SCHUNK is recognised for delivering dependable, high-precision components that meet the demands of various industries. With a commitment to quality and a focus on innovation, SCHUNK equips businesses around the world with the tools they need for efficient and effective operations, we are the one-stop-shop for your manufacturing requirements –no matter the size of your business.

Visit SCHUNK’s Stand at MachineBuilding.Live and interact with products like grippers, robot accessories as well as rotary and linear modules.

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Just a few clicks are sufficient to upload the step or STL data, design the finger and trigger the order for the additively manufactured components. What sounds simple in theory is apparently also simple in practice. Christopher Lamprecht, production planner at ROS, comes to this conclusion. “With just a little bit of background information on CAD, the program is very easy to use. It is ultimately a great modular design. You upload the step model, align it in the X, Y and Z-directions, rotate the part how you want to grip it and then the fingers are automatically adjusted. It really is child’s play,” Lamprecht highlights.

Comparable with an online photo service, the operator configures the required gripper fingers by means of a few specifications with regards to material, gripper type, installation position and finger length. Once the basic information has been entered, the tool shows the delivery date and the exact price. Upon changing the material, the price changes automatically, making it very easy to compare the available materials with each other. Using a volume-based price model, Schunk can pass the cost benefits of cumulative production directly onto its customers: the smaller the volume, the more affordable the fingers.

Significant time savings

With around 300 employees, ROS develops and manufactures highly precise tools and plants in the Coburg and Ummerstadt plants for the production of function and visible parts from the plastics Duroplast and Thermoplast. In the field of seat systems, ROS provides a comprehensive portfolio of components for headrests and seat adjustments.

Worldwide, in virtually all cars in the premium segment, guide bushings are fitted by ROS to lock the headrests. ROS is extremely open to innovative technologies like Schunk eGRIP. In two assembly plants for a Bavarian car maker, the company has fully used the potential of the 3D design tool for the first time. Within two weeks, the additively manufactured gripper fingers are on Christopher Lamprecht’s table – additively manufactured, with the contour precisely specified by him.

Almost twenty different module variants are produced on the two fully automatic machines. Each achieves an output of several hundred parts per hour. So it is worthwhile if the gripper fingers are designed so universally that no conversion is required. “By being able to additively manufacture the fingers, we always have the same gripper by which we can cover all variants. I don’t have to change any mountings and have neither maintenance nor retrofitting work. This is a huge advantage,” Lamprecht explains. With minimum effort, he adjusted the gripper fingers to the optimum contour. “All in all, the online tool has saved a great deal of work in device construction.”

From developing the idea, to the first tests, milling operations and coordination, two days would certainly have been needed, he estimates. “But with eGRIP, the effort was half an hour max.” When the fingers were delivered, they worked straight away: “You mount the jaws, teach in your point, close them and that’s it. Awesome.”

The effect of the world’s first online shop for individually designed gripper fingers is impressive. According to Schunk’s estimates, it enables the design time for gripper fingers to be reduced by up to 97%. The production and delivery time is reduced by up to 88%. In addition, the finger price is reduced by up to 50%.

A lot of variants

Eight to ten different sleeve variants can be produced for each machine today: for this, the guide bushings are separated on one linear unit and delivered suspended. A camera records the rotational position and transfers the values to the robot, which grips and places the sleeve precisely aligned on the rotary table using a multi-tooth guided Schunk universal gripper PGN-plus 64. At each station, springs, buttons and caps are then assembled.

A second robot, which is also fitted with a Schunk PGN-plus gripper, serves to discharge NIO parts. For this, secure access must be ensured, regardless of which components were fitted before and which ones were not. The gripper jaws of the two Yaskawa robots used differed accordingly.

Polyamide, aluminium or stainless steel

So that the material of the gripper fingers can be precisely adjusted for the specific application, there are three materials on offer from Schunk eGRIP: stainless steel fingers with a material density of 8 g/cm3, a tensile strength of 700 N/mm2, an elasticity modulus of 190 kN/mm2, an elongation at fracture of 34%, and a tolerance of ±0.1mm (coating thickness 30 µm) or ±0.2 mm (coating thickness 50 µm) are primarily suitable for sophisticated applications in machine manufacturing.

Fingers made of aluminium (AlSi10Mg) or polyamide 12 however show their strengths primarily in dynamic assembly applications. The latter, with a density of barely 0.9 g/cm3, are extremely lightweight, resistant to chemicals, suitable for use with food products and can also be used reliably in connection with cooling lubricants and aggressive media. Schunk also offers top jaws made of FDA-approved polyamide 12 (PA 2201) especially for use in the pharmaceutical and medical sector.

For Christopher Lamprecht, the polyamide fingers also offer additional benefits: “While until now usually conventionally manufactured aluminium fingers had been used, we chose polyamide for the additively produced fingers. This will ensure that the sleeves are handled carefully.”

With respect to the durability, Lampert is confident: “Up until now, the plastic fingers only exhibit minimal wear, which is very good news.” Looking forwards, he sees excellent implementation possibilities for the 3D printing fingers: “When we have to tightly grip difficult parts in the future, we will certainly use eGRIP again.”

Convenient operation

Schunk has provided the order process with all sorts of options: If you don’t want to order the gripper fingers immediately, you can recall the automatically saved offer later using the configuration number, continue processing it or request it via email so as to submit it to the purchasing department later. The external contour of the generated modules, consisting of gripper, top jaws, and workpiece, can also be downloaded free of charge as an STL file and used directly for the construction of the system. Follow-up orders are just as easy, because all orders can be recalled again, activated again or adjusted at any time.

The intelligent web tool, for which there is a user guidance in German and English, is available for the Schunk PGN-plus universal gripper 40 to 125 (polyamide) or PGN-plus 40 to 80 (aluminium and stainless steel), for the pneumatically controlled Schunk MPG-plus 20 to 64 small-components grippers, and for the electrically controlled 24V Schunk EGP 20 to 50 small-components grippers. Orders can also be placed from EU countries and Switzerland.

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Why is certifying individual components so important for you, when it is actually the entire automated system as a whole that has to be certified for collaborative operation?

At our current stage, a large number of users are looking into HRC although only a few applications have been implemented into operational environments so far. The topic is relatively new for all the parties involved, which includes manufacturers of robots or end-of-arm tools and sensors, users, as well as the DGUV.

Our experience shows that the path to certification can sometimes be challenging, especially for the first applications that do not have the benefit of experience. This is exactly what we are dealing with: we are supporting users with the interdisciplinary expertise of our Schunk Co-act team as well as minimizing the efforts involved in certifying entire systems with the help of our certified components.

Why is the certification process so complicated?

In order to get an entire automated system certified by the DGUV for HRC operations, it is necessary to ensure first that operators cannot be injured when it comes into contact. This is where the protection principles of DIN EN ISO 10218-1/-2 and DIN EN ISO/TS 15066 and the Machine Directive come into play, which stipulate that any hazards posed to humans and any associated risks must always be considered and assessed.

That means it is important to make a very precise assessment of factors such as: what work spaces are present? What risks are involved? Where do work spaces have to be restricted in order to prevent injuries? This is only possible if each application is considered on an individual level: each component, task, workpiece, and security system. That simply takes time and careful attention.

Are there any safety concerns or fears with regard to grippers used in HRC applications?

So far we have not come across any great fears among users concerning grippers used in collaborative applications. On the contrary, there is actually a much greater sense of curiosity and enthusiasm – especially when it comes to intelligent systems such as the SCHUNK Co-act JL1 gripper. People see their encounter with the system as playful: they intuitively test out what triggers the safety technologies and how the system behaves. They start to gain confidence, which quickly dispels any fear associated with contact.

Where does the challenge then lie?

Many aspects of human/robot collaboration are just as complex as humans themselves. Unlike conventional systems, simply meeting the standards is not enough. Firstly, standards only require that no serious injury or damage can be caused to the machine or the operator. However, this is not enough when it comes to daily use. Imagine if an HRC system were to bump into an operator 100 times a day.

Even if this did not violate any standards, the system would have no chance of being accepted. It is much more important to make people, rather than the technical system, the main focus of all the considerations. The worker has to trust the robot. The gripper has to adapt to the human – not the other way around.

Doesn’t a gripper like this reach the limits of complexity?

Complex systems do not have to seem complicated nowadays. Take the smartphone: starting around secondary school at the latest, interacting with embedded technologies comes completely naturally to children: they write messages, surf the internet, watch films, photograph notes on the blackboard, make videos of experiments, make payments, or use their phone as a calculator, timetable or school agenda.

They do all of this without thinking about how the device works. They just try out new apps intuitively, especially if their classmates show them first, and then they are practically already part of their standard app collection. This is exactly the scenario that we are pursuing with the SCHUNK Co-act JL1 gripper technology study: despite – or better yet – because of its complexity both inside and out, its use should be as intuitive as possible.

Can you describe the SCHUNK Co-act JL1 gripper safety aura in a little more detail?

The sensor technology installed in the SCHUNK Co-act JL1 gripper detects when humans are approaching and facilitates a reaction independent from the situation, without humans and robots coming into contact. It is divided up into three zones: each finger and the housing make up one zone each and can detect when a human is approaching independently of one another.

This makes it possible for instance by successively triggering the sensor system in both fingers to determine the direction the human is approaching from, and use this information to determine an evasive movement of the robot immediately. Using the freely programmable controls integrated into the gripper, the corresponding reactions can be pre-processed and sent as a signal to the PLC.

For example, it receives the command to reduce the speed by 25, 50 or 75 percent, or to stop. A pre-defined evasion strategy is even possible, as long as the direction of approach is clear. Each reaction mechanism can be defined individually and adapted to the corresponding application.

What technology is behind all of this?

Technically speaking, we use several systems in parallel: First, there is a capacitive sensor, this is, an electric field built around the gripper. As soon as something containing a lot of water enters this field, it is detected, for example a human hand. This makes it possible to distinguish between the approach of a component or another gripper, and the approach of fingers, hands or arms.

In contrast to the established options on the market for work space monitoring, which generally cover a wider area, the capacitive sensor system makes it possible to immediately detect objects within a narrow radius of 20 cm, truly getting closest to the human before ever coming into contact.

The second level is the force/torque sensors, which are installed in the flange. This registers the emergence of unexpected force effects. It detects an effective collision and stops the robot. In addition, it allows for additional functions to be realized, for example, we can determine whether a glass is full or empty. If and how workpieces are gripped. Tactile sensor systems represent the third level: Comparable with the human’s sense of touch, they sense spatially resolved individual contacts, but also large-scale pressure distributions. By means of intelligent algorithms for pattern recognition, objects are identified during the gripping process, and the grip can be reactively adjusted.

This means that during the gripping process it can be recognized, if an object has been optimally gripped, or if a correction has to be done, also because, for example, if instead of an object a human hand has been gripped.

Where are we headed? What will grippers like the SCHUNK Co-act JL1 gripper be able to do tomorrow?

Specifically, there are two main aspects: assisting humans and alternating their handling of different kinds of components. With the help of specially developed gripping strategies, the sensitive SCHUNK Co-act JL1 gripper adjusts its behavior in real time depending on whether it is gripping a workpiece or a human hand. For this, the gripper uses a decentralized control architecture with diagnosis and safety functions carried out in parallel.

In the long run, we believe that grippers, like human hands, will be able to independently manipulate the position and orientation of the gripped components in six degrees of freedom. In this connection, we talk about in-hand calibration technology. It will enable the realization of extremely flexible, autonomous gripping scenarios.

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Gerry is a self-motivated sales professional with a strong engineering background. With extensive manufacturing expertise, Gerry will be a key addition to the existing sales team at Schunk, as the company continues to benefit from a great MACH 2018 exhibition.

Martin Kent, the general manager of Schunk Intec, said: “I am delighted to introduce Gerry as our latest addition to the team. Gerry joined us the week of MACH 2018 and his timely arrival gave him the opportunity to meet the rest of the Schunk team and more importantly customers from his new area.

“Customer service is a key focus point for Schunk; and I believe our new area sales manager, with his deep industry knowledge, will be able to service the wide variety of requests we receive from our customers in the post-MACH period and beyond.”

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The topic spectrum will range from Cobot usage in logistics and distribution, to complex control and monitoring technology for complicated robot systems, to value creation with the help of data-supported methods, such as machine learning, visual perception or speech recognition.

Representatives will include Prof. Dr.-Ing. Sami Haddadin, director at the Institut für Regelungstechnik [Institute for Control Technology] at Leibniz University Hanover, Prof. Dr.-Ing. Sami Haddadin, director at the Institute for Control Systems at Leibniz University in Hanover, Prof. Dr.-Ing. Torsten Kröger from the Karlsruher Institut für Technologie KIT [Karlsruhe Institute of Technology] and Melonee Wise, CEO at Fetch Robotics from San Jose/USA. The expert’s meeting will take place at Schunk’s headquarters in Lauffen/Neckar, Germany.

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Control can be provided via Profinet, Profibus (up to 12Mbit/s) or CAN (up to 1Mbit/s). The Schunk ECM has a USB interface for commissioning and gripper parameterization via PC with the Schunk Motion Tool as well as for firmware updates. Alternatively, it can be put into operation in seconds without connecting a programming device. A USB stick can be parameterised for this purpose and addressing is done manually via an easily configurable rotary encoding switch. Initial module movements can be realized manually via a DIP switch.

The Schunk ECM is also equipped with an LED and 7-segment display for status display and error analysis. It also comes with four optional digital inputs and outputs. It is suitable for evaluating resolvers, encoders with an index, differential encoders and absolute-value transducers (SSI, EnDat). In particular, this enables the control of Schunk EGN, EZN and EVG grippers as well as the Schunk ERS rotary module. This can be used to freely program the stroke, speed, motor current or angular velocity and angular position. In addition, it is possible to pre-position the gripper fingers in order to shorten the cycle time.

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Schunk is working on ‘taming’ grippers for collaborative scenarios and the production field. According to many experts, repetitive activities such as loading and unloading of machine tools will be gradually taken over by collaborative systems. Employees are usually responsible for the management of several machines in respect to raw and finished parts – now collaborative robots are taking over the loading process.

In contrast to conventional automated solutions with robots and protective fences, machine tools will be freely accessible during such collaborative applications whilst individual orders and small series runs will be individually handled by the employee. Another field of application of collaborative systems is the handling of workpieces in areas potentially detrimental to human health, such as the X-ray inspection of aluminium cast parts. The direct handling in radiation ranges of the X-ray machine can now be taken over by the Co-act gripper before the component is handed over to the employee for individual post-processing and finishing.

Grippers with DGUV seal

According to Schunk, it will become more common in the future to separate parts of a process and divide the tasks between humans and robots. This applies in areas where full automation will be difficult to implement or whether it is economically feasible. This particularly concerns applications where the quantities are too low for a fully automated solution and are too comprehensive for manual tasks or vice versa. The Schunk HRC solutions bring decisive advantages for such scenarios. They increase productivity, ensure a high degree of flexibility and reduce the employee’s workload. Moreover, they reduce the risk of injuries and ensure constant quality of reproducible processes independent from the operator’s daily condition.

Following the underlying standards and guidelines, Schunk has defined three central principles for HRC grippers. First, a gripper will never cause injury during gripping. Second, a gripper must always recognise contact with humans. And thirdly, a gripper must never lose the workpiece. Depending on the application, the innovative family-owned company uses different technologies and components for this purpose. The basic version of a so-called inherent HRC gripper includes a limitation of the gripping force, which is activated in situations of danger and limits the gripping force to 140N. In addition, a HRC compatible design with rounded corners and edges reduces the risk of injury.

In the future it will be possible to equip the Schunk Co-act grippers with additional features such as secure drives to ensure heavy parts are reliably held in the event of an emergency stop. An environment sensor can also permanently control the environment of the gripper. Intelligent software evaluates the sensor signals and processes them. The safety directive for industrial robots DIN EN ISO 10218 is the basis for the Schunk Co-act series and the aspects of the future DIN EN ISO 20218 have already been taken into consideration. Beside the Schunk SVH 5-finger hand, which is already certified and approved for collaborative operation by the German Social Accident Insurance (DGUV), certification of further Schunk co-act grippers will probably be finished at the end of 2017.

Sensory aura

The Co-act Gripper JL1, which Schunk describes as the world’s first collaborative gripper, which directly interacts and communicates with humans, shows what is possible for the future. The HRC gripper was honoured in April with the coveted Hermes Award for its high degree of innovation. Provided by a sensory aura and artificial intelligence, which is completely integrated in the gripper, the Co-act Gripper JL1 is able to permanently collect information on the gripped component and its environment, to process them and to carry out situation-dependent reactions.

Innovative kinematics that allows a parallel and angular grip ensures that part variants can be flexibly and alternately handled. Tactile sensors that are integrated in the fingers can monitor the reliable grip and ensure that sensitive components are not damaged. By means of specifically developed gripping strategies, the sensitive gripper adapts its behaviour in real time, regardless of whether a component or a human hand is gripped. A touch screen and an integrated LED panel allow communication and intuitive interaction with humans. With OPC UA interfaces, the gripper is able to communicate with the robot and the higher level control unit.

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The new arrival only requires one connection plug to control the gripper, parameterise and to use the integrated diagnostics function. It can be directly connected to the IO-link class B master without a Y distributor. The required control and power electronics are integrated into the compact module, so no space is taken up in the control cabinet. The gripping force can be individually adjusted to the workpiece via the IO-link. This permits handling scenarios with complete flexibility for a wide variety of parts. In order to achieve the shortest closing and cycle times, the gripper fingers can be pre-positioned as desired.

The sensors are integrated as standard and can be used to measure the stroke and speed of the gripper fingers, as well as the power consumption. This eliminates additional costs for external sensors, the wiring effort is reduced and the process reliability increases, since fewer moving and thus wear-resistant cables are used. An integrated diagnostics function permanently monitors the status of the gripper and automatically transmits errors to the higher-level control system. Moreover, system operators can store any maintenance intervals of the system.

The Schunk PGN-plus-E IO-link has a redesigned, robust multi-tooth guidance system that allows higher maximum moments with lubricant pocket through-holes in the multi-tooth guidance, as well as a diagonal pull kinematics with a high surface coverage in all stroke positions. A brushless DC servomotor drives the mechatronic universal gripper and this ensures consistently high process stability and a lifelong maintenance-free operation. It can be mounted on two gripper sides and in three screw directions. The gripper seamlessly fits into the pillar of the alternative mechatronic modules from Schunk.

All modules feature 24-V technology. In the meantime, the product range has further expanded and complete handling systems based on 24V technology can be combined from linear axes, rotary modules and grippers. Beside the version with IO-link, the gripper is also available for control via digital I/O.

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SCHUNK used the exhibition as an opportunity to show-off its SVH 5-finger-hand. This crowd generating product is the world‘s first gripper that has been certified and approved by the German Social Accident Insurance Association (DGUV) for collaborative operation. By obtaining this certification, the SCHUNK SVH 5-finger-hand has given SCHUNK a decisive step forward on its way towards safe human/robot collaboration.

The SCHUNK SVH 5-finger hand grips nearly as perfectly as the human hand. The electronics are completely integrated into the wrist and this allows the SCHUNK SVH 5-finger hand to simulate nearly all human hand movements. Incorporating a total of nine drives, various gripping operations and movements can be executed with high sensitivity. The elastic gripping surfaces ensure a reliable grip on all types of objects. The SCHUNK SVH can be connected to industry-standard robots and lightweight robots via defined mechanical interfaces. This impressive hand was particularly busy at the exhibition greeting stand visitors with countless handshakes and gestures.

Bringing another industry first to the crowds at Advanced Manufacturing and Subcon, SCHUNK also introduced the TENDO Slim 4ax, the world‘s first hydraulic expansion toolholder in standardised heat shrinking contour.

The SCHUNK TENDO Slim 4ax hydraulic expansion toolholder combines the complete outside geometry of heat shrinking mountings according to DIN 69882-8 with the impressive qualities of the SCHUNK hydraulic expansion technology. The SCHUNK vibration-damping hydraulic system ensures a high surface quality, protects the spindle, increases tool life and subsequently reduces manufacturing costs.

The TENDO Slim 4ax has a robust base body that delivers the ideal shape accuracy by means of excellent radial rigidity. The TENDO Slim 4ax was designed particularly for axial operations and demonstrates its strength and performance when drilling, countersinking, reaming and threading on 5-axis machine tools. By means of plug & work configuration, the TENDO Slim 4ax can replace heat shrink mountings without reprogramming the external contour. Another benefit is the rapid tool change using an Allen key.

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In the field of automatic loading and unloading of machining centers, the GSW-M Magnetic Gripper provides a compressed air and coolant supply via the tool mounting. The advantages of the system are that end users can benefit from a low-price module for flexible automation in the machine tool. The innovative new system provides automated changeover from the gripper to the storage rack, providing fully automated workpiece changeover without a robot or gantry system interface.

The universal GSW-M Magnetic Gripper can be configured to suit a wide variety of workpieces.

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