ROBOTIC SYSTEM FOR HANDLING SHEARING RAILWAY WAGONS

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ROBOTIC SYSTEM FOR HANDLING SHEARING RAILWAY WAGONS

1.0  PURPOSE OF SUPPLY

 

The scope of the supply is the realization of an automatic sheet loading system with maximum dimensions of 4000x2500x6mm taken from a “loading stacking table” and deposited on an “entry table” and an exhaust system of an assembled sheet of maximum dimensions of 25000x2500x6mm from a roller table to an unloading table.
The system is integrated into the laser cutting and welding machine and the entire cell is responsible for carrying out the operations in automatic cycle.

2.0  SUPPLY COMPOSITION

2.1 Loading station

  •  n. 1 loading stacking table
  • n. 1 Cartesian robot with 2 X and Z Cartesian axes
  • n. 1 gripper with suction cups
  • n. 1 peeling system
  • n. 1 thickness measurement system
  • n.1 command and control unit

 

2.2 Unloading station

  • n. 1 Cartesian robot with 2 X and Z Cartesian axes
  • n. 1 gripper with suction cups
  • n. 1 window position detection system
  • n. 1 control panel and remote control

3.0  DESCRIPTION OF THE SUPPLY

 

3.1 Loading station

It consists of a table fixed to the floor and levelled with adjustable feet. The support surface of the sheet pack consists of crosspieces arranged parallel and spaced so as to facilitate the entry of the blades in the event of a forklift load. On the 2 sides of the work surface there are references for the correct positioning of the sheet pack on the table.

For the picking of the sheet metal from the pack the chosen clamp is of type with tilting suckers; the quantity and dimensions of the suction cups take into account the presence of any window openings and their drawing. To measure the presence and position of the windows, a metric wheel and sensors will be used to determine the descent of the suction cups mounted on the central staples of the gripper equipped with a vertical actuating cylinder.

The Z axis arm will act supporting the gripper in a decentralized way in order to have the X axis carriage and the relative X-axis beam outside the “loading stacking table” to allow easy loading of the sheet pack even with bridge crane.

The X axis beam will be supported by 2 columns firmly grounded.

The offered system is complete with a sheet separation system, a meter for the control of the sheet thickness and plate presence probes.

The separation unit consists of a suction cup (which, with a sudden and repeated movement of lifting and descending, causes the sheet to detach from the underlying pile) by a breath of air, by the action of the magnets and brushes.

The entire system supplied will be electrically interfaced to the laser for carrying out load cycles automatically.

3.2 Unloading station

It consists of a Cartesian axis movement system, while the “roller table” and the unloading table are supplied by the laser manufacturer. Therefore, also the stopping position of the side on the roller tabke is an activity managed by the laser manufacturer; in any case, the offered system is able to unload the side panel regardless of the length and the stopping position of the side panel.

The gripper chosen is suction cups and also in this case in the design phase it was considered that a certain amount of suction cups will not come into action due to the openings made for the windows. In fact, the suction cups positioned on the central current of the clamp will be mounted on cylinders that will come into operation according to the detection of the position of the windows; the detection is obtained with a metric wheel and optical sensors positioned at the beginning of the “roller table”, coming out of the cutting and welding machine.

The gripper is divided into 2 equal sections that will be mechanically joined during installation; each section is therefore equal to a length of about 12500mm. Each of the 2 sections of the gripper has an aluminium frame made up of currents arranged parallel to each other along the longitudinal axis of the sheet to be unloaded and connected to each other by crosspieces. Appropriate sensors will be located at different points of the gripper to detect during the descent of the Z axis on the “unloading table” the assumed height of the previously unloaded sides and then determine the release height of the side in the gripper.

At the centreline of the section is located a Z axis gripper / arm interface plate with a length of 5000mm, offset towards the rear part of the clamp.

In addition to the Z-axis arm, four steel ropes with tie-rods and fixed to the Z-axis arm are used to support each gripper; therefore the gripper in its overall length is supported in 8 points (by tie-rods) in addition to the 2 main constraints of the Z axis arms.

The two Z-axis arms will then be decentralized so as to have the Y-axis wagons and the relative Y-axis beams external to the unloading table to allow easy unloading of the sheet pack even with bridge crane in compliance with the project specifications.

Each Y axis beam will be fixed to a suitably sized column and firmly secured to the ground with a support foot sufficiently lengthened and supported by tie beams joining the column itself.

The entire system supplied will be electrically interfaced to the laser for unloading cycles automatically.

4.0 TECHNICAL DATA

 

4.1 Loading

Sheets form
max. 4.000 length  X 2.500 width  X 6 height  mm

min.  1.000 length X 1.500 width  X 1 height mm

Sheet max weight 500 Kg
Sheet metal pack height in loading max.   100 mm
Entry table height 1100 mm
X axis travel   5.000 mm
Z axis travel 600 mm
Positioning repeatability 0,5 mm
Robot cycle time 90 sec. (*)

 

4.2  Unloading

Sheets form

max. 25.000 length X 2.500 width X 6 height mm

min.  4. length X 1.500 width X 1 height mm

Sheet max weight 3.000 Kg
Sheet metal pack height in unloading max. 250 mm
Roller table height 1100 mm
X axis travel  3.000 mm
Z axis travel 600 mm
Positioning repeatability 0,5 mm
Robot cycle time 80 sec.