Flexible Stocker ＜Case Study＞

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Flexibility increases productivity per square foot and leads to a reduction in headcount.

Spindle FMC

We have built a system that efficiently machines spindles and housings which are used for our various machine models. The Okuma Multus U5000 has been integrated with our stocker, allowing the system to perform with no changeover required. The integrated system resulted in a reduction of footprint and manpower, while improving cycle time and efficiency. 
A video of Spindle FMC in action can be seen below. 

Main features and specifications

Articulated robot

  • A flexible, articulated robot is used to handle different types of workpieces. Long tools are stored in the stocker, and the robot is capable to load and unload these tools from the spindle of the Okuma Multus U5000.

Multi Stocker

  • The flexible multi-stocker can handle various shapes, such as spindles and housings.

Automatic Workpiece Measuring System

  • Actual measurement of the workpiece is effective at preventing collisions after changeover. Length and diameter of the workpiece are measured with the laser sensor mounted to the robot's hand. Workpiece clamping position is also optimized.

Multi-stocker for long tools

  • Long tools can be stored in the stocker instead of the machine tool's magazine. This allows long tools to be replaced or inspected during machining, without interrupting the machine's production cycle. A single multitasking machine can preform processes being done with 5 machines.

A single multitasking machine paired with the stocker can handle processes that are normally performed with 5 machines

  • The reduction in machines allows for a reduction in the number of skilled operators required to run the operation. A single skilled operator is able to manage the system, with a 1/3 reduction in required movement; and an overall improvement in efficiency.

Stocker for different types of workpieces

  • The stocker and robot system which we incorporated flexible concept are a streamlined system that can handle different types of workpieces. Operators only need to set up daily machining schedule, workpiece and tools, and then move on to next task. 
Classification Unit Komatsu NTC Flexible Stocker & OKUMA MULTUS U5000
Workpiece type Type 84 types (Current registration number : Maximum 99 types)
Unattended operation hours Hours 21 hours/day
Workpiece changeover Times None
Workpiece length mm 320～782
Workpiece diameter mm Φ45 to Φ270 (clamping Φ230)
Long tool size mm Length = 400 to 850 / Diameter = up to Φ80
Tool weight Kg 20

Video Introduction

Komatsu NTC & Okuma Spindle FMC Automation - Case Study

The integration of the Okuma U5000 multitasking machine with our in-house designed and manufactured stocker lead to a reduction in machining time, footprint, and headcount.
(This video is available in Japanese only. Thank you for your understanding.)

　　　　　　　　　　　
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Flexible Stocker ＜Case Study＞