Zimmer’s flexible robot cell enables both rapid deployment and intuitive operation, smoothing the path to the introduction of automation.

The proliferation of collaborative robots (cobots) in recent years, together with a general increase in the adoption of the smaller variety of industrial robots, has certainly sparked a greater interest in automation and encouraged many to explore the possibilities through the integration of robots for a wide range of tasks.

The robot or cobot itself however is but one part of the overall solution. The robot still has to be installed alongside the manufacturing process, interfaced to the line, and of course equipped with the necessary tooling and technologies to enable it to perform the required tasks.

ZiMo’s compact design and mobile positioning concept enables the rapid deployment of the system where and when it is needed, overcoming the perception of complexity. This, combined with a comprehensive range of gripper and EOAT options, means that the system can be easily configured for a variety of handling and process operations.

The fact that ZiMo can be used without the need for any complex integration means that the handling system offers absolute freedom of use and the versatility to be quickly and easily reconfigured for new assembly, pick and place or even training requirements. A significant benefit for users of ZiMo is the fact that no prior programming knowledge is required when commissioning the system.

ZiMo’s ‘robot neutral’ concept means that this flexible robot cell can be used with a wide range of smaller industrial robots or cobot’s and be set up and commissioned intuitively via the Zimmer HMI. This saves valuable time and resources, allowing users to focus entirely on areas of production that offer real added value for their business.

A comprehensive range of accessories including gripper and vacuum systems, sensor technology, and the MATCH robot modules, mean that should production needs or processes change, ZiMo can be reconfigured quickly, without any significant effort or expense, to meet the new requirements. In instances where the system is to be used in conjunction with one of the smaller industrial robot types, floor scanners can be integrated on each of the four corners of the system to provide the safe operating environment required when using this type of robot.

Zimmer Group UK’s managing director Richard Mason comments on the advantages of the system: “ZiMo makes it possible for users, even those with no prior automation or programming experience, to take advantage of the benefits of a small industrial robot or cobot by supporting their employees in monotonous, time-consuming tasks throughout the day, and at night if required.

“The variable set-up options for the workbench and its compact size make ZiMo a reliable, flexible robot cell for almost any small robot or cobot application, including loading and unloading of machines, pick-and-place tasks, or assembly. Users of the system will benefit from reduced cycle times, enhanced productivity and improvements in consistency and quality.”

The ZiMo concept of a mobile, flexible automation platform, capable of being used with small industrial robots or cobots from a wide variety of manufacturers, and which is simple and intuitive to set up and deploy, will no doubt alleviate the obstacles for those looking to take their first steps into automation, or indeed those seeking to further expand the use of this type of technology within their manufacturing operations.

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Zimmer Group has completed over 35 different projects, totalling over 5,000 development hours, in applications relating to the automated handling of tyres, rims and wheels. And the company’s technology continues to gain traction within this sector.

The route to finished wheels is complex with many different manufacturing processes and steps. As with virtually all areas of automotive manufacturing, automation plays a key role in the production of tyres and rims. There are several key challenges to be addressed when handling tyres and rims including the different material processing and manufacturing stages for the tyres, plus the wide range of sizes to be accommodated.

Zimmer Group’s expertise and know-how extends across the sector and includes passenger car radial tires (PCR), truck and bus radial tires (TBR) and off-the-road tires (ORT), and covers all of the processes from calendering, right through to the handling and palletising of finished tyres.

Tyres must be handled at several different stages of manufacture, including in their green state, and then subsequently as finished products. In the production of the tyre, various semi-finished items are placed together and are assembled into what is termed a ‘green tyre’. This is completed in two stages, firstly the casing, and then the tread/belt assembly. The ‘green tyre’ is then ready for the vulcanisation process.

Handling these yet unfinished products can be achieved in several ways, depending upon the specific requirements of each individual customer. Zimmer UK managing director Richard Mason explains: “Our solutions are tailored around the configuration and demands of each individual application. Some solutions call for internal gripping concepts and this can be achieved using 4 or 6 jaw systems. Alternatively, it is possible to grip around the circumference of the Green Tyre if that solution is preferred.”

Following the vulcanisation process, the finished tyres are then transported for palletising, where there may be several different formats for palletising the tyres. Some configurations have the tyres placed horizontally to build up columns on the pallet or stillage, other configurations have the tyres placed at an angle to allow them to effectively interlock with each other for transportation. Depending upon a combination of throughput requirements and palletising layout, tyres can be gripped, handled, and transferred individually, or in pairs. There is also a gripping concept available from Zimmer Group which will pick up a vertical column of multiple tyres in a single cycle if required.

Flexible solutions for rim and wheel handling

Every tyre needs a rim to make it functional, and Zimmer Group also makes a valuable contribution to the manufacture of these products. The challenges here include the fact that there is a wide range of diameters, typically from 14” to 24” and of course a variety of designs, and different finishes which need to be protected during handling.

Zimmer Group has developed a standard solution for handling the most common car rim sizes. The design of this pneumatically operated solution, which incorporates long stroke grippers with up to 220mm per jaw, means that little or no set up time is required when changing from one product size to another.

Other valuable features include Z axis compensation, to allow for variation in pick height, active stroke limitation to optimise cycle times, and consistent positioning using clamping elements. Regardless of whether the rims are being handled through mechanical processes or surface treatments, the system allows flexible operation as a single, double, or multiple gripping solution.

With the knowledge and expertise gained from over 35 different projects, Zimmer Group is now able to offer a holistic approach to the many different handling and transfer operations which are required within tyre and wheel rim manufacture. There is also a solution available for wheel to vehicle assembly on automotive production lines, which completes the technology line up.

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The slim design and low set-up profile of the clamping plate and clamping pallets allows both close-proximity pallet loading on the machine table and optimum use of the space within the machine. High clamping forces create an extraordinarily rigid system. Excellent retaining forces enables the highest torque levels, together with a high precision connection between the robot and the clamping plate. This makes handling of heavier pallets in particular, easier, and safer.

The pallet changer was designed for clamping pallet couplings or clamping pins with high levels of repeatability. The innovative structural design means that the system is clamped without the need for pneumatic pressure. However, clamping forces can be further increased by using Zimmer’s PLUS connection, which provides pneumatic assistance. In addition to four rotation locks for pallet coupling, the system features an integrated blow-out or cleaning function which prevents dirt or liquid from collecting in the pin holder, contact surface, and rotation locks.

The pallet coupling is used as a pallet interface for the product and creates the connection to the clamping pallet. The rotation lock enables backlash-free positioning of the bearings when joining with the product. Safe operation can be verified by sensors by means of piston position sensing and a clamping position check. All functions can be controlled directly via the pneumatic connections on the sides. There is also the option to control the unit by means of alternative connections on the bottom of the product.

Automating processes using the zero-point clamping system dramatically increases productivity of tasks that require precision. Machine set-up times are reduced by up to 90%, and cleaning and maintenance of the system is minimal. The option to link processes, one after the other, in a single workpiece clamping system, in various machining cells, based upon identical clamping system geometries, allows manufacturing synergies previously unachievable. The workpiece carrier with the zero-point clamping system accompanies the workpiece all the way through the different production processes, ensuring maximum precision and optimum cost efficiency.

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Becoming part of what are recognised as two of the UK’s premier industry associations will allow the company to foster closer relations with businesses across a wide range of industry sectors. PPMA is the UK’s trade association for suppliers of processing and packaging machinery to both the domestic and overseas markets. BARA promotes the use of, and assists in the development of industrial robots and automation within British industry.

The comprehensive range of gripper and linear motion technologies manufactured by Zimmer Group is applicable to multiple robot and automation applications across diverse UK manufacturing sectors.

Zimmer Group UK managing director Richard Mason commented: “By becoming PPMA and BARA members we will have the opportunity to engage proactively with the associations, their various promotional events, and of course other members. This will make it possible to promote a greater awareness of the benefits which robotics and automation, supported by our technologies, can bring to UK manufacturing.”

The comprehensive range of products and systems manufactured by Zimmer Group are widely used across a diverse range of applications and industry sectors including plastics, automotive, medical device, pharmaceutical and consumer goods.

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As the transition away from vehicles powered by internal combustion engines to the new generation of EV’s and Hybrids continues to gather pace, OEMs are not only investing in their new pollution free models, but the manufacturing systems and technologies required to meet the growing demand from consumers.

It is not just the motive power of these vehicles which is different, the production of electric vehicles requires a complete re-think of the technologies used to manufacture their powertrain components. With batteries, electric motors, controllers, cables, and connectors replacing the conventional ICE mechanical parts, new manufacturing methods and systems are being developed to achieve the production efficiencies, economies of scale, and quality levels for which the automotive sector has become recognised.

Producing battery cells and modules economically is an important factor in ensuring that this market can continue to grow at the pace required. As for internal combustion engines, high levels of automation will be essential. Zimmer Group has been able to leverage from its extensive knowledge of powertrain assembly systems and is now applying this expertise, working in partnership with a number of premium businesses across battery manufacturing, module assembly, and electric motor production.

Richard Mason, managing director of Zimmer Group UK, explains: “Zimmer Group started developing EOAT solutions for electromobility applications as far back as 2014, and has since invested a significant number of engineering hours and R&D budget in developing and perfecting systems for this growing market segment. As a result, today, Zimmer Group’s technologies are now used by all of the leading automotive manufacturers in the EV sector. We are very proud of that achievement.”

Battery cells, modules and more

Energy storage systems for EVs generally have a modular design and consist of single battery cells that are joined into modules which are then grouped to form battery packs. The commonly used Li-ion battery has 3 different cell types which are either: small solid cylindrical cells, larger soft pouch or polymer cells, and larger solid prismatic structure types. At each stage of the manufacturing process, these cells need to be handled, grouped, and transferred efficiently and securely.

Individual cylindrical cells are handled in multiples and arranged into modules, which in turn are assembled to produce completed battery packs. Zimmer Group has developed a comprehensive range of EOAT / Gripper technologies to handle the different battery cell types through the various assembly stages. In addition, the company has gripper technologies to handle the frames, baseplates and intermediate layer and cooling plates used in the construction of the final battery packs.

Today Zimmer’s EOAT and gripper solutions are a key part of some 40 high profile electromobility projects, totalling 400 grippers and 2,000 devices, covering all aspects of the EV powertrain.

The Zimmer Group is therefore now an established and valued partner to a growing number of premium automotive manufacturers and integrators of production lines, providing handling systems and fixtures for the production of battery cells, battery packs and battery modules. The company also supplies specific system solutions for rotors, stators, contact rings, gears, and various added value parts along the EV supply chain.

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French kitchen manufacturer Schmidt has risen to the challenge of producing customer specific products using an innovative robotic machining cell for drilling, and assembly of kitchen furniture components. The cell is part of a production line used to manufacture complete kitchen units with a batch size of one.

Schmidt is recognised internationally as a quality supplier of kitchen products and has around 1,500 employees worldwide. The company has production facilities in Sélestat, Alsace, in France which is where the robotic machining cell is located. The robot processing cell was designed and built by the Zimmer Group, which delivered this production system as a turnkey supply.

At the heart of the system are five large ABB robots, connected by a flexible transport system within which the workpieces are clamped and moved, depending upon their size, using four freely programmable shuttles. The design and functionality of this recirculating shuttle system was recognised with a German Innovation Award in 2019. Operating on a cycle time of less than 2 seconds, furniture components have holes and grooves machined, plus fittings assembled, with all operations performed by the robots. A 2m-high side panel of a tall cabinet can be immediately followed by a shelf measuring just 15 x 20 centimetres, without any changeover or setup time.

“When we first discussed our plans for such a cell, we were told don’t do it, it can’t be done with sufficient precision using robots,” recalls Zimmer Group managing director Achim Gauß. “At first that was the case. We had to invest a lot in both hardware and software.”

The solution was derived through a compensation algorithm, developed in-house, which uses laser tracking measurement of the robots in the machining area. In addition, the individual furniture parts are clamped into the shuttles by a loading robot and then measured in terms of dimensions and position. This single set-up allows the parts to move along the various processing stations before finally being removed from the shuttles by the unloading robot. This ensures that there is no loss of accuracy due to un-clamping and re-clamping at different stations.

A special feature of this robotic solution, for which the Zimmer Group draws from its own pool of grippers and tool changers, among other things, is the drilling operation. This is performed by ABB industrial robots which process the parts with an accuracy of two tenths of a millimetre.

Achim Gauß continues: “Our customer Schmidt wanted a system that had 100% availability, if possible, where maintenance requirements did not have to lead to a complete machine shutdown. This is only possible with a modular system. In addition, there was the desire for flexibility, accuracy, future proofing, as well as a batch size of one production without predefined machining programs.”

Zimmer Group’s experts solved the availability problem by ensuring easy accessibility to all parts. Individual shuttles can be removed and replaced without the system coming to a complete standstill. In extreme cases, a ‘simple’ exchange of a complete processing robot is also possible.

Performance and flexibility at the highest level

In order to achieve the desired production output, the machining operations are automatically assigned between two machining robots and typical machining operations are combined in one drilling stroke. To achieve this, each of the machining robots carries a multifunctional head with 41 tools, in order to be able to perform all necessary machining operations without changing tools.

The desire for the greatest possible flexibility was achieved using special software – the so-called optimiser – which generates the machining program from the workpiece description in the customer’s central database when the system is loaded. This direct link between the control system to the higher-level manufacturing execution system achieves full production networking. In addition, Zimmer Group’s HMI provides intuitive operation and extended diagnostic options for the entire robot machining cell.

“In order to be able to reliably organize such a complex system during the design process, but also later when in operation, you need one hundred percent real-time simulation,” explains Achim Gauß. “Such a digital twin makes the system not only highly flexible but also extremely useful for work preparation and scheduling for the customer. We learned a lot in this project and have been able to transfer this know-how to all our components with the digital twin.”

With the help of the digital twin in the HIL system, the cell can be built virtually to be able to check the system performance and functionality even before installation. The Zimmer Group’s robotic machining cell both embraces and implements the principles of Industry 4.0.

Schmidt is delighted with the final result, as the cell offers considerable economic advantages in addition to extremely high system availability. For example, the use of industrial robots instead of traditional machine technology together with the simpler design, results in significantly lower investment costs. The re-circulating shuttles within the innovative transport system can be individually controlled in terms of speed, cycle time and positions, and can either be operated individually or in combination.

Considered over the entire life cycle of the system, the flexible robot concept also offers a high level of investment security, as the modular design enables subsequent expansion and future proofing with new processing modules.

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Electric Vehicle (EV) manufacturers are currently looking for innovative automated solutions to make their manufacturing processes and production assemblies simple, reliable, and productive. It is not uncommon for automotive product development and the development of new manufacturing concepts to take place in parallel.

This however requires maximum flexibility in both the design and build of an automation solution and in the mindset of the engineers involved. Since batch sizes in (EV) battery production have yet to reach their full potential, a flexible manufacturing concept should, or rather must, therefore be developed, alongside a flexible automation concept.

In order to actively support the technological transition from combustion engines to electro mobility, several modular solutions for EV vehicle manufacturing have already been developed by Zimmer Group’s System Technology division. Zimmer Group UK’s Ian Sinclair explains: “We started developing EOAT (end-of-arm tooling) solutions for electro mobility in our R&D department as far back as 2014 and have since invested over 50,000 engineering hours in developing and perfecting systems for this market segment.

“We had to develop the first gripping systems under enormous deadline pressure, as the time constraints were set very tight by our customer at the time. However, it took just four months from the first meeting to delivery. Today, we are now a valued supplier to all of the leading automotive manufacturers in the EV sector, including Tesla, Porsche, BMW, Mercedes Benz, BYD and many more.”

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The new MATCH Gripper Ecosystem available from Zimmer Group enables robots to utilise multiple gripper types and end effectors, further enhancing the capability and functionality of these already flexible systems. Targeted at lightweight industrial and collaborative robots, this unique platform is the result of a joint project between Zimmer Group and J Schmalz which combines the best expertise in the world of gripping technologies.

This gripper change system can be operated either fully automatically, with the robot releasing and collecting different grippers or end effectors to and from a docking station, or manually with just one hand in just a few seconds using simple click to remove functionality. The system is compatible with pneumatically or electrically operated grippers which utilise either vacuum or mechanical gripping principles.

Multi-faceted system with standardised interfaces

The quick-change system incorporates the mechanical interface together with pneumatic and electrical connections. These options make it possible for the system to be used by many different robot types and a wide variety of end effectors. For electrically operated grippers, the quick-change system is capable of hot-swapping, changing grippers during live operation with the integrated pin array transmitting both the load and signal currents. For pneumatically/vacuum-based grippers, four internal and two lateral channels supply the gripper systems with compressed air or vacuum pressure. The design, combined with high levels of manufacturing quality, guarantee a long service life greater than 100,000 cycles. The position and orientation of the fixed and interchangeable elements of the system are clearly defined in use, eliminating the potential for mis-alignment of the two halves.

The flexibility of the system gives the user access to a wide range of applications, whether they are with mobile robots, collaborative robots or other types of automation – across production, assembly, warehouse logistics, shipping and even laboratory automation operations.

Smart system with intuitive software

Zimmer Group and Schmalz each have their own systems that the user can draw upon for digital integration. In addition to the SCM communication module (master gateway), additional functionality is offered by the intuitive guideZ setup software for further configuration of the gripper, and Schmalz Connect Suite for diagnostics of IO-Link devices in the cloud.

Ian Sinclair, managing director of Zimmer Group (UK) commented: “This unique modular system is generating a significant amount of interest from a diverse range of both existing and potential new customers. The benefits of this technology mean it is fast becoming a key component in supporting the ongoing growth in lightweight and collaborative robot applications.”

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Electrically operated grippers from Zimmer’s GEP2000 series offer a number of advantages for small parts handling including: adjustable gripping forces of between 80 N and 400 N and jaw strokes of between 10mm and 16mm. Another important feature of this range of grippers is their mechanical self-locking mechanism, which prevents the loss of the workpiece in the event of a power failure.

All grippers within the range feature an integrated control system and are available in three control versions: With IO-Link, digital I/O and digital I/O plus an analogue output to set or interrogate the jaw positions.

With the IO-Link version, the gripper offers all the system-specific advantages of that interface, which includes not only simple handling and operation, but also easy integration. By connecting a single cable, the gripper can receive data from and transmit data to the master controller. Parameters such as gripping force and gripping speed are set centrally. The gripper uses IODD (IO Device Description) to send signals to the higher-level control system.

The resultant benefits include considerable time savings during initial setup or when replacing the gripper. IO-Link also sets new horizons for advanced diagnostic functions and predictive maintenance, which in turn enhance machine availability. No additional hardware, in the form of other controllers is required thanks to this highly sophisticated control system. The IO-Link master is all that is needed to act as a link between the gripper and the fieldbus, and no additional software needs to be installed on any PLC being used.

Simple operation

Zimmer Group also provides its own Human Machine Interface (HMI) for easy operation. This tool, which has a special gripper-adjustment user interface, is able to store parameters for up to 32 different workpieces.

In the I/O version, the grippers operate as simply as a conventional pneumatic valve. The gripper opens when it receives a control signal, and the jaws are closed when it receives another one. In this cost-effective version, a four-pole cable that supplies the gripper with both electrical energy and control data is all that is required. A commercially available central distributor can be used to control several grippers at the same time. Should gripper position information be required, this can be achieved using magnetic field sensors, which can be accommodated in the two grooves incorporated within the gripper. The gripper is able to use these sensors to send a signal as soon as a set query position is reached in just the same way as a traditional pneumatic gripper.

Zimmer Group has developed a simple solution for adjusting the maximum gripping force, which can be set directly on the gripper using a potentiometer with four separate positions. This is not only quick and easy, but also offers the advantage of the setting being easily visible, even if the power has failed or if the gripper has been removed.

For applications where more precise information relating to the position of the gripper jaws is required, Zimmer Group offers a digital I/O version together with analogue sensing. An analogue sensor, which outputs a voltage of between 0 and 10 volts, depending on the jaw position, is integrated into the gripper as standard. This voltage can be evaluated using an analogue card in a higher-level control system, making it possible to determine the position of the gripper jaws with an accuracy of less than 0.05 mm.

Longevity in service

Zimmer Group’s GEP2000 series electrically powered grippers feature an industry leading mechanical configuration. The hard anodised aluminium housing is at the heart of the grippers’ robust construction and reliability, and the field proven flat guide design will allow the gripper to perform 10 million part handling or assembly cycles without requiring maintenance.

All versions in the range offer a mechanical emergency release, which is an important safety feature. Should there be a need for the gripper to be opened manually, in exceptional circumstances, the screw on the self-locking gearbox can be turned using a separate screw which is easily accessible externally. As a result, the gripper can still be opened, even in the event of a power failure when for example, a workpiece needs to be removed.

All grippers are sealed to IP40 standard, and their high accuracy allows for rapid replacement minimising any interruption of production. The grippers in the GEP2000 series are powered by 24 VDC, and the gripper jaws are able to operate with a current draw of less than 500 mA. The current draw only increases to 2 A, a current that all conventional IO-Link masters can supply, for a few milliseconds at the moment of start-up, when the mechanical self-locking mechanism is released, and the motor is being brought up to speed.

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