The origin of an innovative, new high-speed assembly system from Canadian systems integrator Transformix Engineering Inc. came not from a project to assemble small parts in high volumes, but rather a need to plant sugarcane.

Since Transformix opened its doors in 1995, the company has designed special machines for a wide range of industries. It has built machines for reworking nuclear fuel rods and machines for cleaning newly pilgered metal tubes. The company has designed machines to assemble small products, such as IV sets and aerosol valves, and large products, such as train axles.

So when the company was asked to design a high-speed machine to produce sugarcane billets for planting, it was just another day at the office.

尽管甘蔗确实会产生种子，但通常是通过种植甘蔗本身的短长度（称为钢坯）而生长的。但是，茎的任何部分都不会。每个坯料必须至少包含一个芽，新鲜的茎可以发芽。由于芽沿着甘蔗的长度随机出现，因此机械化产生坯料的过程绝非易事。该过程必须快速准确。最大程度地减少对方坯的损害也很重要。

Transformix’s engineers solved the problem with a vision system and a high-speed servo, says Larry Allingham, vice president of operations for Transformix.

剃须刀刀片安装在电动机的轴上。甘蔗纵向送入机器。茎通过相机下方，视觉系统定位带芽的区域。然后，它向电动机发出信号，以加速或放慢速度以在正确的时间切割钢坯。将钢坯沉积到一个垃圾箱中，而垃圾甘蔗则被沉积在另一个垃圾箱中。整个过程发生在眼睛的眨眼中。

连续运动组件

Transformix在拐杖切割机上的经验启发了一种新的方法来设计连续运动组装系统。要了解这种方法有多新，回顾技术的位置很有用。

Depending on the system and the product, rotary indexing dials or pallet-transfer systems can produce 15 to 250 assemblies per minute. In contrast, continuous motion assembly systems can routinely produce 400 to 800 parts per minute, and some machines can produce more than 1,800 parts per minute.

With intermittent motion systems, the assemblies must pause periodically so that some action can be performed. The assembly tools, such as screwdrivers and pick-and-place units, are stationary. With continuous motion systems, the assemblies never stop moving. Assembly operations are carried out as the parts are moving, and the tools travel with the work in process.

连续运动组装系统的心脏是圆柱形旋转炮塔。炮塔由一个带有一系列称为销钉的工具的圆盘拨号，围绕其周长。炮塔的大小和周围的别针数量各不相同。

零件在馈线或上游操作的轨道上输入系统单文件。星轮与炮塔同步移动，将零件接一个地剥离，然后将它们转移到围绕表盘周围均匀间隔的巢。当炮塔旋转时，每个引脚依次启动，直到过程完成并卸载组件。凸轮控制销钉的运动。

Continuous motion systems are used to assemble small, high-volume products, such as aerosol valves, bottle caps, syringes, electrical connectors, tube assemblies, lipstick tubes, ballpoint pens, irrigation components, spray valves for household cleaners, and foam generators for beer cans. The parts assembled on continuous motion systems are typically round and symmetrical, but they don’t have to be.

也就是说，连续的运动组件系统最适合可以快速，轻松地将其捕获或推动一起推动的零件。如果弹簧是组件的一部分，则它们的末端应该有关闭的线圈，因此它们更容易喂食。如果将一个部分插入另一部分，则基本部分中的倒角将有助于补偿组装过程中的任何未对准。

Continuous motion systems can accommodate most assembly processes, as long as they can be done quickly and from a vertical direction. These include crimping, dispensing, curing, ink-jet printing, labeling, laser marking, riveting, screwdriving, slitting, ultrasonic welding, vision inspection, leak and flow testing, and functional testing.

CNC Assembly

当Transformix被要求为消费产品设计标准，CAM驱动的连续运动组装系统时，该公司的工程师质疑有关该技术的一些基本假设：

Why do continuous motion assembly systems need to have so much tooling?

Why can’t continuous motion dials turn faster than 15 to 30 rpm?

凸轮真的需要吗？

Could the tooling be programmable?

他们对这些问题的回答导致CNC组装是一个新的自动组装平台，将连续运动组装系统的速度与机器人的灵活性相结合。

“Manufacturing plants demand greater output per unit of time and space,” says Ken Nicholson, director of technology at Transformix. “These objectives have been tough to achieve with assembly machines, since they are typically customized to specific products. This means companies usually have relatively low speed, specialized machines spread across their factories, consuming a lot of expensive floor space.

“If they do install high-speed machines, they are invariably for high-volume, long-running products, since high rates have always been incompatible with flexibility and adaptability. Our goal in developing CNC Assembly was to give manufacturers a standard machine that could run at high rates—200 to 600 parts per minute—but that also had the quick-change versatility to run a range of different products.”

To achieve this combination of speed and flexibility, the CNC Assembly platform relies on high-speed servomotors, rather than cams, to control and coordinate individual assembly operations.

Nicholson解释说：“我们使用连续的运动技术以高速率将零件运送到组装工具，然后采用机器人，伺服控制的动作来执行操作。”

CNC组装平台由一个标准的，即插即用的模块组成，每个模块都旨在适应一组常见的装配任务。

“We call it CNC Assembly because it is directly analogous to CNC machining,” says Nicholson. “Just like CNC machining centers, CNC Assembly machines are general-purpose tools that can be configured and programmed to run a wide range of products. And just like CNC mills are different from CNC lathes, different CNC Assembly machines are intended for different functions.”

CNC组装系统的底座是旋转工具平台（RTP），这是常规连续运动系统中炮塔的等效。在典型的应用中，RTP配备了一到四个工具站，并且旋转75至200 rpm。每个工具站都由一个或多个线性电动机而不是凸轮驱动。

Transformix设计了一系列伺服控制的快速速度匹配（RSM）设备，以运送往返RTP的零件。

For example, the RSM feed screw is a subturn feed screw that handles only one part at a time. (In contrast to conventional, variable-pitch feed screws that contain multiple parts within them as they turn.) With each turn, it picks off a part from a linear track. The screw’s servo is electronically cammed to the servo turning the RTP. As a nest or pocket on the RTP approaches, the screw’s servo accelerates so the part can match the speed and position of the pocket—just like the servo that cut billets in the cane processing machine.

This design enables the RTP to capture parts at a much faster rate than a conventional continuous motion machine—and with 80 percent to 95 percent less tooling, says Allingham.

RSM系列中的其他设备包括旋转磁盘和“线性跑步者”。磁盘上有一个或多个口袋加工到圆周上以携带零件。线性跑步者是一个大型的，伺服驱动的X-y定位阶段。配备有抓手的旋转执行器可以安装到平台上，进入RTP以交付或取回零件。像进料螺钉一样，磁盘和跑步者的运动也被电子camm与系统的其他部分的运动匹配。

The CNC Assembly system is already being used by several manufacturers. For example, Transformix recently designed a system to assemble a small product made from bent wire. The system feeds, cuts, bends and wraps the wire. It then solders the wire to another part. The system operates at a rate of 200 parts per minute with just one tooling set.

Although it was designed for high-speed operation, CNC Assembly can be economically deployed for jobs requiring rates of 60 parts per minute or less—particularly when flexibility is required, says Allingham.

For more information about CNC Assembly, call 800-639-5644 or visitwww.transformix.com.