weiss rotary table free sample

In 1996, Precision Detroit Company established a relationship with WEISS GmbH. WEISS has been manufacturing high quality index tables for decades and is the leading automation component manufacturer in Europe today.

In August, 2007, WEISS GmbH established WEISS North America, Inc. as a wholly-owned subsidiary. On September 30, 2007, WEISS North America, Inc. acquired the assets of Precision Detroit Company, Inc. relative to its PDC Geneva Motion index tables and its network of sales representatives throughout the U.S. and Canada.

Today, WEISS North America is not only a rotary table manufacturer but your complete automation manufacturer and solutions partner. WEISS has decades of expertise in providing automation, drive and control solutions to industrial markets. WEISS offers industry-specific, cost-effective and efficient technology solutions to help you maximize your efficiency, increase your productivity and achieve optimal system performance. We understand that your application has unique processes and specific requirements and we work closely with you to develop the perfect automation solution for your particular needs.

Successfully competing in our increasingly competitive global environment requires strategy, innovation and proven reliability from a partner that you can trust. Give us a call at 888-WEISSNA, fill out the form above, schedule a call below or simply send us an email to discuss your automation needs.

Rotary indexing table use is widespread in automated assembly machinery and selecting the proper mechanism is essential for both maximizing performance and minimizing the cost of this critical component. This how-to-guide will explore two common devices that can be used for rotary indexing and give advice for proper selection. These two popular devices are cam indexing drives and servo rotary tables.

Cam indexers are a ubiquitous mechanism that have been used for rotary tables for many decades. They are a great fit for applications that will always index the same angle and that require high-precision positioning at a very reasonable cost. A cam indexer uses a mechanical cam to provide the motion control to position the load. A mathematical motion curve is machined onto the cam that provides extremely smooth and repeatable motion.

A cam indexer has two main modes of operation. One mode is referred to as “Cycle-on-Demand”. This indicates that the camshaft will be cycled one revolution at a time to advance the output one position at a time. This is typically achieved by using an inexpensive camshaft sensor package to detect camshaft position and a VFD to stop and start the motor. The camshaft dwell period offers a wide window for the camshaft to stop without affecting the position of the output. To cycle the indexer, a PLC gives a command to the VFD to accelerate the drive motor to a preset speed, the cam rotates one revolution indexing the output, a sensor sends an in-position signal to the PLC, and the PLC signals the VFD to stop the camshaft during the cam dwell position. The table will be in the dwell position for however long is necessary to complete the work at each station. The dwell time can range from a fraction of a second to several minutes or hours depending on the application. This combination allows very accurate positioning with an inexpensive drive system.

A fully programmable servo rotary table is another common option. There are two specific cases where a servo rotary table is advantageous. The first is when a flexible motion pattern is required. An example is two different products being run on one machine that each require different indexing patterns. The other situation that suits a servo indexer is when extremely fast positioning is required followed by a long dwell period. A cycle-on-demand cam indexer is limited by the need to accelerate the camshaft up to speed during the dwell period before output motion is started. There are practical limitations to how fast the camshaft can be accelerated so there will be a delay before motion is started. With a servo rotary table, the output rotates as soon as the servomotor starts moving. A practical example would be a load being indexed 90 degrees in 0.25 seconds. This is not difficult for a continuous cam indexer or a zero-backlash servo indexer, but a cycle-on-demand cam indexer may struggle with that motion. For quick servo indexing applications, a preloaded gear reducer with zero-backlash is critical to achieving smooth indexing motions with minimal settling time. A zero-backlash RollerDrive mechanism would be an optimal choice to achieve accurate positioning with great dynamic response.

For either style of indexer, application information including moment of inertia, indexing angle, indexing time, and dwell time is required. A reputable manufacture should then be able to properly size the rotary table for the application.

Boasting a 1300 mm footprint, the TO1300 suddenly makes larger scale applications possible that previously seemed out of reach− as current direct-drive tables are relatively small and limited to a diameter of 750 mm. Additionally the TO1300’s high-tech drive operates predominantly without mechanics or gearboxes.

With over ten years of expertise in the field of direct drive torque motors, WEISS often designs and develops out of the logical response to changing market requirements and customer demand. This was the case with the TO1300 as a client’s concrete custom requirements stipulated a high mass inertia of 160 kgm2 and a large index increment of 45° with fast cycles−namely an index time of 0.21 seconds with a dwell time of 0.29 seconds.

For challenging tasks of this nature, a mechanical heavy duty table is typically the logical choice. Due to their gearing ratio, however, these tables don’t fare well in service life calculations for use at such high speeds as the needle bearings simply suffer from too much wear.

The correct alternative is a direct drive; which inspired the development of the TO1300. With a direct drive, only one bearing is under load which is virtually free of backlash. The table is low-wear and easily capable of delivering the desired dynamic performance requirements.

Unique to the TO1300 is that customers can customize it to their individual requirements. For example; they can make a modular selection between bearings, encoder and motor, and thereby alter the following table characteristics:

A specialist in automation, WEISS also offers many sizes for the TO series direct-drive rotary indexing tables; ranging from small to very large. Optimal solutions for specific application challenges can be achieved from the series wide range of options. Each TO model is also available in a version with a cleanroom certificate.

Corporate Profile: An integral part of the Weiss global network, Weiss North America (ISO-9001 Certified) leverages over 45 years of reliable world-wide expertise to comprise an integrative, customer-specific approach to its vast array of electromechanical products. Our 100% vertical range of manufacturing ranges from rotary indexing tables, handling systems, and linear assembly systems−providing flexible technology for turnkey solutions that incorporate electronics, mechanical systems, software, and comprehensive engineering support. This enables us to provide pre-installed, intelligent, and highly convenient solutions for the entire field of kinematics.

Leading development partner for the transportation industry with a global operating workforce of over 5,600, EDAG (Detroit, MI / Fulda, Germany) recently was faced with the task of designing a heavy-duty ring for a new production concept. Featuring a distinctly large central opening, the WEISS CR2600 heavy duty ring rotary table is a unique combination for this size of a classic rotary table and shuttle system in which robots can access the workpiece from both sides.

Hahl commissioned industry leading specialist for rotary tables and automation WEISS North America, Inc. (Willoughby, OH), and its’ parent company WEISS (Buchen, Germany), to initiate detailed and collaborative engineering discussions with them to develop a complete, integrated solution for EDAG’s unique production system.

Based on its‘ powerful CR series range of heavy-duty rings, which feature large open centers, WEISS North America began customized engineering specifications on a unique CR2600 rotary table that could ultimately accommodate four tools−and a robot in the center.

The table should also feature sufficient space in the center for a robot to carry out both machining and logistics functions−thus permitting space saving while enhancing the flexibility and productivity of the system.

Key specifications for the new CR2600 heavy duty ring table quickly came into focus:A permissible vertical axial 500kN dynamic and 1000kN static force on the drive plate

Additionally, the new member of the WEISS CR family would inherit all the positive design characteristics of the series’ range: a flat design, zero backlash and optimum power transmission, as well as a drive unit positioned far to the outside which can easily be taken into operation with WAS.

According to Stanislav Cafuta, a WEISS system developer, “The key was designing the ring’s central opening with a diameter of two meters, tool weights of up to 20 tons, and a reach of up to 2.5 meters – demands which even our largest heavy-duty rings were unable to meet at the time.”

Several technical hurdles had to be overcome before the new-generation CR2600 was able to achieve its production goals. With its very high vertical integration rate, WEISS was able to monitor and guarantee quality while procuring large parts with long delivery times more quickly.

One of these critical parts was the bearing. The development of a so-called YRT bearing, a combination of two axial bearings and a radial bearing, is a time- consuming matter. To overcome this issue, the WEISS engineers decided to speed up the process by giving the bearing supplier Schaeffler (Fort Mill, SC), a helping hand by assuming responsibility for the development of the bearing cages themselves. As a result, the total development time and delivery for the new CR2600 heavy duty ring table was compressed to six months.

Featuring a distinctly large central opening, the CR2600 heavy duty ring table is a unique combination for this size of a classic rotary table and shuttle system in which robots can access the workpiece from both sides. The system is currently running with two tools for two components, so that the rear hatches and bonnets can be manufactured in a combined process.

According to WEISS North America’s Vice President, Bill Eppich,“Ultimately, the CR 2600’s unique configuration opens up other possibilities for the installation that sparks the imagination. This is due to the user-programmability of the table, as well as savings in floor space brought about by the option of positioning even large robots at its center.”

In the market for a rotary table? The checklist of requirements starts with speed, accuracy and rigidity. Will it be used for contour machining? Do you need high-speed indexing for high-volume parts? What features and capabilities will help in the short and long term within the industries your company serves? CTE spoke with multiple rotary table manufacturers to discuss market trends, product innovations and add-ons that can improve overall machine tool performance.

In addition to a standard rotary table, many manufacturers require additional system features to meet the special machining requirements necessary in production facilities, according to Randy Conley, rotary table product manager at CNC Engineering Inc., Enfield, Conn. “Today’s rotary table customers typically look for a turnkey package that includes an additional axis interface, control options, rotary table hardware, installation, training and a complete documentation process. We also have to offer accessories like workholding fixtures, tailstocks, risers and hydraulic power units,” he said.

Off-the-shelf rotary tables are not always enough as customers seek equipment made specifically for their individual machining applications and the accessories. “For example, the application may require an outboard support spindle and a trunnion plate. A subplate or riser may be required. These parts would all be designed based on a particular manufacturing process for a particular machine,” Conley said.

CNC Engineering’s custom rotary table comes with a single PVC cable with a waterproof connector that can be connected or disconnected in a few seconds with a half turn. This cable has proven to be highly durable and remains flexible after years of use. Image courtesy CNC Engineering.

Conley said small improvements through the years have been the norm for rotary tables. “Most commonly, that has meant higher speeds and greater clamping torque. Many rotary table manufacturers offer worm wheel models that are able to run at 100 rpm or more, within a limited-duty cycle. Pneumatic clamping torque is often in the range now that could only be provided with a hydraulic clamping system just a couple of years ago,” he added.

Many manufacturers offer direct-drive rotary tables that eliminate the worm gear (see chart on page 66). “These tables can offer higher speeds than the traditional gear drive tables but, depending on the application, the drive torque may be lower. Furthermore, users may find it necessary to retune the servo drive for different applications to maintain optimal performance and stability,” Conley added.

“These direct-drive rotary tables specialize in eliminating backlash and can provide a stiff mechanical system for highly dynamic applications,” said Gregory Kane, marketing manager at IntelLiDrives Inc., Philadelphia. “Integrated with precision bearings and ring encoders, these tables provide high performance for indexing applications compared to other mechanical transmission rotary systems.”

Today’s rotary table users seek products that are accurate, efficient and easy to use, according to Frank Cerrito, general manager at Koma Precision Inc., East Windsor, Conn. “Our customers are looking for automatic fixturing to increase production and reduce errors, for example. They’re asking for higher speeds, higher accuracy and less backlash.”

These tables are being purchased for old and new machine tools, according to Conley. “Often our customers would like to be able to use an older rotary table on a new machine, as well as an older machine. Depending on the control vintages, we can often accommodate that need,” he added.

The Weiss rotary indexing ring has a large central opening to allow a customer to position all tooling and cables internally. Image courtesy Weiss North America.

Additional considerations play a part in choosing the right rotary table. This includes everything from number of axes, position requirements, faceplate size, motor location and energy requirements. “A customer may need a low-profile rotary table that reduces rotor inertia, improves start/stop behavior and enhances velocity control compared to conventional rotary systems,” Kane said. “This is due to the lightweight, direct-drive motor, resulting in precise bidirectional speed and position control, which is critical for high-speed motion contouring.”

Weiss North America Inc. says its index tables are sized properly so the use of an overload clutch is not needed in a jam-up situation. Overload clutches increase the maintenance cost of the table, according to John Treter, the Willoughby, Ohio, company’s product sales manager.

“Our tables are also filled with oil at the factory and will never need to be changed,” Treter said. “Because of these two differences, Weiss is a maintenance-free solution. We also manufacture risers, tool and stationary plates and machine bases. This saves our customers the hassle of purchasing multiple components from multiple vendors.”

The size of the through-hole is an additional factor. “A table with a large center hole allows [running] routing cables and pressure/vacuum lines through the aperture, placing test objects into the aperture, and inserting work tools and installing slip rings,” Kane said.

“Sometimes there may not be a pre-engineered solution for keeping a rotary table connected to the control throughout a pallet change,” Conley continued. “Designing and building a system for a particular machine model is often more work than a customer wants to take on. CNC Engineering has developed several types of cable management systems. If we’re dealing with a new model, we typically customize one of our existing systems to adapt it to a new machine configuration.”

Weiss North America introduced the first rotary indexing ring, which features a large central opening. “This allows the customer to internally position all tooling, cables, etc. and to work from the inside out, saving sought-after floor space,” Treter said. “From there, we moved to servo mechanical, offering another option utilizing the same design yet incorporating the flexibility of servo technology.”

Remote diagnostics is another area gaining momentum in the industry, according to Kane. More manufacturers are beginning to look at monitoring equipment that can help prevent production downtime and eliminate costly repairs. These capabilities can be performed over the Ethernet or on mobile devices. With the release of Weiss Application Software 2 early this year, a remote diagnostic portal for a Weiss technician has been added. “This helps ensure a quick fix for the customer if something were to happen,” Treter said. “It is very simple to email a Weiss technician the program parameters to be diagnosed.”

Koma Precision, which distributes Tsudakoma rotary tables, offers a detailed comparison chart (www.komaprecision.com) for those interested in some of the advantages and disadvantages of a worm wheel vs. a direct-drive system. Here are some of the differences that distinguish the rotary tables from one another.

We combine rotary index tables with industrial automation systems so each task of your manufacturing process blends seamlessly into the next. For example, in the past we’ve created industrial automation systems that join rotary indexing machines with pick-and-place units for some of our clients. Contact us to see what we can do for you.

Rotary indexers are just one part of the equation when building a custom assembly cell. It’s important to remember the entire scope of the project and be cognizant that the rotary table should be able to move precise distances before stopping cleanly, with no backlash or wobbling. It needs to be balanced and capable of handling the tasks at hand.

Our automation experts have years of experience in consulting with our customers to create machines that suit their needs. We incorporate rotary tables from industry leaders like WEISS, Fibro, and Camco into our machines to create the perfect fusion of form and function. Our dedication to quality is unmatched in the world of custom machinery.

We seamlessly integrate rotary indexing tables into our automated machinery to provide you with custom solutions that work for your business. If you’re looking to take your manufacturing process to the next level, give the custom machine builders at Paramount Tool a call at (616) 582-5300 today. We’re always happy to answer any questions you may have about our rotary indexing machines or the machine building process as a whole. For a free quote, fill out our contact form and we’ll get back to you as soon as we can.