including all peripheral components.<\/li>\n<\/ul>\n<\/div><\/div><\/div>
High Clocking<\/h2><\/div>\n- Two universal joint stars in 29.2\u00a0seconds each!<\/li>\n
- This results in a cycle time of 14.6\u00a0seconds per gimbal star!<\/li>\n
- Depending on the processing effort, the machine is able to achieve a cycle time of only 11.5\u00a0seconds when processing universal joint stars.\/li><\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
Experience the production line Universal Joint Star in action<\/h3><\/div><\/span><\/div><\/div><\/div> <\/div> <\/div> You are currently viewing a placeholder content from YouTube<\/strong>. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.<\/p> More Information<\/a> <\/div> Unblock content<\/a> Accept required service and unblock content<\/a> <\/div> <\/div> <\/div><\/div><\/div><\/div><\/div><\/div>Efficient loading and unloading of the machining area<\/h2><\/div>Large quantities: The assembly<\/h3><\/div><\/div><\/div>The raw parts arrive at the machine in larger quantities as bulk material<\/strong>. A lift and tilt device<\/strong> is used to load a step conveyor which places the blanks on a conveyor belt. During the infeed section on the conveyor belt, the blanks are aligned and separated at the end of the belt by two anti-cyclically operating pneumatic guide units so that they can be picked up by the robot within easy reach.<\/p>\nThrough the infeed section on the conveyor belt, the surplus workpieces are pushed onto a chain belt and guided back into the step conveyor.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Capacity: The step feeder<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>The conveyor belt \u2013 separation and alignment<\/p>\n<\/div><\/div><\/div><\/div><\/div>
Agile and fast: The robot arm<\/h3><\/div><\/div><\/div>A robot<\/strong> now takes over the workpiece and places it in the loading portal<\/strong>.<\/p>\nIn the system shown in the picture, a robot from ABB was used at the customer’s request: here the IRB 1200 model. This robot arm is predestined for the task with its small size and extreme maneuverability. The high speed also speaks for this model.<\/p>\n
Optionally, robots of all known manufacturers can be integrated.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Ready to be taken over by the robot<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Teamwork: robot and loading portal<\/p>\n<\/div><\/div><\/div><\/div><\/div>
No waiting times: The loading portal<\/h3><\/div><\/div><\/div>The loading and unloading process of the processing machine in combination with the measuring process of the finished workpieces is not performed by the robot<\/strong> alone. Only in combination<\/strong> with the loading gantry<\/strong> does efficient loading and unloading of the processing unit become possible: The loading gantry, which can be moved in the X, Y and Z directions, is equipped with four grippers; two parallel grippers each serve for unloading and two centric grippers for loading the machine. After the centric grippers have been loaded with the blanks, the portal moves into the machine room, where it first removes the two finished workpieces<\/strong> before inserting the blanks into the clamping devices arranged one above the other.<\/p>\n<\/div><\/div><\/div><\/span><\/div>A firm grip: centric gripper for raw parts<\/p>\n<\/div><\/div><\/div><\/div><\/div>
Quality with 100 % testing<\/h2><\/div>Double sided double pack: The 2 x 2 processing<\/h3><\/div><\/div><\/div>The machining process<\/strong> starts while the loading gantry with the two finished parts travels to the measuring station and transfers the parts there directly. The robot<\/strong> then loads the loading portal<\/strong> with two new blanks.<\/p>\nHK-CON relies on “interrupted” machining to compensate for any minimal shifts in the zero point that may occur due to the large machining forces during roughing: First, the face and diameter of pins 1 and 3 are simultaneously roughed. Then the star is rotated by 90\u00b0 to rough the face and diameter of pins 2 and 4 and then finish directly. Finally, the star is rotated by 90\u00b0 once again – cones 1 and 3 are now finished.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Facing slide with tool<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Finishing the rough-machined tenons<\/p>\n<\/div><\/div><\/div><\/div><\/div>
The finished workpieces: Removal and measuring station<\/h3><\/div><\/div><\/div>The robot removes the finished workpieces from the measuring device – while the next unmachined parts to be processed go into machining – and places them on the parts chute.\u00a0The measuring device is an in-house development.<\/p>\n
Measurement 1:<\/strong>
\nIn combination with a measuring computer (Marposs, Promess or other manufacturer), the two last machined journal diameters and the total length of the finished part are measured 100 percent.<\/p>\nMeasurement 2:<\/strong>
\nSince the universal joint stars are machined dry, the finished parts have an increased temperature during measurement. This is recorded by a thermocouple integrated in the measuring station in order to calculate the exact measured value via temperature compensation. In addition to the output “ok” and “n.ok”, the
\nthe measuring computer returns the data to the machine, which automatically makes the necessary tool corrections.
\nThe values on which the correction is based are regularly compared with the reference values of a setting master.<\/p>\n<\/div><\/div><\/div><\/span><\/div>Checking the dimensional accuracy<\/p>\n<\/div><\/div><\/div>
<\/span><\/div><\/div><\/div><\/div><\/div>Tested and found to be good: The withdrawal<\/h3><\/div><\/div><\/div>The robot unloads all “OK” finished parts according to the PLC command on the parts chute<\/strong> to a turntable<\/strong>.
\nAll “not OK” parts are collected separately.<\/p>\n<\/div><\/div><\/div>
![\"HK-CON](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Kreuzgelenkstern-Anlage-HK-CON.jpg\" "\\"Kreuzgelenkstern-Anlage-HK-CON\\"")
<\/span><\/div><\/div><\/div>![\"Kreuzgelenkstern\"](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Kreuzgelenkstern-Image-HK-CON.png\" "\\"Kreuzgelenkstern-Image-HK-CON\\"")
<\/span><\/div><\/div><\/div><\/div><\/div>The machine concept: Precision, speed, reliability<\/h2><\/div><\/div><\/div>During a machining cycle, two raw parts are machined simultaneously.
\nAll sides of the workpiece are machined in one system to save time.<\/p>\n<\/div>
<\/span><\/div>Further information about workpieces<\/a><\/p>\n<\/div><\/div><\/div><\/span><\/div>PDF-Download: Cycle time optimized production system universal joint star<\/span><\/a><\/div><\/div><\/div><\/div><\/div>Suitable for<\/h3><\/div>\n- Universal Joint Stars<\/li>\n
- Threaded and offset fittings<\/li>\n
- 3- and 4-way valves<\/li>\n<\/ul>\n<\/div><\/div><\/div>
Task<\/h3><\/div>\n- Roughing the ends and tenons<\/li>\n
- Finishing the cones<\/li>\n<\/ul>\n<\/div><\/div><\/div>
Special feature<\/h3><\/div>\n- Complete cutting process in one machine<\/li>\n
- Very short processing times<\/li>\n
- Coolant-free machining process significantly increases tool life (factor\u00a02) compared to coolant-based processes<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/span><\/div><\/div><\/div><\/div><\/div><\/span><\/div><\/div><\/div>
Equipment<\/h3>\n\n- 2 horizontal swivel axes (A1, A2) one above the other<\/li>\n
- 4 facing heads (Z1-Z4, X1-X4)<\/li>\n<\/ul>\n
Tool spindle<\/h3>\n\n- Tool holder on facing head: T-Max\u00ae P cutting head for turning<\/li>\n
- Torque: 16 Nm<\/li>\n
- Power: 8,9 kW<\/li>\n<\/ul>\n
Peripherals<\/h3>\n\n- Measuring station for 100% measurement. The component length\u00a0and the journal diameter is measured.<\/li>\n
- Robot for loading and unloading the measuring station<\/li>\n
- Step conveyor, conveyor belt and loading portal to the<\/li>\n
- Loading the machine<\/li>\n
- Loading portal with three servo axes (U, V, W axis)<\/li>\n
- Suction<\/li>\n
- Chip conveyor<\/li>\n<\/ul>\n
Machine dimensions<\/h3>\n\n- Machine tool: 4800 x 2000 mm<\/li>\n
- Machine tool incl. periphery: 6500 x 3800 mm<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
Highlights<\/h2><\/div>\n- Significantly improved tool life through dry machining.<\/li>\n
- 100 % measurement with temperature compensation and automatic measured value feedback for autocorrection.<\/li>\n
- The machine has a minimum footprint including all peripheral components.<\/li>\n<\/ul>\n<\/div><\/div><\/div>
High Clocking<\/h2><\/div>\n- Two universal joint stars in 29.2\u00a0seconds each!<\/li>\n
- This results in a cycle time of 14.6\u00a0seconds per gimbal star!<\/li>\n
- Depending on the processing effort, the machine is able to achieve a cycle time of only 11.5\u00a0seconds when processing universal joint stars.\/li><\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>
Experience the production line Universal Joint Star in action<\/h3><\/div><\/span><\/div><\/div><\/div> <\/div> <\/div> You are currently viewing a placeholder content from YouTube<\/strong>. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.<\/p> More Information<\/a> <\/div> Unblock content<\/a> Accept required service and unblock content<\/a> <\/div> <\/div> <\/div><\/div><\/div><\/div><\/div><\/div>Efficient loading and unloading of the machining area<\/h2><\/div>Large quantities: The assembly<\/h3><\/div><\/div><\/div>The raw parts arrive at the machine in larger quantities as bulk material<\/strong>. A lift and tilt device<\/strong> is used to load a step conveyor which places the blanks on a conveyor belt. During the infeed section on the conveyor belt, the blanks are aligned and separated at the end of the belt by two anti-cyclically operating pneumatic guide units so that they can be picked up by the robot within easy reach.<\/p>\nThrough the infeed section on the conveyor belt, the surplus workpieces are pushed onto a chain belt and guided back into the step conveyor.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Capacity: The step feeder<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>The conveyor belt \u2013 separation and alignment<\/p>\n<\/div><\/div><\/div><\/div><\/div>
Agile and fast: The robot arm<\/h3><\/div><\/div><\/div>A robot<\/strong> now takes over the workpiece and places it in the loading portal<\/strong>.<\/p>\nIn the system shown in the picture, a robot from ABB was used at the customer’s request: here the IRB 1200 model. This robot arm is predestined for the task with its small size and extreme maneuverability. The high speed also speaks for this model.<\/p>\n
Optionally, robots of all known manufacturers can be integrated.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Ready to be taken over by the robot<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Teamwork: robot and loading portal<\/p>\n<\/div><\/div><\/div><\/div><\/div>
No waiting times: The loading portal<\/h3><\/div><\/div><\/div>The loading and unloading process of the processing machine in combination with the measuring process of the finished workpieces is not performed by the robot<\/strong> alone. Only in combination<\/strong> with the loading gantry<\/strong> does efficient loading and unloading of the processing unit become possible: The loading gantry, which can be moved in the X, Y and Z directions, is equipped with four grippers; two parallel grippers each serve for unloading and two centric grippers for loading the machine. After the centric grippers have been loaded with the blanks, the portal moves into the machine room, where it first removes the two finished workpieces<\/strong> before inserting the blanks into the clamping devices arranged one above the other.<\/p>\n<\/div><\/div><\/div><\/span><\/div>A firm grip: centric gripper for raw parts<\/p>\n<\/div><\/div><\/div><\/div><\/div>
Quality with 100 % testing<\/h2><\/div>Double sided double pack: The 2 x 2 processing<\/h3><\/div><\/div><\/div>The machining process<\/strong> starts while the loading gantry with the two finished parts travels to the measuring station and transfers the parts there directly. The robot<\/strong> then loads the loading portal<\/strong> with two new blanks.<\/p>\nHK-CON relies on “interrupted” machining to compensate for any minimal shifts in the zero point that may occur due to the large machining forces during roughing: First, the face and diameter of pins 1 and 3 are simultaneously roughed. Then the star is rotated by 90\u00b0 to rough the face and diameter of pins 2 and 4 and then finish directly. Finally, the star is rotated by 90\u00b0 once again – cones 1 and 3 are now finished.<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Facing slide with tool<\/p>\n<\/div><\/div><\/div>
<\/span><\/div>Finishing the rough-machined tenons<\/p>\n<\/div><\/div><\/div><\/div><\/div>
The finished workpieces: Removal and measuring station<\/h3><\/div><\/div><\/div>The robot removes the finished workpieces from the measuring device – while the next unmachined parts to be processed go into machining – and places them on the parts chute.\u00a0The measuring device is an in-house development.<\/p>\n
Measurement 1:<\/strong>
\nIn combination with a measuring computer (Marposs, Promess or other manufacturer), the two last machined journal diameters and the total length of the finished part are measured 100 percent.<\/p>\nMeasurement 2:<\/strong>
\nSince the universal joint stars are machined dry, the finished parts have an increased temperature during measurement. This is recorded by a thermocouple integrated in the measuring station in order to calculate the exact measured value via temperature compensation. In addition to the output “ok” and “n.ok”, the
\nthe measuring computer returns the data to the machine, which automatically makes the necessary tool corrections.
\nThe values on which the correction is based are regularly compared with the reference values of a setting master.<\/p>\n<\/div><\/div><\/div><\/span><\/div>Checking the dimensional accuracy<\/p>\n<\/div><\/div><\/div>
<\/span><\/div><\/div><\/div><\/div><\/div>Tested and found to be good: The withdrawal<\/h3><\/div><\/div><\/div>The robot unloads all “OK” finished parts according to the PLC command on the parts chute<\/strong> to a turntable<\/strong>.
\nAll “not OK” parts are collected separately.<\/p>\n<\/div><\/div><\/div>
During a machining cycle, two raw parts are machined simultaneously.
\nAll sides of the workpiece are machined in one system to save time.<\/p>\n<\/div>
![\"Kreuzgelenkstern\"](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/08\/Kreuzgelenkstern.png\" "\\"Kreuzgelenkstern\\"")
<\/span><\/div>Further information about workpieces<\/a><\/p>\n<\/div><\/div><\/div> You are currently viewing a placeholder content from YouTube<\/strong>. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.<\/p> More Information<\/a> <\/div> The raw parts arrive at the machine in larger quantities as bulk material<\/strong>. A lift and tilt device<\/strong> is used to load a step conveyor which places the blanks on a conveyor belt. During the infeed section on the conveyor belt, the blanks are aligned and separated at the end of the belt by two anti-cyclically operating pneumatic guide units so that they can be picked up by the robot within easy reach.<\/p>\n Through the infeed section on the conveyor belt, the surplus workpieces are pushed onto a chain belt and guided back into the step conveyor.<\/p>\n<\/div><\/div><\/div> Capacity: The step feeder<\/p>\n<\/div><\/div><\/div> The conveyor belt \u2013 separation and alignment<\/p>\n<\/div><\/div><\/div><\/div><\/div> A robot<\/strong> now takes over the workpiece and places it in the loading portal<\/strong>.<\/p>\n In the system shown in the picture, a robot from ABB was used at the customer’s request: here the IRB 1200 model. This robot arm is predestined for the task with its small size and extreme maneuverability. The high speed also speaks for this model.<\/p>\n Optionally, robots of all known manufacturers can be integrated.<\/p>\n<\/div><\/div><\/div> Ready to be taken over by the robot<\/p>\n<\/div><\/div><\/div> Teamwork: robot and loading portal<\/p>\n<\/div><\/div><\/div><\/div><\/div> The loading and unloading process of the processing machine in combination with the measuring process of the finished workpieces is not performed by the robot<\/strong> alone. Only in combination<\/strong> with the loading gantry<\/strong> does efficient loading and unloading of the processing unit become possible: The loading gantry, which can be moved in the X, Y and Z directions, is equipped with four grippers; two parallel grippers each serve for unloading and two centric grippers for loading the machine. After the centric grippers have been loaded with the blanks, the portal moves into the machine room, where it first removes the two finished workpieces<\/strong> before inserting the blanks into the clamping devices arranged one above the other.<\/p>\n<\/div><\/div><\/div> A firm grip: centric gripper for raw parts<\/p>\n<\/div><\/div><\/div><\/div><\/div> The machining process<\/strong> starts while the loading gantry with the two finished parts travels to the measuring station and transfers the parts there directly. The robot<\/strong> then loads the loading portal<\/strong> with two new blanks.<\/p>\n HK-CON relies on “interrupted” machining to compensate for any minimal shifts in the zero point that may occur due to the large machining forces during roughing: First, the face and diameter of pins 1 and 3 are simultaneously roughed. Then the star is rotated by 90\u00b0 to rough the face and diameter of pins 2 and 4 and then finish directly. Finally, the star is rotated by 90\u00b0 once again – cones 1 and 3 are now finished.<\/p>\n<\/div><\/div><\/div> Facing slide with tool<\/p>\n<\/div><\/div><\/div> Finishing the rough-machined tenons<\/p>\n<\/div><\/div><\/div><\/div><\/div> The robot removes the finished workpieces from the measuring device – while the next unmachined parts to be processed go into machining – and places them on the parts chute.\u00a0The measuring device is an in-house development.<\/p>\n Measurement 1:<\/strong> Measurement 2:<\/strong> Checking the dimensional accuracy<\/p>\n<\/div><\/div><\/div> The robot unloads all “OK” finished parts according to the PLC command on the parts chute<\/strong> to a turntable<\/strong>.<\/span><\/div>Suitable for<\/h3><\/div>
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Task<\/h3><\/div>
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Special feature<\/h3><\/div>
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![\"HK-CON](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Anlage-Achsen.jpg\" "\\"Anlage-Achsen\\"")
![\"Bearbeitungsraum](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/HK-CON-Kreuzgelenkstern-Bearbeitungsraum.gif\" "\\"HK-CON-Kreuzgelenkstern-Bearbeitungsraum\\"")
Equipment<\/h3>\n
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Tool spindle<\/h3>\n
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Peripherals<\/h3>\n
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Machine dimensions<\/h3>\n
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Highlights<\/h2><\/div>
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High Clocking<\/h2><\/div>
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Experience the production line Universal Joint Star in action<\/h3><\/div>
![\"YouTube-Logo\"](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/YouTube-Logo.png\" "\\"YouTube-Logo\\""){kind=logo}
Efficient loading and unloading of the machining area<\/h2><\/div>
Large quantities: The assembly<\/h3><\/div><\/div><\/div>
![\"Fassungsverm\u00f6gen:](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Stufenfoerderer.jpg\" "\\"Stufenfoerderer\\"")
![\"Das](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Foerderband.jpg\" "\\"Foerderband\\"")
Agile and fast: The robot arm<\/h3><\/div><\/div><\/div>
![\"Fertig](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Fertig-zur-Uebernahme.jpg\" "\\"Fertig-zur-Uebernahme\\"")
![\"Teamarbeit:](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Teamarbeit-Roboter-und-Beladeportal.jpg\" "\\"Teamarbeit-Roboter-und-Beladeportal\\"")
No waiting times: The loading portal<\/h3><\/div><\/div><\/div>
![\"Fest](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Zentrischgreifer.jpg\" "\\"Zentrischgreifer\\"")
Quality with 100 % testing<\/h2><\/div>
Double sided double pack: The 2 x 2 processing<\/h3><\/div><\/div><\/div>
![\"Planschieber:](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Planschieber.jpg\" "\\"Planschieber\\"")
![\"Taktzeitoptimierte](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Schlichten.jpg\" "\\"Schlichten\\"")
The finished workpieces: Removal and measuring station<\/h3><\/div><\/div><\/div>
\nIn combination with a measuring computer (Marposs, Promess or other manufacturer), the two last machined journal diameters and the total length of the finished part are measured 100 percent.<\/p>\n
\nSince the universal joint stars are machined dry, the finished parts have an increased temperature during measurement. This is recorded by a thermocouple integrated in the measuring station in order to calculate the exact measured value via temperature compensation. In addition to the output “ok” and “n.ok”, the
\nthe measuring computer returns the data to the machine, which automatically makes the necessary tool corrections.
\nThe values on which the correction is based are regularly compared with the reference values of a setting master.<\/p>\n<\/div><\/div><\/div>![\"Masshaltigkeit:](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Masshaltigkeit.jpg\" "\\"Masshaltigkeit\\"")
![\"Messung:](\"https:\/\/hk-con.de\/wp-content\/uploads\/2020\/09\/Messung.jpg\" "\\"Messung\\"")
Tested and found to be good: The withdrawal<\/h3><\/div><\/div><\/div>
\nAll “not OK” parts are collected separately.<\/p>\n<\/div><\/div><\/div>