Double-wrist Robot inside Vertical 3-axis MCORIGAMI
Double-wrist Robot inside Vertical 3-axis MC Create jigs to move and fix the work material. 100-micrometer cubes can be put into volume production with the world’s first automatic work shifting robot.
✔You are looking to automate manufacturing of complicated works 5mm or less in size, which you currently rely on experienced craftsman to handle and produce.
✔You need to manufacture parts 0.1mm or less in size with high process capability index.
✔You feel like trying machining of materials not possible with stacked-type 3D printers.
✔There is lack of personnel but still you wish to perform stable and reliable machining work.
✔You wish to make more out of machining centers you own.
Small-sized Butterfly-style Flapping Robot
(Taro Fujikawa Laboratory, Tokyo Denki University)
World’s smallest universal joints were used, enabling light weight with sufficient stiffness.
Parts Manufacturing System with Repeat Accuracy within 0.003mm (verified)
Analysis was performed to verify accuracy of 1mm cubes, cylinders, and forceps produced using ORIGAMI, and 0.003mm* accuracy was verified. (* The sample was created as test product at Iriso Seimitsu Co., Ltd., and the accuracy values are not listed as guarantee of manufacturing precision of ORIGAMI.)
Micro Manufactured Product Examples
Planet gears, shaft holders, bolts, and other micro part product examples are listed here.
Background Manual shifting of works is the bottleneck of machining.
In machining industry, shifting of works is the most risky and dangerous phase, with chances of breakage and deformation.
In vertical 3-axis machining centers, X-axis, Y-axis, and Z-axis is used to create products, and works are usually taken and shifted (passed-on) by hand. Even hands of careful workers may shake or make error in movement some millimeters or less, which may lead to breakage and deformation. The smaller the products are, the larger the risk. In micro-manufacturing, repeat accuracy of the operation is the huge challenge.
Only limited number of experienced craftsmen can work in micro-manufacturing field
The precision of shifting of works depended on expertise of craftsmen, and if such craftsmen are not available, what happens? Product quality will not be maintained, and so precise manufacturing will not be possible. There is even risk of work breakage. This is why at present only limited experienced workers can handle micro-machining works.
Fully automated 6-face machining was not possible
Machining centers with 3-axis or at maximum of 5-axis will only enable machining of, at most, five faces of six-faced works, such as cubes. In order to perform machining to multiple faces, the work needed to be cut off from the material, and half-finished part needed to be taken out. Another jig that is suitable for the next machining needed to be created and set onto the machine. The half-finished product was then set on to the machining center at an ideal angle or direction. If the product was small and delicate, positioning of the product with jigs, or change in positioning of products, became a complicated task, taking much man-hours. This was the big challenge in micro-machining.
ORIGAMI Solves Challenges
Point 1 Shifting of works is automated, and manual process is eliminated, resulting in better process capability index.
ORIGAMI is a double-wrist robot to be positioned inside vertical 3-axis machining center. Works inside machining center can be shifted automatically, without manual handling. This means ORIGAMI can replace the technological knowhow of experienced craftsman, using numerical control. This is an innovative system, useful for works less than 20mm in size, for machining of parts 1mm or smaller. For detailed parts 1mm or smaller in size, handing-over of half-finished products is automated, eliminating risk of error in positioning possible if done by hand. Sometimes it takes about an hour to hand-over works, and now that is done at an instant. No need to worry about manual errors and risks. Another merit is that strain of works can be numerically expressed, and related jigs can be created automatically, without help from experienced craftsmen. Stable and mass production is possible.
Point 2 Fully automated 6-face machining possible, with 3-axis machining centers
When ORIGAMI is installed inside a machining center, it drastically upgrades performance of the machine. Even with 3-axis machining centers last-face machining will become possible. No need any more to worry about multiple face machining. Change in method of work positioning made this possible. NC program is used for operation, so you can operate the machine just as usual. There is no need to learn to use ORIGAMI. Just place it on your 3-axis machine, and your machine will start working like a 3D printer, machining works from various directions.
Complicated and small products can be manufactured with ORIGAMI, without additional cost of a new machining center. Just add ORIGAMI onto your existing machining center. Do not worry about temperature control, or big investment in infrastructure. Just make the most out of what you already own, and search and try new possibilities.
Installment and Usage
⚫︎ Even machining centers produced 15 years ago can be used.
⚫︎ORIGAMI can be installed on all sorts of vertical 3-axis machining centers.
⚫︎With the NC program to operate 3-axis machining centers, you are all ready to go, without learning new programming language or complicated setups.
⚫︎No need to control room temperature, no special environmental facility necessary.
System Structure Example
⚫︎NV5000 (DMG MORI) Introduced in 2002, rotation 12,000 r/min
*ORIGAMI can be used on machining centers with low rotation.
⚫︎If you are considering purchasing a 5-axis machining center, you might be able to go on with your vertical 3-axis, just add ORIGAMI, and be satisfied with the cost performance and the product.
*If you are considering purchase, we recommend CMX 600 V (MORI SEIKI).
In ORIGAMI, jig is created to fix the work material, which is then used when shifting and re-fixing the work.
*The material of the jig depends on the product to be manufactured. Multiple templates are provided for different work shapes.
1. Install ORIGAMI onto your machining center, according to the manual provided.
2. Check the model and decide on the first reference plane. Then create data for ORIGAMI jig.
3. Install work material on the First Unit, and jig material on the Second Unit of ORIGAMI.
Automatic Cutting Work
1. The Second Unit rotates 90 degrees, and machines the jig needed to fix the work material.
2. Machining of jig
3. Machining of the first work surface
4. The First Unit rotates, continues machining work on the second surface (perpendicular to the first surface).
5. The Second Unit rotates, approaches, and fixes the work with the created jig.
6. Work cut off from the First Unit.
7. With the Second Unit, the work is fixed, and machining is performed on the last surface.
Configuration of ORIGAMI
|ORIGAMI Main Body (MC cable not included) Axis Configuration (5-axis) ・First Unit Spindle ・First Unit Tilt Axis ・Second Unit Spindle (Rotating Axis) ・Second Unit Tilt Axis・Second Unit Horizontal Shifting Axis||W600㎜ × D260㎜ × H219.5㎜|
|ORIGAMI Control Table||W600mm x H219mm x D9.1mm|
|ORIGAMI Control Box||W600mm x D210mm x H700mm（weight:85kg）|
|Power cable (3-phase, 200V/16V)||10m|