FPS – Flexible Pallet System
What is FPS?
Modular Automation for 4 and 5 Axis
Flexible Pallet System (FPS) enables lights-out manufacturing and high spindle utilization in high-mix production with 4 and 5 axis milling and mill-turn machines, also with compact vertical 5-axis machines. This modular CNC automation solution handles machining pallets and zero-point plates of 300-630 mm and its unique 360-degree design ensures a fit for any shop floor – including tight spaces and low-ceiling facilities. FPS integrates CNCs of over 90 brands and can be extended from simple single-machine system into a full linear FMS.
FPS is controlled by Fastems’ Manufacturing Management Software (MMS) that is designed specifically to plan, run and monitor high-mix manufacturing. It is a tool for everyone working in production or managing it, giving a real-time view of production activities and identifying exactly what needs to be done next to ensure timely deliveries.
Automate Your Horizontal or Vertical Milling Machines
FPS is an extendable and modular automation solution for 4 and 5 axis milling machines with 300 to 630 mm pallets or zero-point plates. Its high pallet capacity, small footprint and automated production scheduling allow for high machine tool utilization and excellent lights out machining capability.
Modular automation with reach for hundreds of milling and mill-turn machine tools with or without automatic pallet changer.
The system can be extended from a single-machine system into a full linear FMS when the production needs change.
360-degree layout allows placing the CNCs, configurable pallet storage modules and loading stations in any four sides of the system.
COMPARE
The Best Automation for 4 or 5 Axis Machines
The wide integration library with hundreds of machine tools with and without the automatic pallet changer, 360-degree extensible configuration options, and configurable pallet storage modules are what make FPS a superior automation solution for milling machines.
| Comparison | Machine with automatic pallet changer | Pallet pool | FPS |
|---|---|---|---|
| Machine tool brands | - | Limited | Any |
| Machine type | - | Machines with APC | Machines with/without APC |
| New or existing machine tools | - | New | Both |
| Unmanned production capacity | 2 pallets | 6-24 pallets | Unlimited |
| Avg machine utilization | 40 % | 65 % | 85 % |
| Machines run per operator | 1 | 1 | As many as the system has |
| Extandability | Buy a new machine | Buy a new system | Plug-and-play extension |
| Automatic production planning | No | No | Yes |
| Order priorization | Manual | Manual | Automatic |
| Automatic real-time KPI reports | No | No | Yes |
| Cutting tool automation | - | - | Can be integrated |
| Automated fixture loading cell | - | - | Can be integrated |
EASY USE
Streamline Your Production
MMS, the control software of FPS, is designed to plan, run and monitor high-mix manufacturing. It is a tool for everyone working in production or managing it, giving a real-time view on what happens in production and most importantly, identifying exactly what needs to be done next to ensure timely deliveries and maximum spindle utilization.
1 | Production Planning
MMS generates production schedule automatically based on customer orders in your ERP or other listing. It also adapts automatically to sudden changes such as rush jobs or machine breaks.
2 | Production Resource Check
All the needed production resources are automatically checked in advance: NC programs, machines, tools, materials and fixtures. MMS guides employees to prepare all the missing resources before the machining is planned to begin.
3 | New Workpiece Introduction
Introducing new work pieces into production is possible in under 60 seconds with EasyRoute feature, and MMS Order Generator enables automatic production for recurring or stock balanced orders.
4 | Track Production KPIs
MMS automatically monitors production and reports key performance indicators in real time to the users – as well as gathers production data and gives practical tips on how to improve your productivity even further.
NUMBERS
Technical Data
Flexible Pallet System comes with two variants: FPS Stationary (FPS-S), a simple one or two machine automation solution; and FPS, the full linear FMS with high integration capabilities.
| 500 kg | 1000 kg | 1500 kg | ||||
|---|---|---|---|---|---|---|
| FPS-500S | FPS-500 (linear) | FPS-1000S | FPS-1000 (linear) | FPS-1500S | FPS-1500 (linear) | |
| Load weight, incl. pallet | 500 kg (1,102 lbs) | 1000 kg | 1500 kg (3,307 lbs) | |||
| Nominal machine pallet size | 300-500 mm | 500-630 mm | 500-630 mm | |||
| Load rotational diameter (Ø) | 630 mm (24.80″) | 900 (35.43″) | 1,100 (43.31″) | |||
| Load height, incl. pallet (H) | 1200 mm (47.24″) = 2 storage levels 600 mm (23.62″) = 3 storage levels 300 mm (11.81″) = 4 storage levels | 1200 mm (47.24″) = 2 storage levels 800 mm (31.50″) = 3 storage levels 450 mm (17.72″) = 4 storage levels | 1350 mm (53.15″) = 2 storage levels 600 mm (23.62″) = 3 storage levels | |||
| Max pallet storage capacity | 2 storage levels = 12 3 storage levels = 18 4 storage levels = 24 | 100+ (depends on system configuration) | 2 storage levels = 10/12* 3 storage levels = 15/18* 4 storage levels = 18/24* *depends on machine model | 100+ (depends on system configuration) | 2 storage levels = 12 3 storage levels = 18 | 100+ (depends on system configuration) |
| System length | 4100 mm (161.42″) | 4170 mm (164.17″) with 3-meter track 7150 mm (281.5″) with 6-meter track | 5600 mm (220.47″) | 4280 mm (168.50″) with 3-meter track 7390 mm (290.55″) with 6-meter track | 5600 mm (220.47″) | 4660 mm (183.46″) with 3-meter track 7760 mm (305.51″) with 6-meter track |
| Track extension lengths | – | 2980 mm (117.32″) or 5960 mm (234.65″) | – | 3040 mm (119.69″) or 6120 mm (240.95″) | – | 3040 mm (119.69″) or 6120 mm (240.95″) |
| End storage length | – | 800 mm (31.50″) | – | 1200 mm (47.24″) | – | 1250 mm (49.21″) |
| Width excl. stations | 3500 mm (137.80″) | 3250 mm (127.95″) | 4600 mm (181.10″) | 4050 mm (159.45″) | 4500 mm (177.17″) | 4300 mm (169.29″) |
| Height, incl. load | 3100-3650 mm (122.05-143.70″) | 3500-4100 mm (137.80-161.42″) | 3500-4150 mm (137.80-163.39″) | |||
| Transport height | 2800 mm (110.24″) | |||||
| Control software | Fastems MMS | |||||
DOWNLOAD
Guide: Automating Milling Machines
This whitepaper discusses topics around shop floor productivity: striving for LEAN manufacturing, what kind of machine tool strategy to select and how to feed the machines with pallet-based automation solutions. We also represent the most typical pallet automation solutions in the market and the production planning methods around them.
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