Liebherr Automation Systems - ThomasNetcdn.thomasnet.com/ccp/00165308/198739.pdf · Liebherr Automation Systems 7 Liebherr gantry robots can be deployed in a variety of ways: For

Liebherr Automation SystemsInnovative solutions for your production

Liebherr Automation Systems2

Liebherr Automation Systems 3

Liebherr – Your partner for automation systems

Liebherr offers a wide range of automation systems that support modern high-efficiency production. They not only contribute to reducing production costs but also enable a fast and flexible re-sponse to fluctuations in demand from the market. Economy, user friendliness, quality and reliability as well as a high level of flexibility are at the forefront.

The range of products comprises robotic palletisers, conveying sys-tems, storage systems, pallet handling systems and robot integra-tion. The use of modular systems with high quality components as well as a brond knowledge of the demands of manufacturing pro-duction systems mean that a high level of availability is assureed.

As a general contractor or in conjunction with well-known machine manufacturers, Liebherr automates production lines, highly effi-cient production cells for processing centres, standalone systems and integrates production-relevant additional equipment.


Economical Automation Solutions

Pallet Handling Systems Page 14

Gantry Robots Page 6

Storage SystemsPage 12

Conveying Systems Page 8


Additional equipment Page 18

Robot integration Page 16

Hardware and Software Page 20

Service and Locations Page 22



Liebherr gantry robots can be deployed in a variety of ways: For transporting, palletising, goods handling, loading and unloading or storing. Linear gantry robots are available in five sizes and gantry robots with layer pickup available in three sizes for workpiece weights of 0.5 kg to 1,500 kg solve a wide range of automation tasks. For all sizes, Liebherr of-fers a modular system with which the automation system can be adapted to the respective application, e.g. cylinder head, engine block or gearbox manufacturer.

LPR 200LP 200PP 10 LP 2000

Gantry Robots

Gantry robots Workpiece weight (kg) Transport load (kg)

LP 10 0,5 - 10 40

LP 20 10 - 40 160

LP 200 40 - 250 600

LP 2000 250 - 600 1,500



Conveying Systems

Plastic chain conveyor (KKB)Plastic chain conveyors from Liebherr are designed to trans-port any number of irregularly shaped workpieces without them coming into contact with each other. Transportation of the workpieces on pallets. Due to the linear effect they can be operated independently of cycles.

Pallet accumulating conveyor Plastic chain conveyor

Liebherr conveying systems are adapted not only to the shape, position, weight and size of parts but to the material as well. Standardised assembly groups provide an ideal enhancement to the programe.

Pallet accumulating conveyor (PSB)Pallet accumulating conveyors also serve to transport any number of irregularly shaped workpieces without them coming into contact with each other. Here, too, transporta-tion of the workpieces is on pallets. Due to the linear effect they can be operated independently of cycles. Return of the pallets is on the underside of the conveyor to save space.


Conveying Systems

Timer chain conveyor (TKB)Timer chain conveyors serve to trans-port parts on workpiece carriers. These are permanently joined to the drive chain and are conveyed depending on the cycle.

Hinged chain conveyor (SKB)With the aid of hinged chain conveyors, it is possible to transport workpieces with a flat surface, e.g. gear wheels. Depending on the scenario, multi-track versions are also possible. By joining individual belt sections, hinged chain conveyors can be extended to any length. Due to the linear effect they can also be operated independently of cycles.

Tooth chain conveyor (ZKB)Tooth chain conveyors transport work-pieces that do not have a flat surface, e.g. those with journals or shoulders. By joining individual belt sections, tooth chain conveyors can be extended to any length independently of cycles.


Accumulating conveyor (SFB)With accumulating conveyors, it is pos-sible to transport workpieces either directly or on pallets. By joining individ-ual belt sections, the transport length can be extended according to require-ment and, furthermore, accumulating conveyors operate independently of cycles.

Drag frame conveyor (SRB)Drag frame conveyors serve to transport parts with a flat surface, e.g. gear wheels, hubs or rings. The workpieces are dragged by a frame that is connected to a chain. Transportation is either directly on the transport conveyor or indirectly via workpiece carriers. The prism-shaped mountings mean that, gen-erally, no interchange parts are nec-essary.

Friction roller conveyor (FRB)With friction roller conveyors, workpieces can be transported directly or on pallets. In this case, the transport length can be extended as required by joining individ-ual conveyor sections. Due to the linear effect they can be operated independent-ly of cycles. The friction method means that the transport surface on the work-piece is not damaged.



Storage Systems

Palletizing cell (LPC) The palletizing cell is the basic module for realising an ultramodern production system. Standardised transport containers with basket technology facilitate a uniform ap-proach to logistics as well as flexible future-orientated pro-duction.

Shelf magazine system The shelf magazine system combines fixed workpiece sup-ports with a robotic palletiser system. Here, the shelf maga-zine can be loaded either from the top or from the side. Debonding to the modular design, the overall system can be extended and, depending on the layout, enables storage based on the principle of "first in – first out".

Storage systems for workpieces can be deployed in a variety of ways: whether for decoupling on a production line, as a loading and unloading system or as a classic logistics module with storage functionality.

Decoupling module (EKM)The decoupling module serves as a means of storing and decoupling on flexible production lines. It features a high storage capacity with small surface area requirement and is suitable for a very wide range of workpieces and pro-duction concepts. The workpieces are placed on pallets in the decoupling module and made available via pull-out mechanisms for the robotic palletisers or robot systems to allow loading and unloading. A manual loading and unload-ing drawer for gauging parts for Statistical Process Control (SPC) can be included if required. This draw also allows for easily extracting and reintroducing of parts in and out of the system. The integrated control system with standardized software reduces commissioning times.

Shelf magazine system Magazine with indexing chain conveyor Decoupling module


Pallet Handling Systems

Liebherr pallet handling systems are deployed to automate process-ing centres in the area of individual part production and small series production. The basis is a work-piece clamped on a machine pal-let. An intelligent overall concept, which includes retooling during main operation as well as resource and work order scheduling, in-creases productivity and thereby reduces the unit labour costs. Pal-let handling systems from Liebherr are offered in two versions: rotation loading system (RLS) or a linear loading system (PHS). Both ver-sions are modular in design and can therefore be adapted to the re-spective requirements of the pro-duction concept.

Pallet handling system (PHS)On the linear-type pallet handling system, the number of connected machines can vary depending on requirement as, too, can the setting-up and storage ar-eas. With the means to extend the system with unprocessed and finished part management on material pallets, all of the requirements of a modern production system can be covered. The linear system is made in three construction sizes for transport loads of 500 kg to 6,500 kg.

Standard setup station Special refrigerator application Mobile setup station


Rotary loading system (RLS)Rotary loading systems from Liebherr are distinguished by their high storage depth in relationship to its footprint and are designed for one or two machining centers. In combination with the Liebherr rotation storage tower (RTS), the storage ar-eas can be configured individually to meet specific needs. The rotary loading system is available in two construction sizes and is designed for transport loads from 800 kg to 1,500 kg.

Pallet handling system Workpiece diameter (mm) Transport load (kg)

PHS 750 1,000 500 / 700 / 1,000

PHS 1500 1,150 / 1,700 1,500 / 2,000 / 2,500

PHS 3500 1,900 / 2,400 3,500 / 5,000 / 6,500

Rotation loading system Workpiece diameter (mm) Transport load (kg)

RLS 800 600 / 800 800

RLS 1500 900 / 1,300 1,500



Flexible robot systems and deployed to load and unload workpieces in produc-tion environments. Here, all well-known robots manufacturers can be utilized. In addition to numerous standard applications, the special "random bin pick-ing" area is included in Liebherr's range. Thanks to Liebherr developed software along with a vision system, it is possible to reliable remove random parts from a container.

Robot IntegrationRequirements

Object identification and selection Collision-free withdrawal of parts Object positioning

"Random bin picking""Random bin picking" substitutes complicated sorting systems, height-ens productivity and relieves the strain on personnel. Unloading workpieces from a parts container is a complex interaction between image detection system, software and robot. Based on

the range of parts, all process-relevant steps have to be adapted to each other in such a way that optimum withdrawal and positioning is achieved.

Optical data collection and evaluation


Additional Equipment

To set-up production lines in order that complicated tasks can be solved, Liebherr supplies not only the basic products but also all requisite ancillary equipment, e.g. for labelling, detection by camera systems, orientation or the centrifuga-tion of oil-coated parts and discharge of measured parts (SPC station).

Static process control (SPC)The statistical process control is a fixed element of any pro-duction line in modern production systems. Liebherr supplies these modular-based stations for discharge and inclusion.

Orientation stationModern production machines require that workpieces are loaded with the correct orientation. If the loading system is incapable of doing this, Liebherr offers ancillary orientation stations.

Camera systemsWith the aid of camera systems, labels and codes on the workpieces can be read and their information transferred to higher lever production management systems.

Static process control (SPC)


Centrifugal stationTo prevent the displacement or mixing of cooling lubricants, it is necessary for the workpieces to be cleaned automati-cally. Depending on the needs of the customer and the workpiece, different processes are employed. The most common processes are: centrifugation, vacuum or draining stations.

Labelling systemsWith the high quality labelling systems offered by Liebherr, digital combinations or codes can be lasered, etched or en-graved with needles on the workpiece.

Centrifugal station Data matrix code (DMC)

PR 11

IF (R350>0) AND (R21==3)

IF (R21>1) AND (R41>1)

IF (R351>0) AND (R41==1)

IF (R352>0) AND (R41==1)

req. to load/unload MC

load FIFO ready and GR1

clamped

GR 1 and GR2 clamped

unload FIFO ready and GR2

unclamped

anticipation FIFO ready and GR2 unclamped

req. to scan Part DMC-code

Next Page

R350==1 SV_M1_C1R350==2 SV_M2_C1R350==3 SV_M3_C1R350==4 SV_M4_C1




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X150-Port1X150-Port2

X130-Port

X127-Port

X120-Port

DP/MP1

DP


Hardware and Software

Customer-specific complete solution based on modular system The comprehensive modular hardware and software build-ing block system ensures continuity between a mechanical function and the hardware and software functions neces-sary to achieve this. Tested software modules with a func-tional description are configured as a complete solution according to the functions necessary for the process. Even before the purchase order is awarded, a detailed customer-specific process description is created (sequence of opera-tion – SoO).

Representation of flow chart Complex processes are also visualized in flow charts and then implemented accordingly.

Control structure

HT8 Distribution Box

Flow diagram

GANTRY

LOADING HATCHLOADING HATCH

MACHINE 01 MACHINE 02 ElectricalCabinet

ElectricalCabinet

ElectricalCabinet

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔


Additional software enhances process safety Complex production systems require a universal intelligently conceived system. With the Liebherr Manufacturing System (LMS), Liebherr offers user-friendly ancillary software that safeguards the process safety on a production and assem-bly line. The LMS is capable of logging a temporary retrac-ing of parts as well as securing specific data and making this available to all users participating in the system. The system offers a range of assessments and can be deployed, for ex-ample, so that correct adherence of the production process can be monitored.

Liebherr Manufacturing System (LMS)

Standardized interface With a standardized software interface, a wide variety of processing machines can easily be integrated, allowing then for shorter commissioning times and full production at launch. Production scheduling, trouble free operation and minimezed maintenance are realized throughout the entire product life cycle.

Interface definition

OP10E OP20E OP10W OP20W OP30E OP30W OP40 OP50E OP60E OP50W OP60W

Check part status

Write process data

Write history data

OP10_20EIP: 10.103.0.11

Port: 4001

OP10_20WIP: 10.103.0.21

Port: 4002

OP35_EWIP: 10.103.0.31

Port: 4003

OP50_60EIP: 10.103.0.41

Port: 4004

OP50_60WIP: 10.103.0.51

Port: 4005



The Liebherr Automation Service has its headquarters in Kempten (Germany), and has a network of Liebherr service centres around the world. The experts who man the cus-tomer hotline provide professional first-aid should help be needed. Included in the services offered are the provision of spare parts, inspections, maintenance or modifications to systems. Since the products have a universal modular de-sign, rapid provision of spare parts is assured, which means that periods of downtime are kept to a minimum. Thanks to the use of commercially-available components, such as drive and control systems, a high level of availability for the whole system is assured.

Service and Locations

Liebherr-Verzahntechnik GmbHWerkzeugmaschinen, AutomationssystemeKempten (Germany and Europe)

Liebherr Automation Systems Co.Saline, Michigan (USA)

Liebherr Brasil Ltda.Guaratinguetá / SP (Brazil and Mexico)

Liebherr Machinery Service Co. Ltd.Shanghai (China)

Liebherr-Russland OOO1 Borodinskaja Str. 5Moscow(Russia)

Liebherr automation systems are designed to be particularly maintenance-friendly. All necessary lubrication points are supplied from a central lubrication system that, as with all pneumatic components and bus modules, can be found on an easily accessible maintenance unit.

Kempten

Shanghai

Saline

Guaratinguetá

Moscow

Liebherr-Verzahntechnik GmbHWerkzeugmaschinen, AutomationssystemeKaufbeurer Straße 141, 87437 Kempten, Deutschland +49 (0)831 786-0, Fax +49 (0)831 786-1279www.liebherr.com, E-Mail: [email protected]

Machine tools and automation systems from Liebherr

Liebherr-Verzahntechnik GmbHWerk EttlingenVerzahnwerkzeugeHertzstraße 9-1576275 Ettlingen, Deutschland +49 (0)7243 708-0Fax +49 (0)7243 [email protected]

Liebherr-Utensili S.r.l.VerzahnwerkzeugeVia Nazioni Unite 1810093 Collegno TO, Italien +39 (0)114 248711Fax +39 (0)114 [email protected]

Liebherr-Gear Technology Inc.WerkzeugmaschinenLiebherr Automation Systems Co.Automationssysteme1465 Woodland DriveSaline, MI 48176-1259, USA +1 7344 297225Fax +1 7344 [email protected]

Liebherr-Machine Tools India Pvt. LtdWerkzeugmaschinen353/354, 4th Main, 9th Cross, 4th PhasePeenya Industrial AreaBangalore - 560 058, Indien +91 (0)80 41 273033Fax +91 (0)80 41 [email protected]

With about sixty years of industrial experience, Liebherr is one of the world's leading manufacturers of CNC gear cutting machines, gear cutting tools and automation sys-tems. The company's innovative products are the result of pioneering ideas, highly qualified staff and state-of-the-art manufacturing systems at each of their locations. They are characterised by economy, ease of use, quality and reliabil-ity in combination with a high degree of flexibility.

High quality gear cutting toolsLiebherr manufactures high quality, precision tools for the soft and hard machining of gears and all Liebherr gear cut-ting machines are fitted with Liebherr tools. The range also includes Lorenz bearing tools and products customised for specific customer applications.

Automation systems for a broad range of applicationsLiebherr has a wide range of products for linear portals, pallet-handling systems, conveyor systems and robot in-tegration for projects in all areas of production and can provide above-average availability of systems.

www.liebherr.com

System solutions in the area of machine toolsIncluded in the production programme are gear hobbing machines, gear shaping machines and hobbing and profile grinding machines, all noted for their high degree of sta-bility and availability. Liebherr can supply all technologies required for the manufacture of high quality gears and con-tinues to develop these technologies. Particular importance is attached to the energy efficiency of the machines. Gear cutting machines from Liebherr are supplied to re-nowned manufacturers of gears and gearboxes as well as large-scale slewing rings worldwide. They are in demand primarily from the automotive and construction machinery industries and also increasingly from the wind power indus-try for the manufacture of gears for wind turbines.

Liebherr employs roughly 1200 staff in the area of machine tools and automation technology and has production facili-ties in Kempten and Ettlingen (Germany), Collegno (Italy), Saline (Michigan, USA) and Bangalore (India). They are sup-ported by expert and reliable marketing and service special-ists at a large number of locations worldwide.

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Liebherr Automation Systems - ThomasNetcdn.thomasnet.com/ccp/00165308/198739.pdf · Liebherr Automation Systems 7 Liebherr gantry robots can be deployed in a variety of ways: For