Robotic solutions for self-organized production

The Berger Gruppe produces high quality machines and robotic cells for machining and finishing steel strips and parts such as knives, cutlery, tools, cast and forged parts. As systems partner of ABB and KUKA, the Berger Gruppe has been implementing until today more than 600 robotic applications integrating about 40 robots each year.

At Hannover Messe USA, trend-setting innovations in the fields of robotics will be presented. The company will focus on the one hand on the machining of cast iron parts with robotic multi-tool head and on the other hand on robotic solutions with interacting robots.

Robotic cell for machining cast parts

This presented robotic station is designed for deburring and milling cast parts. As complex geometries require a precise and defined deburring technology, the robotic cell is equipped with a special multi-tool head receiving up to five rotating tools such as burrs, abrasive pencils, grinding flap discs or brushes. The programmed curved lines are processed in geometrical sequence. An integrated 3D probe measures the complete piece or single contour elements controlling the workpiece position in process.

Deburring of cast parts with robotic cell RSP/1R

Robotic cell for self-organized production

This fully automatic process chain of robot cells is designed for polishing the inner side and the shell surface of hollow-ware. It consists of 33 interacting robots. By means of incoming signals and sensor technology, decentralized intelligent systems decide which action to perform. The robots communicate with each other, require raw material or show the consumable level – each of it as an independent, intelligent unit. In that respect, the Berger Gruppe consequently implements the central idea of industry 4.0. Linked control technology and intelligent spare part supply are employed bringing ever closer the idea of self-organized production.

With this robotic solution, the Berger Gruppe won the Robotics Award 2018 at Hannover Messe.

Polishing of hollow-ware with 33 interacting robots in the robotic production line RP6/RP5

Berger Machine Interface 4.0

The Berger Machine Interface 4.0 integrates a universal bus-based detection of sensor signals such as temperature of cooling lubricant engine load, AE signals for spindle control, air pressure and air quantity. The data are reduced and visualized with an evaluation software. The interface is linked with IOT or the company network. For the individual connection with existing BDE or ERP systems with OPC server, special interfaces are programmed.

The BMI4.0 offers the condition for intelligent resource control (IRP) and for preventative maintenance and real-time monitoring of the machinery. It records the process data for process optimization identifying process interdependencies. In this way downtime and setup time are optimized and consequently the capacity planning is improved.