The GF Machining Solutions Transformer modular automation system addresses concerns about flexibility and cost of automation systems. It is expandable and scalable, allowing customers to start with one or two machines and expand to twelve. The open architecture design allows for integration of different machine tools and manufacturing technologies. The system uses standardized modular components like pallet racks and magazines, and a robotic pallet changer, that can be quickly configured or reconfigured to meet changing production needs. This flexibility provides faster payback on the investment than traditional automation systems.

1. GF Machining Solutions
EDM I Milling I Laser Texturing I Tooling & Automation I Customer Service
Automation System Loads up
Expandability, Scalability and precision

2. Automation System Loads up Expandability,
Scalability and Precision
Manufacturing automation technology boosts pro-
ductivity, profitability and global competitiveness.
However, many shops are reluctant to commit to an
automation system due to concerns about flexibility
and cost. Determining the scope of an automation
system involves trying to anticipate a facility’s future
needs, and system design, assembly, and installation
can include long lead times and significant expense.
The System 3R Transformer modular automation
system from GF Machining Solutions addresses
those concerns. The system is expandable and scal-
able; a shop can begin with automation of one or two
machines and then easily expand the cell to include
up to 12 stations. The system’s adaptability and flex-
ibility ensure that it will never be too specialized or
too small to meet a facility’s future requirements.
OEM automation systems often are designed to
integrate certain machine tool brands or styles.
The open architecture approach of the Transformer
system permits integration of differing manufactur-
ing technologies including mills and turning centers,
EDM machines, measurement devices and even
part-cleaning equipment. Unconstrained by compat-
ibility issues, individual operations can be optimized
and incorporated to achieve full automation of an
entire process.
The basic components of the Transformer system
are a robotic pallet changing unit and modular racks
or rotating magazines that store pallets fitted with
referencing chucks from System 3R. The chucks pro-
vide repeatability of 2 µm and enable the transfer of
parts from one machine to the next without the need
to check positioning or repeat setups.
System 3R tooling allows palletization of workpieces
and EDM electrodes of a wide range of sizes. Dif-
ferent versions of the system feature pallet sizes
from 54 mm x 54 mm to 700 mm x 500 mm, and the
pallet-changing robot can handle part/pallet combi-
nations weighing up to 200 kg (440 lbs).
In a one-, two- or three-machine cell, a stationary ro-
botic changing unit accesses either a bookshelf-style
or a rotary pallet magazine. A rotary magazine pro-
vides three times the capacity of a bookshelf maga-
zine, in the same amount of space.
To handle as many as 12 machines, the pallet-chang-
ing robot rides on a modular rail system. The rail
system is made up of standardized sections that can
be quickly added and linked to produce the length
needed to service the number of machines desired
for the cell.
Most automation arrangements are engineered to
meet the requirements of specific part production
and shop environments. Expanding or changing the
system requires dismantling the prior setup and
building a new one from scratch. With the Transform-
er system, on the other hand, the standardized modu-
lar components combine to create customized auto-
mated solutions. Together, the modular nature of the
robotic handling, rail and magazine components and
easily updated software enable a Transformer sys-
tem to be expanded or modified in a matter of a few
days rather than in the weeks or months required
with traditional automation arrangements. Plus,
modularity and simple connectivity enable a shop
to expand a Transformer rail system while the rest
of the system continues to operate. Standardization
of components also contributes to lower equipment
costs.
There are two control modes for the Transformer
system. It can be operated as what is called a sim-
ple system, which works much like a toolchanger
in that the machine tool sends direct commands to
the robot. Or for multiple-machine cells, full capa-
bility and flexibility is achieved with the use of Work-
ShopManager software, which links all machining
processes together in a clearly-arranged production
system. The software’s CellManager employs with
pallet-identification systems, including visual labels
or RFID technology, to record the position of every
pallet at any given moment. This permits control of
every aspect of the cell, from automatically loading
jobs to each machine to recording and monitoring
cycle times for each operation. Production data can
be entered manually or imported through a data
exchange interface with major enterprise resource
planning (ERP) systems.
The software permits random loading of pallets and
on-the-fly modification of work order and priorities.
As a result, the system handles small and large pro-
duction lots with the same level of efficiency, to the
extent that automated one-piece production is pos-
sible. When a cell houses a variety of processes, the
WorkShopManager software is especially essential in
maintaining production flow.
Payback on the investment in a Transformer system
is rapid, a result of significantly increased machine
utilization. The system’s accuracy and reliability
permit lights-out operation that multiplies machine
utilization by a factor of three or four.
A selection of grippers, including turning, tilting,
tipping arm and double-effector units is available to
maximize flexibility of the pallet-changing robotic
unit. In-process accessories that enhance system
capabilities include in/out loading stations for larger
pallets that can be operated without stopping produc-
tion; a station for draining workpiece cavities after
they are machined; and a cleaning station that pre-
pares a part for precision inspection on a CMM.
The Transformer automation system is especially
suited to lights-out production of small to medium
size precision components in tool and die and mold-
making operations, as well as any other tight-toler-
ance manufacturing applications.

3. GF Machining Solutions
Your Contact
GF Machining Solutions
560 Bond St.
Lincolnshire, IL 60069
USA
Website: www.gfms.com/us
Phone: 847.913.5300
Email: info.gfms.us@georgfischer.com
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