According to Starrag UK, there are some shining examples of UK-based companies that can harness the power of automation. Aerospace Manufacturing reports.

It is now widely accepted that automation changes rather than replaces the role of humans and, certainly in terms of metalcutting, that it effectively bridges the skills gap and enables levels of throughput that were undreamt of before the advent of bar feeds, robots, pallet systems, etc.

“But the UK is way behind the rest of the world in its uptake of automation and the bottom-line benefits that such technologies can bring,” begins Lee Scott, Starrag UK’s director for sales and applications. “Chips make money, so every level of automation that can keep machine spindles running longer should be considered. Whether that means adopting the simplest of in-machine grippers for parts handling - as used in Starrag Bumotec mill-turn machining centres, through to even the largest rail-guided systems that can handle pallets 20m long to feed Starrag’s Ecospeed-based manufacturing systems - and everything in between.

“There are some shining examples of UK-based companies that do harness the power of automation, but the number of firms in this country that are running their machines fully automatically, often 24/7, is relatively fewer compared to what’s happening in Continental Europe - as well as further afield in the far east and the USA, for example.”

Pointing out that Starrag is increasingly building global business success around its ‘systems’ expertise, Scott highlights how Starrag brand machines are sitting at the heart of a host of machining cells and systems that are running unmanned/cuttting metal around the clock. He adds that, where appropriate, Starrag has “cherry-picked automation technologies and additional machines/equipment and stirred these into the mix for seamlessly integrated and profitable systems”.

“That could well mean also embracing component washing stations, co-ordinate measuring routines and parts marking - even systems that incorporate tool regrinding; effectively machining cells that are self-calibrating. In such instances, the only human involvement may be workpiece loading and unloading.

“Crucially though, it is a case of horses for courses in determining the correct level of automation required to meet each user’s specific demands based around product quality at a prescribed throughput and piece part cost. Automation will always produce a benefit but there’s no point in over-engineering a solution that would never payback! So, Starrag works closely with customers to determine exactly what is needed and, as a result, we can accurately predict ROI.

“Also, potential users should not think that automation only best suits high-volume manufacture as there are many examples of how incredible gains are being made in small batch, variable output environments. Indeed, in many cases it could be argued that automation is the ideal complement to small batch/random manufacture.”

Software is the key

Whatever the level of automation however, it is clear that software is the key to controlling the operations – whether a one-/two-machine cell or a factory-wide flexible manufacturing system.

“In addition to working closely with third-party software specialists, Starrag has also developed its own cell controller, which is at the heart of its Integrated Production System (IPS),” adds Scott.

IPS provides a modular solution that can be aligned with specific requirements, allowing individual users to effectively select their own solutions to realise the benefits of Industry 4.0 through automating and digitising their production.

Aligning with Starrag’s claim of ‘Engineering precisely what you value’, IPS can offer functionality to meet individual tasks, including: Internet of Things (IoT): Cloud-based solutions help users analyse and optimise processes more specifically to further increase productivity; Human-Machine Interface (HMI): With touch sensors, the user interface can be used confidently on the shopfloor, even by operators wearing work gloves; Machine Production System (MPS): This monitors production in real time and protects people and the machine against incorrect operation and collisions; Efficiency control: With a number of measures (e.g. reduction in friction due to the use of high-quality drive elements and energy recovery), the holistic concept reduces energy consumption by more than 20%; Process Quality Control (PQS): A chatter monitor warns of dangerous vibrations when machining; Machine Qualification System (MQS): An integrated fingerprint module informs the user about machine condition and, where necessary, displays the corresponding maintenance instructions on the HMI.

Developed by Starrag, the cell controller monitors machines and can guide and control the entire production process - in conjunction with a higher-level ERP system where applicable. The cell controller is an ‘open’ system that can link different system components, making it a practical and cost-effective tool for customer-orientated Industry 4.0 solutions.

“IPS not only enables users to control and monitor their Starrag machines, but it also enables them to use data effectively in a networked production world,” concludes Scott. “Importantly, that also includes full part traceability which is increasingly demanded nowadays.”

www.starrag.com