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Geiger Fertigungstechnologie GmbH, which produces sophisticated turned and milled parts for drive technology and sensors, relies on highly automated robots in its workshops. However, the demands on interfaces that enable efficient cooperation between people and systems are increasing.

When designing a new robot cell on a machine tool of a milling center in spring 2022, the company from Pretzfeld therefore relied on functional handles from Kraus & Naimer GmbH, specialists for switches, functional handles and enclosures as well as touch panels. The three-color illuminated handle bars use the traffic light system to indicate the loading status of the drawers for the workpiece feed and removal. The integrated pushbutton enables direct, secure access to the components without the machine operator having to switch to an additional control panel.

It's hard to miss when one of the functional handles on the 5 m long, automated robotic cell changes colour:

• The traffic light system clearly shows the loading status of the nine drawers for workpiece loading and unloading.
• The time has come: one compartment is finished. With just one movement, an employee unlocks and opens the drawer, removes the blister with the finished parts and inserts a new one with raw parts.
• The compartment is closed and immediately released again via the integrated push button on the handle.

Thanks to this smooth cooperation between humans and robots, the associated milling machine is reliably loaded in order to produce sophisticated components for air conditioning compressors in electric vehicles.

In-house system design relies on a simple human-machine interface

"With around 5.5 million precision parts for the automotive sector that leave our halls every year, robot automation is the heart of our production lines," reports Björn Bauer, control and electrical engineer at Geiger Fertigungstechnologie GmbH. "It is therefore all the more important that our machine operators work together smoothly with the highly automated robot cells." For this reason, one of the goals of the in-house tool and system design is to optimize each production line in order to make communication points between the machine operator and the system as uncomplicated and efficient as possible to implement.

The functional handles of type FH04-LL from Kraus & Naimer GmbH in Karlsruhe fit perfectly into the concept. "The particularly long, rounded grip not only fits comfortably in the hand, but also lights up conspicuously and can thus draw attention to the operating status of a unit from afar," says Andreas Hennig, Sales Manager at Kraus & Naimer. In this way, the machine operator can follow the productivity of the automated robot at a glance and fill or empty the corresponding drawers in good time without having to pay attention to an additional control display.

Robust materials for optimal function

"The color effect is realized with the help of an illuminated plastic insert made of PMMA," says Hennig, explaining the structure of the functional handles. "The translucent thermoplastic is characterized by its robustness and scratch resistance, which makes the material the ideal choice for the harsh environment of industrial production." 

The insert is attached to a durable grip bar made of extruded aluminum. The two short handles – one of which has a push button – are made of glass-bead reinforced polyamide. Due to its particularly good mechanical properties, this material is recommended for applications such as handles, where tensile and compressive forces are frequently exerted. In addition, the FH04-LL corresponds to protection class IP 65 and is therefore dust and water jet proof. This means that the compact electronics can withstand even a rough and demanding environment.

With the FH04-LL, a 5 m long connecting cable is routed out of the screwing surface of the handle shank as standard. On request, however, the integration of an eight-pin plug, the adjustment of the handle length or other lighting is possible. "We don't just respond to individual customer requests with our extensive range of switches," says Max Rauh, who is responsible for sales in southern Germany. “Most functional handles and switch enclosures can be modified and labeled. In exchange with the customer, we find the right solution from the standard range or produce a tailor-made variant.” Geiger Manufacturing Technology also relies on this, where main switches from Kraus & Naimer are already in use. "The feel and function of the product simply won us over and every component that improves our production lines makes our life easier," summarizes Bauer.

The entire range of functional handles can be found here.