Single system, double broaching: innovation in the world of keys
We have created an innovative system on behalf of one of our important customers. The analysis of broaching needs led to the identification of several specific objectives that the ACS system should have met. Firstly, the customer needed to equip himself with an automation capable of performing medium-large productions. Secondly, it required the ability to process two different broaching profiles at the same time, thirdly with the aim of increasing accuracy compared to traditional machines. In addition, the customer also requested a reduction in broach format changeover and maintenance times.
Innovative solutions towards traditional solutions
The traditional solution for ACS would have been to offer the customer two different identical and independent broaching machines. Each of these would be revised to ensure optimum accuracy and specially set up.
However, ACS took the opportunity to study an innovative solution that included a single system, capable of satisfying all customer requests. We have designed and built a system that involves the combination of two traditional broaching machines, reducing the components and therefore the overall costs. The two machines maintain processing independence, but share a single electrical cabinet and a single management software. In addition, the overall dimensions of the new system are smaller than a traditional system.
Centralized management and precision in broaching
The loading and unloading of the rotors takes place by means of a system consisting of two robots, managed by a single software and control panel. This choice made it possible to further optimize production times and costs.
The adoption of linear guides for the movement of the workpiece pallets has also made it possible to improve the accuracy of broaching processing. The linear guide system has replaced the traditional chain system thanks to an appropriate mechanical modification.
Finally, the time taken for format change and maintenance on the two broaches has been reduced to a minimum thanks to the innovation introduced in the automation system. The latter is able to work with a broaching bench, while the operator intervenes on the second broaching bench, all in complete safety.