Universal robot solution for all EMAG machine types
Automation of EMAG machines: Camera-controlled robot solution
The SherpaLoader® automation solution makes EMAG vertical turning machines and machining centers more productive and economical. The camera-controlled robot system takes over the workpiece feed fully automatically and ensures unmanned production - even at night and at weekends. Unlike rigid devices, the 3D camera laser system recognizes workpieces flexibly on Table Trolleys, Pallets or in the SpaceBox. The solution is suitable for retrofitting existing EMAG machines as well as for new machines - regardless of the control system and year of manufacture.
Non-binding adviceAdvantages of robot automation for EMAG machine tools
Maximize spindle time with autonomous workpiece feed
The SherpaLoader® keeps EMAG machines permanently in operation. Workpieces are fed automatically so that the spindle time is optimally utilized. Downtimes due to manual loading are eliminated, which significantly increases machine utilization. The result is a higher production volume with the same machine capacity.
Reduce personnel costs with higher productivity
Automation significantly reduces the need for operating personnel. A robotic arm takes over loading, while the machine works Lengthwise and more efficiently. This means that skilled workers can be deployed for more value-adding activities. At the same time, the costs per manufactured part are reduced, which increases competitiveness.
Consistent production quality thanks to precise robot handling
The camera-controlled system recognizes each workpiece exactly and positions it with high precision. As a result, the production quality remains consistently high - regardless of the batch size. Errors caused by manual handling are avoided, which reduces rejects and increases process reliability. The precise control and repeat accuracy ensure that every Part is handled under identical conditions.
Economical production of small and medium series
Automation for EMAG machines is not only suitable for large series. Small and medium quantities can also be automated economically. Short changeover times make production flexible and efficient. This means that changing jobs can be implemented without long downtimes, which makes production planning easier.
Innovative workpiece detection with 3D camera laser system
The SherpaLoader® system recognizes workpieces fully automatically using a 3D camera laser system. The technology precisely detects the position and orientation of each part without the need for fixed fixtures. Workpieces can be provided unsorted as the Vision System reliably identifies them. This flexibility saves time and significantly reduces set-up costs.
Faster changeover in less than 5 minutes when changing workpieces
With the SherpaLoader®, workpieces can be changed in less than 5 minutes. It is operated via an intuitive user interface without the need for programming adjustments. The system learns New parts by simply teaching them in via Vision System. As a result, production remains flexible and reacts quickly to changing jobs.
Flexible material provision via SpaceBox, Table Trolleys or Pallets
Workpieces can be provided in different ways. The SpaceBox offers structured storage, while Table Trolleys or Pallets are suitable for larger quantities. The robot system flexibly accesses all forms of provisioning. This versatility adapts perfectly to existing production processes.
Simple operation without FANUC programming knowledge
The SherpaLoader® is controlled via a clear graphical user interface. FANUC programming knowledge or robotics expertise is not required. New parts are set up by simple on-screen training. This makes automation accessible to All machine operators and reduces dependence on specialists.
Robot systems for EMAG vertical turning machines
For small to medium-sized turned parts:
SherpaLoader® T7 and T12
The SherpaLoader® T7 and SherpaLoader® T12 are ideal for EMAG vertical turning machines with small to medium-sized workpieces. The camera-controlled gripping system recognizes different part geometries and ensures consistently precise handling. The compact design fits seamlessly into existing production environments.
For medium-heavy turned parts:
SherpaLoader® T25 and T50
With the SherpaLoader® T25 and T50, larger EMAG vertical turning machines can be efficiently automated. Higher payloads and short cycle times make these models an economical solution for medium series sizes. Even demanding materials are handled safely and with process stability.
Handling heavy workpieces:
SherpaLoader® T88 and T225
For heavy and large-volume turned parts, the SherpaLoader® T88 and SherpaLoader® T225 provide the necessary robustness. The systems guarantee reliable operation even with large batch sizes and high cycle requirements.
Robot systems for EMAG machining centers
Leichte Werkstücke:
SherpaLoader® M7 und M12
For light workpieces on EMAG machining centers, the SherpaLoader® M7 and SherpaLoader® M12 is the right choice. These models are characterized by short changeover times and reproducible processing quality.
Medium-duty applications:
SherpaLoader® M25 and M50
The SherpaLoader® M25 and SherpaLoaders® M50 cover the medium weight range and offer maximum adaptability. High positioning accuracy meets flexible application options - perfect for changing quantities and different part ranges.
Heavy workpieces:
SherpaLoader® M88 and M225
For heavy and solid workpieces, the SherpaLoader® M88 and SherpaLoader® M225 is used. The reinforced design ensures stable operation even under demanding conditions and with continuous utilization.
Retrofitting of existing EMAG machines
Universal interface for all EMAG control systems
The SherpaLoader® system is compatible with all common EMAG control systems. Integration takes place via standardized interfaces, regardless of machine age or control generation. FANUC controls are supported as well as other systems installed in EMAG machines. This universal compatibility makes it possible to automate even older existing machines without costly conversions.
Retrofit solution for EMAG machines without robot preparation
EMAG machines without factory robot preparation can also be automated. The SherpaLoader® system does not require any special machine preparation or interface packages. Retrofitting is done by connecting to the existing machine control system. This means that even older EMAG machines can be economically integrated into modern production concepts.
Alternative to pick-up spindle systems for flexible part ranges
The camera-controlled robot solution offers more flexibility than classic pick-up spindle systems. While pick-up spindles are limited to defined workpiece geometries, the SherpaLoader® grips a wide variety of parts. Workpieces can be changed in just a few minutes without mechanical retooling. This flexibility makes the solution ideal for production with a changing range of parts and smaller batch sizes.
Extension modules for complex production processes
Complete machining through component turning and multi-sided Editing
The SherpaLoader® system can be extended with a turning module. Workpieces are automatically turned and fed back into the machine to Edit both sides. Complete machining takes place without manual intervention, which saves time and increases process reliability. EMAG machines thus become fully automatic production cells for both Sides Machining.
Cleaning and quality assurance in the automated production process
Additional modules enable the integration of cleaning stations directly into the production process. Workpieces are automatically cleaned after Machining and prepared for subsequent processes. Optionally, measuring stations can be integrated to check the parts during the automated process. These extensions turn EMAG automation into a continuous process chain with integrated quality control.
Precise workpiece alignment for vertical spindle mounting
The camera-controlled alignment positions workpieces precisely for mounting in the vertical spindle. The system recognizes the position of the workpiece and corrects the position automatically. This eliminates manual alignment processes and shortens cycle times. The precise positioning ensures consistent clamping quality and optimum machining results.
Economic efficiency of robot automation on EMAG machines
Productivity increase through unmanned shifts and weekend operation
Automation enables the operation of EMAG machines without operating personnel - even at night and on weekends. This significantly increases machine utilization without incurring additional personnel costs. Unmanned shifts make optimum use of expensive machine capacities and significantly increase output. Continuous production makes production processes easier to plan and shortens delivery times.
Cost savings with simultaneous capacity expansion
The SherpaLoader® reduces the costs per manufactured part by increasing capacity utilization. At the same time, production capacity is expanded without having to invest in additional EMAG machines. Labor savings and reduced scrap improve profitability in the long term. Automation typically pays for itself within a short time due to these combined effects.
ROI calculation for EMAG retrofit
The investment in robot automation can be calculated in concrete terms. Factors such as increased productivity, personnel savings and additional production time are included in the ROI analysis. Depending on the workload and shift model, the system pays for itself within a short period of time. An individual profitability calculation shows the specific savings potential for the respective EMAG machine.
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 EMAG machine automation
All common EMAG machines can be automated with the SherpaLoader®. The system can be used regardless of the year of manufacture, control system or machine configuration. Both new machines and older existing machines can be retrofitted.
The SherpaLoader® is installed without interfering with the EMAG machine substance. The connection is made via standardized interfaces of the machine control system. Existing warranty claims remain unaffected.
The fastest commissioning of the SherpaLoader® was completed in just 3 days, including training. The machine is immediately ready for productive use.
The installation can be scheduled to minimize production downtime. Preparatory work is carried out in parallel with ongoing operations.
The SherpaLoader® enables continuous 24/7 production on EMAG machines. The system works reliably overnight and at weekends without supervision.
Unlike pick-up spindle systems, the SherpaLoader® offers maximum flexibility for the range of workpieces. Parts can be changed in less than 5 minutes without mechanical retooling. Different geometries and sizes can also be handled without changing fixtures. The camera-controlled detection automatically adapts to different workpieces, which significantly reduces set-up costs.
Personal advice on CNC automation for your EMAG machine
Individual requirements analysis and automation concept
Every production facility has specific requirements for automation and workpiece handling. A detailed analysis of the existing EMAG machines, range of parts and production processes forms the basis. This results in a customized automation concept that is optimally suited to the production environment. The consultation takes into account technical feasibility, cost-effectiveness and future expansion options.
Demonstration of the SherpaLoader® functions on a machine
The functionality of the SherpaLoader® can be experienced directly on a reference machine. The live demonstration shows the camera-controlled Gripper, the intuitive operation and the automatic process. You can bring your own workpieces and test them to check the feasibility. This creates a realistic picture of automation for your own EMAG machine.
Customized offer preparation with profitability calculation
The offer is tailored precisely to the respective EMAG machine and the production requirements. A transparent profitability calculation shows the amortization period, cost savings and increase in productivity. All components are specified in detail - from the robot model to optional expansion modules. The calculation is based on realistic application scenarios and makes the return on investment comprehensible.
Continuous support from planning to commissioning
Support begins with the concept phase and extends to full commissioning. Installation, programming and integration into existing production processes are carried out by experienced technicians. Machine operator training ensures that the system is used optimally from day one. Support for optimizations and extensions is also available after commissioning.
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It is always our pleasure to have the system set up and started without any instructions from the operator.
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