{"id":2737,"date":"2025-06-20T20:00:16","date_gmt":"2025-06-20T18:00:16","guid":{"rendered":"https:\/\/bluejournal.schunk.com\/de\/?p=2662"},"modified":"2025-06-23T10:45:07","modified_gmt":"2025-06-23T08:45:07","slug":"a-perfect-solution-for-the-future","status":"publish","type":"post","link":"https:\/\/bluejournal.schunk.com\/en\/01-25\/a-perfect-solution-for-the-future\/","title":{"rendered":"A perfect solu\u00adtion for the future"},"content":{"rendered":"\n

Clever solu\u00adtions are some\u00adtimes needed very quickly. Solu\u00adtions like the new system from EMAG LaserTec. It applies a hard metal coating to brake disks using laser depo\u00adsi\u00adtion welding. The tech\u00adnology is urgently needed because it prevents abra\u00adsion and thus partic\u00adu\u00adlate matter from being produced during the braking process. The parti\u00adcles are hazardous to health. This is why the new Euro 7 emis\u00adsions stan\u00addard will regu\u00adlate all vehicle emis\u00adsions from newly regis\u00adtered cars from 2027 \u2013 including wear and tear from brakes and tires. So, speed is of the essence. When selecting the compo\u00adnents, the EMAG devel\u00adop\u00adment team there\u00adfore relied on SCHUNK Engi\u00adneering. Thanks to this effi\u00adcient process, EMAG was able to obtain precisely tailored compo\u00adnents for its specific require\u00adments in the shortest possible time.<\/p>\n\n\n\n

PLG long-stroke gripper on an inte\u00adgrated handling system<\/h2>\n\n\n\n

\u201cWe launched the ELC 450 LMD so that our customers can meet the require\u00adments for the brake disk of the future. It uses \u2018Laser Metal Depo\u00adsi\u00adtion\u2019 (LMD) to apply a two-layer coating to the brake disk, which makes it prac\u00adti\u00adcally imper\u00advious to wear and corro\u00adsion, while signif\u00adi\u00adcantly reducing fine dust emis\u00adsions,\u201d confirms Martin Fritz, Devel\u00adop\u00adment Team Leader at EMAG LaserTec in Heubach. \u201cSCHUNK provided us with signif\u00adi\u00adcant support in real\u00adizing the auto\u00admated compo\u00adnent feed to the laser cell in a compact and reli\u00adable process, and with a spec\u00adi\u00adfied cycle rate. The pneu\u00admatic long-stroke gripper PLG is used in conjunc\u00adtion with GFS universal swivel fingers \u2013 this is a convincing handling solu\u00adtion for us in the new machine.\u201d The EMAG design engi\u00adneers installed the long-stroke gripper on a line gantry in the ELC. \u201cWe were able to dispense with a classic robot for compo\u00adnent feeding, because there is no room for it in this cramped work\u00adspace,\u201d says Martin Fritz, explaining the ELC envi\u00adron\u00adment. \u201cThe existing linear handling from EMAG and the SCHUNK PLG gripper together with GFS swivel fingers result in ideal kine\u00admatics for the brake disk infeed and outfeed.\u201d
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\u201cSCHUNK helped us to imple\u00adment the auto\u00admated compo\u00adnent feed in a reli\u00adable, compact, and fast way.\u201d<\/p>\n\n\n\n

<\/p>\nMartin Fritz, Devel\u00adop\u00adment Team Leader at EMAG LaserTec<\/cite><\/blockquote>\n\n\n\n

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PLG with GFS feeds the brake disks into the coating cell<\/h2>\n\n\n\n

The compact loading and unloading solu\u00adtion in the work\u00adspace of the ELC 450 LMD DUO proves to be robust in the oper\u00ada\u00adtion of two laser cells. The PLG starts its work at the roller conveyor by picking up the pre-centered gray cast-iron brake disk, which weighs around 30 kilo\u00adgrams. It will have been cleaned, weighed, and preheated to about 300 degrees Celsius in upstream processes, and can be fed to the roller conveyor in manual, semi-auto\u00admated, or fully auto\u00admated mode. The PLG now guides the hori\u00adzontal disk to the mounting spindle of the first laser cell. This is where a stain\u00adless-steel corro\u00adsion protec\u00adtion layer is applied. After the hermet\u00adi\u00adcally sealed laser unit has released the disk, the PLG lifts it off the spindle and turns it using GFS swivel fingers before placing it back on the arbor. The second side of the disk receives its corro\u00adsion protec\u00adtion layer next. When the first laser station has finally released the disk, the handling system moves to the next station above the suction funnel. The disk is also turned over above the funnel, in order to vacuum it on both sides. Finally, the PLG feeds the disk hori\u00adzon\u00adtally to the second laser station, where the hard carbide layer is welded in on both sides.<\/p>\n\n\n\n

In the two cells of the ELC 450 LMD DUO, the coating mate\u00adrial is fed in as a powder and fused onto the compo\u00adnent surface by laser. After a total of four coating processes \u2013 two disk sides and two cells \u2013 the brake disk is ready to be unloaded. Inline quality assur\u00adance measures, such as a layer thick\u00adness sensor, ensure the sepa\u00adra\u00adtion of NOK parts inte\u00adgrated into the process. The PLG brings the finished coated brake disks to the exit point from the ELC work\u00adspace on the corre\u00adsponding roller conveyors for parts removal; down\u00adstream processes then take place.<\/p>\n\n\n\n

Martin Fritz, Team Leader Devel\u00adop\u00adment at EMAG LaserTec in Heubach (left), in discus\u00adsion with J\u00fcrgen Kolbus, Key Account Manager for Grip\u00adping and Automa\u00adtion Tech\u00adnology at SCHUNK.<\/figcaption><\/figure>\n\n\n\n

Defined spec\u00adi\u00adfi\u00adca\u00adtions are quickly fulfilled thanks to online config\u00adu\u00adra\u00adtion<\/h2>\n\n\n\n

\u201cOur spec\u00adi\u00adfi\u00adca\u00adtions for the gripper in this new machine concept were very clearly defined,\u201d summa\u00adrizes Martin Fritz: a long stroke for a disk-shaped compo\u00adnent with a diam\u00adeter of 250 to 500 millime\u00adters, force for a work\u00adpiece weighing around 30 to 50 kilo\u00adgrams, a grip\u00adping height of around 10 to 45 millime\u00adters, and suffi\u00adciently robust for an envi\u00adron\u00adment with residual metal dust. \u201cThe ELC\u2019s tight work\u00adspace set further constraints,\u201d says the Devel\u00adop\u00adment Team Leader. \u201cThe solu\u00adtion has got to be compact. We want the compo\u00adnent to be fed and discharged in a hori\u00adzontal posi\u00adtion, and the open gripper stroke always to move in the process direc\u00adtion. Freedom of setup across a defined range of work\u00adpieces is also a require\u00adment, because we want to be able to grip all disk sizes with just one set of jaws. We also need safety: analog moni\u00adtoring of the jaw stroke provides us with a way of knowing imme\u00addi\u00adately whether the correct work\u00adpiece is being gripped. Last but not least, swiveling should be quick.\u201d<\/p>\n\n\n\n

The bench\u00admark is scope for future devel\u00adop\u00adment<\/h2>\n\n\n\n

A sophis\u00adti\u00adcated machine concept for the brake disk produc\u00adtion of the future requires equally sophis\u00adti\u00adcated compo\u00adnents. It quickly became clear that the newly intro\u00adduced long-stroke gripper from SCHUNK was the right solu\u00adtion. \u201cConfig\u00aduring the gripper together with J\u00fcrgen Kolbus here at the desk made the work much easier, and saved a lot of time,\u201d confirms Martin Fritz. \u201cIt took only a few minutes, and we had our CAD. After less than an hour, we were able to see directly in the Design depart\u00adment whether every\u00adthing fitted.\u201d Special solu\u00adtions in indus\u00adtrial manu\u00adfac\u00adturing are often asso\u00adci\u00adated with high costs and long delivery times. SCHUNK\u2019s quickly config\u00adurable product ranges are the answer to this problem: customers receive an indi\u00advidual, afford\u00adable solu\u00adtion quickly, even for small batch sizes and high demands. The GFS swivel fingers with a swiveling time of only 0.8 seconds were the deciding factor for EMAG in choosing this solu\u00adtion: \u201cThe GFS fingers from SCHUNK were the best solu\u00adtion for the specific process,\u201d empha\u00adsizes Martin Fritz. EMAG installed the PLG with size 50 in the ELC 450 LMD DUO, and met all the spec\u00adi\u00adfi\u00adca\u00adtions with it.<\/p>\n\n\n\n

A complete, fully auto\u00admated process in the coating system takes just under four minutes. Reduced setup and idle times, 24\/7 automa\u00adtion, fast cycle rates \u2013 for EMAG, the new laser appli\u00adca\u00adtion system must meet the high quan\u00adtity require\u00adments resulting from the entry into force of the Euro 7 stan\u00addard. The PLG in combi\u00adna\u00adtion with the GFS swivel fingers signif\u00adi\u00adcantly supports this objec\u00adtive \u2013 in terms of quality, safety, and speed of the process.<\/span><\/p>\n\n\n\n

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1. <\/h2>\n\n\n\n

Grip\u00adping the brake disk<\/strong><\/h5>\n\n\n\n

The PLG\u2019s work on the inte\u00adgrated handling system starts with picking up the gray cast-iron brake disk, which weighs around 30 kilo\u00adgrams.<\/span><\/p>\n<\/div>\n<\/div>\n\n\n\n

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2. <\/h2>\n\n\n\n

Feeding to the laser station<\/strong><\/h5>\n\n\n\n

The line gantry with the PLG feeds the brake disk to the spindle of the first laser machine tool.<\/span><\/p>\n<\/div>\n\n\n\n

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3. <\/h2>\n\n\n\n

Turning the brake disk<\/strong><\/h5>\n\n\n\n

The GFS with prism jaws handle and flip over the brake disk.<\/span><\/p>\n<\/div>\n<\/div>\n\n\n\n

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4.<\/h2>\n\n\n\n

Removing the brake disk<\/strong><\/h5>\n\n\n\n

The now fully coated brake disk is lifted out at the second laser machine tool.<\/span><\/p>\n<\/div>\n\n\n\n

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What is SCHUNK Engi\u00adneering?<\/strong><\/h4>\n\n\n\n

SCHUNK Engi\u00adneering means that the experts on the customer side and from SCHUNK work together to develop new, inno\u00adv\u00ada\u00adtive, and econom\u00adical solu\u00adtions \u2013 world\u00adwide. SCHUNK accom\u00adpa\u00adnies the customer\u2019s processes right from the start in order to under\u00adstand them and opti\u00admize them through customized product devel\u00adop\u00adments. The basis for this is the exten\u00adsive compo\u00adnent port\u00adfolio along with the industry and appli\u00adca\u00adtion exper\u00adtise that has grown over decades. As a reli\u00adable partner, SCHUNK is at the customer\u2019s side from the initial inquiry, through devel\u00adop\u00adment and simu\u00adla\u00adtion, to produc\u00adtion and after-sales service. The spec\u00adtrum ranges from the customized devel\u00adop\u00adment of a single product in large quan\u00adti\u00adties to a compre\u00adhen\u00adsive, tailor-made solu\u00adtion as part of a system.<\/p>\n\n\n\n

schunk.com<\/a><\/p>\n<\/div><\/div>\n\n\n\n

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More about this topic:<\/strong>
A forward-thinking solu\u00adtion!<\/a><\/p>\n<\/div><\/div>\n\n\n\n

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Learn more:<\/strong>
Gripper config\u00adu\u00adra\u00adtion PLG<\/a><\/p>\n<\/div><\/div>\n\n\n\n

<\/p>\n","protected":false},"excerpt":{"rendered":"

MAG LaserTec uses \u201cLaser Metal Depo\u00adsi\u00adtion\u201d to apply a coating to brake disks, thereby reducing the release of fine dust. For shorter setup times and higher process reli\u00ada\u00adbility, EMAG chose the pneu\u00admatic PLG long-stroke gripper and the GFS swivel fingers from SCHUNK. SCHUNK Engi\u00adneering achieved this effi\u00adciently and precisely.<\/p>\n","protected":false},"author":2,"featured_media":2969,"comment_status":"closed","ping_status":"open","sticky":false,"template":"template-cover.php","format":"standard","meta":{"_acf_changed":false,"wp_typography_post_enhancements_disabled":false,"footnotes":""},"categories":[7,48],"tags":[],"class_list":["post-2737","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-customer-success-story","category-01-25"],"acf":[],"_links":{"self":[{"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/posts\/2737","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/comments?post=2737"}],"version-history":[{"count":10,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/posts\/2737\/revisions"}],"predecessor-version":[{"id":3063,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/posts\/2737\/revisions\/3063"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/media\/2969"}],"wp:attachment":[{"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/media?parent=2737"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/categories?post=2737"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/bluejournal.schunk.com\/en\/wp-json\/wp\/v2\/tags?post=2737"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}