At the forefront of modern production are intelligent manufacturing systems, designed for flexibility and rapid adaptation to changing customer demands. These systems enable true rapid machining by allowing quick resets to accommodate varying part specifications. However, the initial setup of these components is intricate and complex. Today, we’ll explore jigs and fixtures systems for smart manufacturing solutions, but first, let’s examine the current state of this technology.
Intelligent Manufacturing Today
Intelligent manufacturing is a cornerstone of Industry 4.0, though the Smart Manufacturing Market is still in its developmental phase as the concept continues to be refined. It’s anticipated that the market will experience significant growth once the technology matures with sufficient solutions. These systems cater to the modern need for rapid production of small batches or even single, customized parts with minimal lead time. Currently, several solutions automate the rapid machining process extensively, with the automation of machine tools achieved by loading the necessary NC programs in the correct sequence.
The real challenge lies in the loading and unloading of parts and ensuring their correct positioning during machining. While robotic arms can handle part loading and unloading, jigs and fixtures are crucial for securing parts in the correct position during machining. The complexity arises because intelligent manufacturing systems must process a variety of different parts.
Why Smart Clamping Systems Are Necessary
A typical intelligent manufacturing system comprises machine tools, cutting tools, blank pieces (or finished parts), jigs and fixtures, loading mechanisms, storage bunkers for parts and blanks, and a set of control sensors to coordinate the entire system.
The typical cycle involves a robotic arm picking a blank piece from the bunker and placing it onto the jig tool. The fixtures then clamp the part securely, allowing the machine tool to begin machining. Once machining is complete, the fixtures release the part, and the robotic arm transfers it to another bunker. While this process seems straightforward, the complexity of the setup stage is significant.
The primary challenge is that the system may need to produce entirely different parts—such as a small cylinder, a plate, or a crankshaft—each requiring specialized clamping solutions. Smart clamping systems can address this issue to some extent. Robotics enables the creation of adjustable jigs and fixtures, which can accommodate a range of similar parts, enhancing the system’s flexibility and efficiency.
Jigs & Fixtures for Intelligent Manufacturing
Understanding the distinction between jigs and fixtures is crucial in intelligent manufacturing. Jigs are used to guide the blank within the machine tool’s working zone, often incorporating stoppers to prevent horizontal movement on a mill’s table. Fixtures, on the other hand, are tools that secure the part in place, such as a bolt and nut used to fasten a blank. At AS Prototypes, we specialize in quick-turn, precision CNC machining services ideal for rapid prototyping, form and fit testing, jigs and fixtures, and functional components for end-use applications.
There are numerous types of jig and fixture mechanisms. The simplest and most adaptable involve standard blocks that can be assembled with bolts, similar to LEGO, to create various configurations. However, this method can be time-consuming. Another flexible approach is using universal standard clamps and chucks, which are effective for manual machining as operators can adjust setups as needed. In contrast, smart manufacturing systems require automated, flexible jig tools.
Main Stages of Jig and Fixture Design for Smart Manufacturing Systems
Designing jigs and fixtures for intelligent manufacturing is a complex task, often more challenging than developing the product itself. Here are the main stages involved in creating an effective CNC fixturing tool:
- Choosing Base Surfaces: Selecting multiple base surface sets within a system can enhance flexibility.
- Choosing the Adjustment Interval: This determines the system’s intelligence. More variability and a larger interval lead to more sophisticated tooling.
- Choosing the Fixtures: Selecting appropriate fixtures is crucial for securing parts effectively.
- Choosing the Fixture Mechanism: Automated systems may use electric, pneumatic, hydraulic, or mixed drives. The choice depends on the machine tool’s drive system, but specific tools may require unique drives, such as pneumatic drives for vacuum fixtures or electric drives for magnetic tooling.
- Designing the Whole Assembly: This involves designing all parts and determining the fixture’s operational cycle.
- Programming the Tooling: Automation requires controlling drives with a specialized NC program, tailored from scratch for each system.
- Preparing to Manufacture: This final stage involves getting ready for the production phase, ensuring all components and systems are in place for efficient operation.
By following these stages, manufacturers can develop jigs and fixtures that enhance the efficiency and flexibility of intelligent manufacturing systems.
Why Developing Fixtures is Important
Developing intelligent adjustable clamping systems offers numerous advantages, making the complex development and manufacturing process worthwhile:
- Cost Reduction: A well-designed intelligent jig tool can replace multiple simpler clamping mechanisms, significantly cutting down manufacturing costs.
- Automation: These systems eliminate the need for operator intervention, crucial for smart manufacturing systems that require fully automated operations. Intelligent clamps allow for completely robotic system resets for new batches.
- Time Efficiency: The setup time for different batches is often the most time-consuming aspect of rapid machining. With adjustable intelligent clamping systems, a variety of parts can be machined without changing the tooling, provided the parts fall within the system’s adjustment range. This flexibility significantly speeds up the manufacturing process.
