Revolutionizing Production: How Smart Hydraulics Drive 24/7 Manufacturing Excellence

When a firearms manufacturer needed to supercharge its production capabilities, the company turned to All World Machinery Supply’s ClampMAX Hydraulic Power Systems and ARROW Workholding Fixtures. The results? Round-the-clock parts production, dramatically slashed labor costs and precision that sets new industry standards.

The firearms manufacturer’s March 2024 request to enhance its hydraulic technology showcased ClampMAX’s true potential. Armed with smart pumps, integrated sensors and full IIoT connectivity, the systems delivered precise pressure and flow control that transformed the customer’s manufacturing floor into a lean, automated powerhouse. Combined with the notoriously dependable ARROW Workholding Fixture, the tandem system orchestrated complex clamping sequences while seamlessly communicating with robotic cells, CNC machinery and other advanced measurement equipment.

“This is taking hydraulic power to the next level,” said All World’s Senior Director of Technology Darrell Janesak. “Once integrated into fully automated robotic cells, ClampMAX Systems ensure consistency, identify part inaccuracies, communicate with the system and log data for continuous process optimization.”

“The future of manufacturing isn’t just singular automated features — it’s intelligent, connected and ready to adapt at the speed of industry demands,” added All World Controls Engineering Manager Frank Grube.

Multiple machine accessories

To help boost customer productivity, All World engineers customized the ClampMAX systems to integrate with a compact, high-speed drill and tap machine. All World also provided a custom-built ARROW Workholding Fixture with two nests and a custom-designed parts measuring unit. While All World had paired ClampMAX systems with robotics before, this marked the first time it was done with a parts measurement station added to a cell.

The ClampMAX Systems, designed with capabilities to connect with any robotic cell operations, increases productivity in three ways — minimizing the need for human intervention, cutting two parts at once, and increasing the speed of parts checking via the automated measuring table. As an additional feature, ClampMAX Systems oversee the workholding fixture, detecting and reporting any issues. This proactive monitoring is crucial in averting expensive machine damage and ensuring part precision.

“It is helping the customer make the best parts they can make with as minimal scrap as possible,” Janesak stated. “It helps improve speed, accuracy, and identifies and records any potential defects warranting further investigation.”

A complex sequence

The IIoT-connected PLC in the ClampMAX System serves as a central hub for all the automated tasks. After the robot is activated, it loads the raw materials into the machine’s dual nest fixture and communicates to the ClampMAX System to initiate the clamping sequence. When the sensors detect that the parts are seated and clamped, they communicate to the robot that the clamp cycle is complete and the robot initiates the machining process. The machining process includes milling three surfaces on each part after pushing or pulling to predefined data points.

Designing this part poses a challenge due to its dimensional constraints. The fixture must precisely position and cut the part in alignment with a thin slot while exerting minimal pressure to prevent distortion, according to All World Mechanical Engineering Manager Steve Hagedorn.

“Being able to locate the part gently enough to not distort it, but still holding strongly enough to machine it, was the tightrope we had to walk during the design process. This one is more like a Swiss watch than a typical fixture,” Hagedorn said.

During the machining process, the ClampMAX System continuously monitors workholding pressure and part seating. After machining, the machining center opens its doors, signaling machining completion to the robot.

The robot transfers the finished part to a secondary pneumatic ARROW Workholding Fixture for detailed post-operation measurements in a gauge master supplied and certified by All World, a process that takes about 8 seconds. Once the robot takes the part and places it into the measurement unit’s fixture, it signals to ClampMAX Systems that it is loaded and to begin measurement.

ClampMAX Systems simultaneously measure 5 points with pneumatically advanced GT probe sensors. After it captures and records the measurement data, it informs the robot of the part’s adherence to the tolerance levels.

Conforming parts are placed in the “good part tray,” while non-conforming ones are sent to the “scrap tray.” Due to the ClampMAX’s precision, the ratio is highly in favor of accurate parts.

Having executed this process with one part, the robot repeats the sequence with a second part. Upon the completion of both parts, the systems are reset, marking the beginning of a new cycle.

Data collection

The automated systems not only perform tasks but also gather valuable data mid-operation. This constant flow of information provides insights into the machining process, including the detection of any recurrent anomalies that could be indicative of underlying issues.

Engineers designed the systems with proactive fault detection in mind. The customer can stipulate the threshold number of defective parts that should trigger an alert to the robot, indicating a potential problem. Upon meeting this threshold, the robot can signal for an interruption, prompting operator intervention for troubleshooting and necessary adjustments.

The customer can choose from additional customization options, including preprogrammed corrective measures that can be taken to address tolerance discrepancies.

To further support reliability, the measurement unit has a self-calibration capability, employing data gleaned from the inspection of a master part to auto-adjust and maintain measurement accuracy.

Real-time visuals

The ClampMAX systems feature a programmable logic controller (PLC), streamlining both the measurement process and data management. Users can enjoy the convenience of a user-friendly human machine interface (HMI) with a touchscreen for effortless monitoring and access to data. Thanks to the smart sensors, which continuously monitor the system and the HMI, operators can view the pressure of each clamp in real time.

The systems can archive an extensive collection of parts measurements and historical data, all readily retrievable through the PLC. Users can export data onto a USB drive, allowing for integration into spreadsheet software for further analysis and trend identification.

Unlimited potential

The automated systems, delivered in July of 2024, are designed to operate continuously, around the clock, which will significantly boost production while reducing labor expenses. Unlike other market competitors, these systems feature a streamlined design that integrates a smart hydraulic system with an embedded PLC. This offers Industrial Internet of Things (IIoT) readiness, ensuring it is up to date with modern industry standards, all while requiring fewer components.

"The focus on combining cost-efficiency with technical sophistication sets this automated solution apart from the rest,” Janesak said.

The firearms manufacturer now produces tens of thousands of quality parts annually, with minimal human error. With these improved production rates, the customer can easily meet their customers’ demands for the specified product.