Posts by seskotristan
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Gear material is different from gear to gear but the most common is 16MnCr5 with 25-30 HRC.
Accuarcy req at chamfer 1/45° is 0,2 mm and at 3/45° 0,5-0,8 mm.
Cycle times also differ from part to part (some gears have 104 teeth and module 4-small teeth some have 16 teeth and module 20-big teeth), for a gear wtih 104 teeth and module 4 our worker needs 35-40 min for bolth sides. So anything below 20 minutes (10 min each side) would be great, also a big problem with manual labor is consistency.
4 or 5 axis cnc is too expensive, and with a regular 3 axis cnc we cant reach the gear from one side because some of the gears we produce have a shaft extending from the gear's face so a 3 axis machine could not reach in most cases.
Regards
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Hey guys, we are looking for a solution for gear deburring/chamfering and the problem is that all the machines on the market (all that I have foud) do not meet our production needs and requirements. Either they chamfer the top face edge or the chamfer just isn't deep enough. The required chamfer ranges from 1/45 to 3/45 (mm/deg) depending on the gear module.
So now we are looking in to robot deburring/chamfering and I think that regular deburring spindles won't do the job when it comes to 3/45 chamfer. So if we wanted to use a hsk milling spindle with 8kW of power and 15 kg in weight im afraid that our Fanuc M710 iC50 which is 12 years old and was out of operation since 2016 won't handle well. I know there is error when you create offline programs but if we used a rotary table and the robot would basically move back and forth would that get us more accuracy or/and consistency?
Sorry for the long post guys/girls but I'm looking for a solution to this problem for the last 4 months. Really fed up with gear chamfers😂
Regards
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Try it harder. It's no problem at all to upload a .zip file.
Did it!
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I'll just send them from my computer when I get home. Since I use winrar.. 7zip is not working for me
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Yes, attach files and then somebody could translate it or you can do it yourself.
Write a program eg. TEST with the following lines:
1: ASCII_SAVE = 1
2: PAUSE
3: ASCII_Save = 0
Then run the program in manual mode untill it stops (line 2), make TP programs backup, then finish the program TEST.
And finally you have all TP programs in ascii.
Have fun!
Hey I tried but my USB port doesn't work.. I can't send the files in here because I use 7zip. Can any1 share his email so we can do this. Thanks to any1 who helps me!!
Regards
Tristan
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Thanks for the support guys! I'll try to do it by myself. But the last time I tried to backup there was some issues with USB port. If it goes well I'll let you know if not I'll send the files here.
Regards and thanks again!
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Hello guys,
so I'm finishing my school years and I need to write a diploma paper for the final exam. I would like to add all the programs to the diploma that I made durring the project. Its well over 500 lines so I would rather not retype them all.
So my question is does any1 have Roboguide so he can open .tp files and send them to me in "PC readable version". I already tried to download the 30-day trial version from MyFanuc but I haven't gotten the approval yet and I need the programs ASAP. And also our R30_iA controller is 14 years old and it doesn't have ASCII backup option unlocked.
If any1 would be so kind to do this for me, I'd owe you one
Best regards
Tristan
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Hello guys,
today I took the rs232 and usb cable (from the connectors to the board) from one r30ia controller to another, because on the second one didn't detect the usb (it was fine on "controller 1"). So I swapped just to check if it works and it did but then when I put it back to the original one (no. 1 controller), when I turned the robot on the screen on the TP went white and it said http 10.0 file not found. I fixed the situation with oppening the boot menu (after turning it on again) and select cold start. And all was good, thank good But I was wondering if any1 knows what caused this or maybe it happened to any1 before?
Thanks for all the replies in advance!
Best regards
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Hello guys, I know it's probably a basic question but still.. My project is to make a gear deburring cell with a fanuc M710, we will be using the ACF module to attach the deburring tool (biax). So the thing is we dont need an indexing table we just want to control the rpm and the rotation direction (directly from the robot if possible). On the market/web I can only find indexing rotary rables that are much more expensive than a regular rotary table should be.
So if anyone knows about a seller in EU for the kind of tables I need please reply and if anyone knows how to make one (just basics), please message me
Best regards to you all!
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Okay no problem.. Aha okay.. because at our company we use fine thread bolts from multiple directions (every 10° maybe) that are screwed in to center the gear.. and this is on a CNC for milling gears.
Thanks again and best regards!
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We have built a system that works this way, but the path for one tooth is teached the standard way.
This system was built many years ago when KRC2 where state of the art, and still works.
The gear just lies centered on the 7. axis table (very big and heavy gears, they have diameters up to 2m). The centering is done manually in less than a minute.
Before deburring the middle point between two teeths is measured with a simple inductive sensor.
The spindle is mounted on a "flexible" fixture, to egalize small variations.
Works like a charm.
And a "funny fact" about that: if deburring fails (too much metal removed) repairing the gear will cost many thousands of euros.
Okay nice to hear about something that works.. thanks a lot! And how do you center the gears manualy in under 1 min? Could you maybe share some pictures of the 7th axis (table) or what messurment tools you are using..? thanks alot to bolth of you!
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Okay so I asked with Fanuc in my country and they said that it should be possible but the accuarcy is limited to 1 pixel. So with biger teeth and small diameters it shouldnt be a problem, but with smaller teeth and big gear diameter can cause some problems due to position of the camera being far away in order to snap the whole gear.. So thanks again I'll let you know how we solved the problem!
Regards
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First, thank you for this reply! I also tought about the "easy" way first, but our customers want the gears chamferd (1-3 mm at an 45° angle). Yeah we need accuarcy around 0.2-0.4 mm and as I said the CAD models are not accurate compared to the real life gear. So I'll check with Fanuc and Yaskawa tech support team what can the systems do and what are they capable of. Btw Fanuc posted a video on this topic: (16) Robotic Cast Deburring with FANUC Robot, iRVision, Image-to-Path Software & Force Sensing - YouTube So if we try to use the same principle with gears in theory it should work right?
Best regards
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Hello,
I'm working on a robot cell for deburring gears. The cell should have 2 or 3 work tables with rotating clamps/grippers (sorry for my english on this one), then the robot will move from one table to the next and so on.. The problem at our company is that we make specific gears and shafts so not that much repetitive work (from 2 parts to 60 parts in one "serial" production). And the CAD models do not match the end product since the our customer designes all gears and then add a table with the tolerance.
So I'd like to know if it is possible to create path from laser scans or a 3D camera?
And also if that is not possible or not accurate enough I was thinking about generating robot path with a PC. So to summ my idea.. we would snap the gear from above to get the rotation data and then the robot would touch the Da and the Df of the gear and also the hight of the gear. Operator would input the other data thru HMI (module, angle alpha, ...). So in what language can we write the program on PC and how to write the program so it would compute a path for each gear and send it to the robot to execute.
Thanks to all of you in advance, this forum has been very helpfull since I started my career
Best regards
Tristan