Universal robot solution for all common DECKEL machine types
Automating DECKEL machine tools: Camera-controlled robot solution
The SherpaLoader® is a camera-controlled robot solution that loads and unloads DECKEL processing machines fully automatically - and thus significantly increases the spindle time. The system can be adapted to both New DECKEL MAHO machines and older existing machines. This makes entry into robot automation economical, fast and without programming knowledge.
Non-binding adviceProven automation: DECKEL MAHO DMU 60 eVo
Successful start with a 5-axis machine
A precision manufacturer with a focus on individual parts, prototypes and small batches was faced with a specific challenge: a customer was increasing its call-off volume - the existing DECKEL MAHO DMU 60 eVo was to be automated economically. An inquiry to the machine manufacturer revealed that the retrofitting of rotary feedthroughs, clamping hydraulics, door drive and Profibus interface alone would have cost a high five-figure sum. None of this was a sensible option for a machine that was already ten years old at the time.
The solution: a SherpaLoader® M25, which was connected directly without cost-intensive machine modifications. Today, the operator is convinced: "We put the MAFU-SHERPA automation system into operation around nine months ago. I can no longer imagine how we could manage the workload of the automated system with manual loading." All the details of this project can be found in the full case study.
Advantages of robot automation DECKEL machine tools
Maximize spindle time with autonomous workpiece feed
The spindle is the heart of every processing machine - and every minute it stands still costs money. The SherpaLoader® takes care of loading and unloading fully automatically so that the machine runs without manual interruptions. The DECKEL machine also continues to work overnight or at weekends - without the need for operating personnel to be on site. The result: significantly more production hours per day with the same machinery.
Reduce personnel costs with higher productivity
Qualified machine operators are rare and expensive. With the SherpaLoader®, the robot takes over the repetitive loading work so that skilled workers can be deployed for more value-adding tasks. One operator can look after several machines at the same time, which significantly increases productivity per employee. The costs per manufactured part are reduced - and competitiveness increases.
Consistent production quality thanks to precise robot handling
Manual loading is prone to errors - especially under time pressure. The SherpaLoader® positions each workpiece under identical conditions, with high repeat accuracy. This reduces rejects, ensures dimensional accuracy and ensures consistent quality - even over long shifts and large series.
Economical production of small and medium series
The SherpaLoader® is optimized for batch sizes of 5 to 5,000 parts - exactly the range in which many DECKEL operators work on a daily basis. Short set-up times mean that even frequently changing jobs can be automated economically. Expensive fixed devices or grid plates are no longer required because workpiece recognition is camera-supported.
Innovative workpiece detection with 3D camera laser system
At the heart of the SherpaLoader® is SherpaVision® - a 3D camera and laser system that automatically recognizes workpieces on Table Trolleys, Pallets and in the SpaceBox and precisely records their position. Round, square and panel blanks are identified without mechanical stops or grid plates. An integrated shutter protects the camera optics from dirt and chips - even under harsh production conditions. This makes the SherpaLoader® the world's first loading robot to automatically recognize these workpiece shapes as standard.
Faster changeover in less than 5 minutes when changing workpieces
When changing parts, only the gripper finger position is adjusted - there is no need for time-consuming magazine or pallet changes. This takes less than five minutes and the machine is back in operation. This advantage is particularly important for frequently changing jobs, as every minute of changeover time costs spindle time. While other systems are still setting up, the SherpaLoader® is already loading again.
Flexible material provision via SpaceBox, Table Trolleys or Pallets
Depending on the Part, batch size and space situation, three material provision concepts are available. The SpaceBox holds over 3,000 small parts on two Euro pallets (approx. 12 m²) and enables autonomous running times of several days. The Table Trolleys with simple docking system is suitable for prototypes and small batches. Heavy or large-format workpieces are fed in via Pallets - parts weighing up to 175 kg can also be automated.
Simple operation without programming knowledge
The system is controlled via EasyControl - a dialog-guided interface with graphical input masks on a 17-inch touch display. New Jobs are set up without specialist robot knowledge; the system is fully set up and handed over for the respective DECKEL machine during commissioning. Your existing team can get started straight away - without the need for training or external programmers.
Robot systems for DECKEL milling machines
Light to medium-weight workpieces:
SherpaLoader® M7 and M12
For machining centers with light to medium-heavy milling components, the models SherpaLoader® M7 and SherpaLoader® M12. The M7 handles edging material up to 4* kg in the range 10×10×10 to 150×150×150 mm, while the M12 covers workpieces up to 8* kg. Both systems are compact, economical and ideal for DECKEL machines with limited space and a changing range of parts.
Medium-duty applications:
SherpaLoader® M25 and M50
The models SherpaLoader® M25 and SherpaLoader® M50 are designed for typical milled components in medium weight classes. The M25 moves workpieces up to 18* kg, the M50 up to 38* kg. The M25 has already been used successfully in the DECKEL MAHO DMU 60 eVo project described above.
Heavy components:
SherpaLoader® M88 and M225
For heavy parts, the models SherpaLoader® M88 and SherpaLoader® M225 are also available. The M88 handles workpieces weighing up to 73* kg, while the M225 is designed to meet project-specific requirements and also enables the automation of parts weighing up to 175* kg. These systems offer maximum load capacity and stability - ideal for demanding milling applications on powerful DECKEL machines.
* depending on workpiece center of gravity
Retrofitting existing DECKEL machines
Universal interface for different controller generations
The SherpaLoader® is compatible with all standard processing machines. New machines are connected via Profibus, Profinet or Ethernet/IP. Older DECKEL machines without a factory bus interface are integrated via free M functions and potential-free contacts - without the need for a costly interface from the machine manufacturer. This means that even an older existing machine can be automated with the same system as a current new machine.
Retrofitting a door automation system
DECKEL machines without a driven safety door can be retrofitted. MAFU-SHERPA offers a maintenance-free electric door drive that integrates directly into the automation process. Opening and closing speeds can be individually adjusted; automatic obstacle detection and safe force and speed limitation in accordance with EN ISO 13849-1 Performance Level d ensure operational safety. Next, non-productive times in the machining process can be further reduced.
Extension modules for complex production processes
Complete machining through component turning and multi-sided Editing
An optional turning module enables the automatic rotation of workpieces directly during the loading process. This means that both sides of a Part can be machined without manual intervention - ideal for 5-axis machining centers such as the DECKEL MAHO DMU series. This saves changeover time, reduces sources of error and enables continuous complete machining in a single clamping operation.
Cleaning and quality assurance in the automated production process
The SherpaLoader® is equipped with a blowing nozzle as standard, which automatically cleans clamping fixtures before chucks are inserted and Machined parts before they are removed. In addition, an integrated cleaning station can be retrofitted to remove chips and cooling lubricant from workpieces after machining. Clean parts are a prerequisite for precise measuring and reliable transfer to downstream processes.
Precise workpiece alignment and clamping for optimum machining results
An optional alignment station ensures that raw parts are precisely pre-positioned before the robot inserts them into the machine. This is particularly important for tight tolerances and complex geometries. Combined with the electric spindle drive for mechanical vices, machines without hydraulics or pneumatics can also be clamped fully automatically - precisely, repeatably and without manual intervention.
Integration of secondary processes such as Marking and Measure
Next, the production process can be expanded with additional modules: Workpieces can be automatically marked or measured directly after Machining - while still within the robot sequence. This shortens the process chain, eliminates separate handling steps and ensures seamless traceability. This is a decisive advantage for companies with documentation requirements - for example in medical technology or aerospace.
Also compatible with all
other CNC machines
With its universal interface, the SherpaLoader® can be connected to all common turning and milling machines - regardless of their year of manufacture. This means that the same SherpaLoader® can be used to retrofit an older existing machine or to automate a new machine.
Frequently asked questions about DECKEL machine automation
In principle, all standard DECKEL and DECKEL MAHO machines can be automated - from older series to more modern machining centers to current DMG MORI models. The decisive factor is not the age, but the technical condition and accessibility for loading and unloading.
In many cases, the robot solution can be prepared in parallel with ongoing production and gradually put into operation. Pre-installations and structured commissioning minimize downtime. The aim is always to achieve the most uninterrupted implementation possible - so that your DECKEL machine is back in production as quickly as possible.
Yes, the universal interface of the SherpaLoader® supports various communication paths - from modern bus protocols to potential-free contacts and M= functions. Even if a DECKEL machine has already been equipped with a new CNC control at an earlier stage, the SherpaLoader® can usually be connected without any problems - without interfering with the existing control architecture.
With the SherpaLoader®, a DECKEL machine can be operated unmanned - even at night, at weekends or on public holidays. The SpaceBox supplies the machine with material for several shifts at a time. This creates productive hours without operators having to be on site - one of the most effective measures for increasing capacity.
Personal advice on the automation of your DECKEL machine
Individual requirements analysis and automation concept
Every DECKEL machine and every production process is different. Workpiece geometries, batch sizes, space conditions and shift models are directly incorporated into the design. The result is a customized solution - None of the standard configurations are off the shelf.
Demonstration der SherpaLoader® Funktionen
A practical live demonstration will show how the SherpaLoader® recognizes, precisely grips and reliably feeds workpieces under camera control. This gives interested parties a clear, realistic impression of the possibilities of automation - before a decision is made.
Customized offer preparation with profitability calculation
Based on the requirements analysis, an individual offer is created - including a comprehensible profitability calculation. This allows the return on investment to be clearly estimated: A properly deployed SherpaLoader® usually pays for itself within 12 months.
Continuous support from planning to commissioning
The entire process is accompanied from the initial analysis to installation and full commissioning. The automation is fully set up and handed over - including instruction of the team. During operation, remote maintenance access and a network of authorized service partners are available, who can be on site within a few hours if necessary.
Arrange a demonstration!
It is always our pleasure to have the system set up and started without any instructions from the operator.
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