Projects
Retrofit of a high-performance levelling machine
New control system, robotics, and material flow for existing plant technology
- Industry
- Metal
- Solution
- Retrofit
With the comprehensive modernisation of an existing levelling machine, AGS has brought the control system, visualisation, sensor technology, drive technology, and material handling up to date. Two robots handle the automated processing of the aluminium sheets and integrate quality and assessment processes into the material flow.
Project highlights
- Retrofit of the existing high-performance straightening machine
- New safety PLC and visualisation
- Replacement of sensors, motor controllers and cabling
- Automated handling with two industrial robots
- Laser-based pallet positioning
- Separate NOK and inspection trolleys
- Connection to higher-level IT and local database
Application & machining processes
- Separation of sheets via suction gripper
- Camera and laser sensors for position, thickness and double-sheet detection
- Automatic feeding to the straightening machine
- Palletising of finished parts and handling of cover sheets
- Separate handling of NOK and inspection parts
- Automatic insertion of paper interlayers
Operating & control concept
- Control panel with clear HMI
- IT connectivity including process database
- Live data on OEE, cycle times and material availability
- Automatic format and zone adjustment of the gripper
Safety concept
- Protective fence and monitored access systems
- Limited robot workspace areas
- Escape releases on safety doors
- Separate jog mode for reject and inspection trolleys
Result
- Higher process reliability
- Reduced downtimes
- Automated material handling
- Constant quality with less manual effort
- Future-proof use of an existing system
Insights | Process
Conclusion
The retrofit demonstrates how existing high-performance systems can be modernised economically and for the long term with new control systems, robotics and sensors.