the liebherr group & liebherr-verzahntechnik gmbh · 2 gantry robot lp 100 & liebherr...
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The Liebherr Group &
Liebherr-Verzahntechnik GmbH
Martin Winterstein
Director Global Market Sales and Market Service
Liebherr-Verzahntechnik GmbH
Kaufbeurer Straße 141
87437 Kempten
International Seminar on Machining Technologies
23 January 2019, Bangalore
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Agenda
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Gantry Robot LP 100 & Liebherr Manufacturing Software 4.02
Pallet Handling System PHS 1500 Allround3
Robot solution with vision system4
The Liebherr Group1
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Multifaceted Product Range
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Liebherr Group
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Top left to bottom right: Plant Kempten, Plant Collegno, Plant Ettlingen, Plant Saline
Since 1952 production of gear cutting machines
in Kirchdorf
Founding year LVT GmbH in Kempten: 1969
Productions Sites:
Kempten – Ettlingen – Bangalore (India) – Saline
(USA) – Seoul (South Korea) – Turin (Italy)
Turnover LVT / Division*
2016: 212.5 Mio. € / 219.3 Mio. €
2017: 238 Mio. €
Prime Markets
Germany & Western Europe, South Korea, USA,
China, Brazil
Number of Employees (31.12.2016)
LVT: 1,145
Worldwide: 1,353
Liebherr-Verzahntechnik GmbH
At a glance
* Konsolidated within the division
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Liebherr-Verzahntechnik GmbH
Global Presence
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Sᾶo Paulo - Brazil
Saline - USA
Moscow - Russia
Bangalore – India
Tokyo –
Japan
Shanghai – China
Seoul –
South Korea
Paris - France
Ettlingen - Germany
KemptenCollegno - Italy
Chongqing – China
Assembly / Production
Sales & Service
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Product portfolio Gear Technology Kempten
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DeburringHobbing
ShapingSkiving M/C Automation
Tools
Grinding
Gear inspection
machines and software
New business partner
for extending Liebherr
Product Portfolio
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Agenda
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The Liebherr Group1
Pallet Handling System PHS 1500 Allround3
Robot solution with vision system4
Gantry Robot LP 100 & Liebherr Manufacturing Software 4.02
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Individually configurable software packages
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Production Schedule App
Management of production orders and processes
Part Tracking App
Guarantee of reliable process
long-term logged part tracking
Production Monitoring App
Recording of production and operating data
Info Board App
Display of machine status on
large screen or on mobile end devices
Liebherr Manufacturing System LMS 4.0
Software solution for monitoring and supporting production processes
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Liebherr Manufacturing System LMS 4.0 (Video)Individually configurable software packages
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Cylinder block manufacturing, Beijing China
Highlight-Projects
OEM Automotive, China Resource: MAG IAS GmbH
Benefits
Cylinder block line with gantry robot and friction
roller conveyor (FRB)-design Liebherr
Manufacturing of friction roller conveyor by
Chinese co-operation partner locally =>
maximum cost-efficiency
Automation of all production processes by
Liebherr
Rate of production/Year: 180.000 parts (step 1)
210.000 parts (step 2)
250.000 parts (step 3)
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Agenda
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The Liebherr Group1
Gantry Robot LP 100 & Liebherr Manufacturing Software 4.02
Robot solution with vision system4
Pallet Handling System PHS 1500 Allround3
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Flexibility due to the modular concept
PHS Allround
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Compact20 % smaller footprint
compared to
PHS PRO
Both ends useable
for setting station,
machine interface
or shelf magazine
loading
Quantitiy of connected
machining centres, shelf
magazines and set-up
stations configurable
Front access for
manual loading of
the machine or
maintenance
assignments
- PHS 800 Allround (2019)
max. 800 kg / 630 x 630 mm
- PHS 1500 Allround (available)
max. 1500 kg / 800 x 800 mm
- PHS 3000 Allround (2020)
max. 3000 kg / 1250x1250 mm
Soflex PCS5 pr
PROCAM EMS
Allaround
Intelligent
Modular Dimensions
User friendly
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Touch-operation, App based
Increase of the intuitive operation – short training time and period of covational adjustment
Extending of leading functions for the operator – autopilot for necessary operating steps
Visualization of processes and procedures
Modern cell controller
PHS Allround
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Large-sized diesel engine manufacturing, Switzerland
Highlight-Projects
Lift module 1 Lift module 2
Benefits
Expansion to the longest pallet
handling system in the world in several
stages by modular system
Integration of second carriage
Transport weight up to 13,000kg
possible
Rate of production/Year:
approx. 500 parts
Max. load 13,000kg
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Agenda
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The Liebherr Group1
Gantry Robot LP 100 & Liebherr Manufacturing Software 4.02
Pallet Handling System PHS 1500 Allround3
Robot solution with vision system4
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1. Randomly arranged parts in
provided container
2. 3D image recognition system
to identify objects
3. Software identification and
selection of work piece
4. Collision detection with
possible offset
5. Intelligent gripper with
additional axes enables
collision-free removal of parts
6. Precisely positioning of work
piece at a defined location or
in a machine
Process descriptionBin Picking - Intelligent work piece handling
A complex interaction between image detection system, software and robot is
required
1. 2. 3.
4. 5. 6.
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Bin Picking - Intelligent work piece handling
Modular system
Handlingmodul (standard) Output module (customized)
Robot
Gripper Additional axis
Compensator Unit
3D–Vision system
Conveyor (optional)
Options (repacking station, …)
Basic system: 3 x 5m
Required hall hight: 4m
Supplying module (standard)
Bin size1.200x1.000x1.000mm
(LxWxHmm)
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Accurate: Laser run-time
Precise: Laser triangulation
Fast: Stereo vision triangulation
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The new intuitive operator interface (HMI)
with graphically guided programming masks
Reach the target in 3 steps:
1) Simply teaching of work pieces, gripper and grip points
2) Fast parameter adjustment
3) Simple configuration of bins
Apply teaching of work pieces, grippers and grip points
Bin Picking - Intelligent work piece handling
Operator interface
Work piece Gripper Grip point
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Bin Picking - Intelligent work piece handling
Typical cycle times - Crankshaft
Crankshaft
(~15kg)
Scan & Calculation
11.0 sec Robot movement
16.0 secCycle time
24.5 sec
Scan and calculation time are partly parallel
Exemplary cycle time for crank shaft Bin
Picking: 24,5 sec
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Bin Picking - Intelligent work piece handling
Bin Picking – Crankshaft (Video)
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Fully automatic line entrance for crankshaft loading
Bin Picking – Crankshaft
Workpiece: Crankshaft
Weight: max. 20 kg
Highlights:
AGV interface
Rotary storage system for 8
different workpiece types
Vision System for part
detection
Liebherr/Fraunhofer Software
Cycle time: 37 sec
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Flexible Manufacturing System for Transmission Case Machining Line
Turnkey System
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Transmission Case Truck
12 & 16 gear shifts
Line cycle time: 120 sec/part
Work shifts: 17/Week
Workpiece: transmission case
Highlights:
Rough Part Gripping based on ENSENSO Vision system (depalletizing)
Marking Station for part identification and tracking, RFID Chip
Part Storage Robot 7th axis, Assembly Station for RFID Chip bases on Liebherr PHS
SCADA-IPC Packages - The system solution for optimizing production by SIEMENS
JIS - just in sequence (outgoing parts in batches)
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Thank you for your attention!