AIMS improves safety for tool manufacturers

The tool manufacturing industry embraces automation solutions at an unprecedented pace. This is a worldwide trend driven by labor shortage, increasing labor costs, the need for maximizing uptime, push for 24/7 machine availability, and customers demanding shorter lead times. Manufacturers need to be more flexible and responsive, implementing technologies such as the ANCA Integrated Manufacturing System (AIMS). AIMS is an ecosystem of individual modules – or building blocks – that can be configured to build a tailored automated tool manufacturing system. Modularity and flexibility let it cater to small and large manufacturers. The system can be designed to be very simple, using a trolley for manual pallet and tool transfer with basic enterprise resource planning (ERP) connectivity. It could also be a complex, fully autonomous production solution requiring minimal human intervention.

One noticeable component of a fully automated AIMS cell is AutoFetch – the AMR robot responsible for transferring pallets between the setting station – AutoSet – to the tool grinder. It also automatically transfers single tools for spot check measurements outside of the grinder. An AIMS cell is typically configured within a footprint of the existing factory with adjoining areas where standard, manual operations are taking place. This is a great flexibility feature but also raises many questions about how autonomous operation can function alongside the traditional production plant with frequent foot traffic.

There’s no need to fence off the AIMS area thanks to technology used with the AutoFetch robot. There are generally two types of automatic vehicles used on the factory floor – automatic guided vehicle (AGV) and autonomous mobile robot (AMR). AutoFetch is an AMR which is different from an AGV, with the main difference being how units navigate their way around the factory. An AGV always follows a predetermined route which is defined by using various guiding aids such as strips embedded in the floor, or reflectors fitted to the walls around the route. An AMR travels using sensors and a scanned map of the area. It doesn’t require any additional infrastructure to transfer material from A to B. It scans and maps the relevant area during AutoFetch setup, marks the load and unload positions, and using sophisticated algorithms the robot finds the optimal way from one point to the other.

Autonomous material transfer with AutoFetch – safety implications

A common question asked relates to AutoFetch safety, since it operates alongside factory personnel. The good news is the AutoFetch AMR is designed to safely operate in a factory environment. The AMR moves from one station to another using an optimized route, and it constantly scans the immediate area for unexpected objects. When an object is detected, AutoFetch will stop and navigate around it. An array of sensors – laser scanners, 3D cameras, and proximity sensors – are used, and for extra security, an AMR-prohibited area could be defined on the map to exclude autonomous traffic altogether. In addition, the AutoFetch can be programmed to reduce speed in certain areas and warn nearby staff with audio warnings such as beeps, horns, or pre-recorded spoken messages.

Seventy-two percent of manufacturers report accidents related to using traditional means of material transport such as pallet jacks, trolleys, or forklifts. The use of AMRs contributes to increased safety in the factory and reduced accidents due to the elimination of human factors such as fatigue, and lack of focus or awareness.

About the author: Jan Irzyk, AIMS product manager at ANCA CNC Machines, is currently focused on ANCA Integrated Manufacturing System (AIMS), driving the expansion of the ANCA portfolio with solutions in line with ANCA's innovative spirit of helping tool manufacturers maximize their outcomes and face current challenges.

ANCA CNC Machines: https://machines.anca.com