Modern automation solutions also enable medium-sized companies to increase their productivity and compete internationally. This article provides an overview of technologies, use cases and decision criteria for CNC automation.
Our CNC robotsCNC automation refers to the automated loading and unloading of CNC processing machines without manual intervention. While the CNC control takes over the tool movements, the automation ensures the continuous material flow: feeding blanks, clamping, removing and depositing machined parts. The goal: maximizing spindle time while reducing non-productive time. While a manually operated machine only produces while the operator is present, an automated system enables production in late and night shifts as well as at weekends - without additional personnel costs. The spectrum ranges from simple accumulating conveyors for identical parts to flexible, camera-controlled robot systems that handle different workpiece geometries without mechanical retooling.
Demographic change is hitting the metalworking industry hard. Qualified machine operators are increasingly hard to find, especially in rural areas. Automation offers a solution: skilled workers are relieved of repetitive tasks and can concentrate on more demanding tasks - programming, quality assurance, process optimization.
Labor costs in Germany are significantly higher than in low-wage countries. Automation makes it possible to produce higher quantities with less manpower. The advantage is particularly evident with rush orders: while competitors rely on shift workers, automated companies can produce overnight and deliver the next morning.
Many companies are thinking about relocating back from abroad. The reasons: Quality problems, long transportation routes, supply chain risks. Automation makes this relocation economically viable thanks to lower transportation costs, shorter response times and proximity to development.
Identical workpieces are stored on a conveyor belt or magazine and fed one after the other.
Advantages: Low investment, simple operation, high reliability
Disadvantages: Only identical parts, high changeover effort, large space requirement
Application: Large-scale production with infrequent product changes (automotive supply industry)
Workpiece carriers are loaded externally and changed automatically. Zero-point clamping guarantees high repeat accuracy.
Advantages: Very short setup times, external pallet loading, high precision
Disadvantages: High investment in pallets, one pallet required for each workpiece
Application: Tool and mold making, aviation industry
Industrial robots handle a wide variety of workpiece geometries. Modern systems use camera technology for workpiece detection - mechanical positioning aids are largely eliminated.
Two main approaches:
Direct workpiece handling: Robot grips blank directly and places it in clamping device. Requires hydraulic/pneumatic clamping or electric torque wrench for mechanical vices.
Vise change: Complete vices with zero-point clamping are changed. Faster loading, but cost-intensive with many different parts.
Advantages: High flexibility, short changeover times with Vision System, additional functions can be integrated
Disadvantages: Higher acquisition costs, more complex commissioning
Application: Contract manufacturer, frequently changing products in small to medium batch sizes
Vision Systems detect the position and orientation of the workpieces and the robot automatically adjusts the gripping movement. Mechanical positioning elements are no longer required.
Advantages: Changeover times under 5 minutes, None mechanical stops, mixed provision possible
Economical sweet spot: Batch sizes 5 to 5,000 pieces with frequent product changes
Processing time: Automation becomes interesting from approx. 8 minutes main time per part Batch size:
Shift operation: Particularly economical if the machine continues to work without personnel (weekend, night)
Personnel availability: Often the only way to utilize capacity when there is a shortage of skilled workers
Quality: Consistent, reproducible work without fatigue errors
As-is analysis:
Interfaces: Modern machines: Profibus, Profinet, EtherNet/IP. Older machines: M functions and potential-free contacts.
Safety: light curtain, safety laser, personnel-safe door drive in accordance with the Machinery Directive.
Gripper: Depending on the workpiece: jaw grippers, collets, vacuum grippers.
Professional commissioning includes adjustment of movements, testing of communication and operator training. Modern systems with graphical user interfaces: New Jobs can be set up in just a few minutes, no programming knowledge required.
Problem: Many existing machines do not have a rotary feed-through. Retrofitting often involves high five-figure costs.
Solution: Electric torque wrenches automate mechanical vices. Cost: Fraction of the machine retrofit.
Problem: Contract manufacturer with a wide range of parts - mechanical systems require long changeover times.
Solution: Camera control recognizes workpieces automatically. Changeover times under 5 minutes by adjusting the gripper span.
Solutions:
Solution approaches:
From 5-10 pieces with frequent product changes. Sweet spot camera-controlled: 5-5,000 pieces.
Typically 1-3 years. Faster for night shifts and weekend production.
Yes, interface via M functions possible. Electric torque wrenches replace missing rotary feed-through.
With modern systems: 3-5 minutes for a New Job, None programming knowledge required.
Remote diagnosis and alerts via SMS/email. Many problems can be solved via remote maintenance.
Camera-controlled systems: conversion in just a few minutes.
Compact robot cells: approx. 4-6 m² in addition to the machine.
Normal machine operators operate the system after training.
Companies report significant improvements: A precision parts manufacturer increased delivery reliability without additional skilled workers - response time to rush orders of days to under 24 hours. A housing manufacturer optimized work processes, with staff concentrating on quality assurance. A contract manufacturer in a rural area secured production despite a shortage of skilled workers through weekend and night production.
Next case studies in our Customer Stories
Automation of a SPINNER TC800 lathe with SIEMENS control and main and counter spindle. Loading of / unloading onto two Pallets.
Automation of a MAZAK Quick Turn 200MS lathe for Machining cylindrical saw cuts, provided by SpaceBox
Automation of a DOOSAN Puma 2600S lathe for Machining of large Cylinders, provided by Euro pallets.
Automation of a MAZAK Integrex 200-II SY turn-mill center for Machining Cylinders, provided by SpaceBox.
Automation of a DMG MORI CLX 350 lathe for Machining of Rings, provided by SpaceBox.
Automation of a MAZAK QT250 MY lathe for Machining Shafts, provided on Euro pallets.
Automation of a HAAS UMC 750 5-axis milling machine for Machining of sawn cuboids, provided on Table Trolleys.
Automation of a DMG MORI CTX beta 1250 TC turn-mill center for Machining of Shafts, provided on Euro pallets.
Automation of an OKUMA LB3000 EX lathe for Machining of cylindrical saw cuts, provided on Table Trolleys.
Automation of a MORI SEIKI SL-250 lathe for Machining of cylindrical saw cuts, provided on Table Trolleys.
Automation of an OKUMA LB35-II lathe for Machining of cylindrical saw cuts, provided on Table Trolleys.
Automation of a DOOSAN Puma TL2400 LM lathe for Machining Shafts, provided on Euro pallets.
Automation of a Mori Seiki SL-204 lathe for the Machining of saw cuts, provided on a Table Trolleys.
Automation of a MAZAK QT250 MY lathe for Machining cylindrical saw cuts, provided on a Table Trolleys.
Coordinate measuring machine integrated into the unloading process for reliable quality inspection data
Station integrated into the loading process for turning workpieces before OP2
Embossing vice integrated into the production process for narrow to very wide workpieces
Station integrated into the unloading process for cleaning the machined workpieces of chips and cooling lubricants
Marking station integrated into the unloading process with reliable carbide needle and large marking window
Cut-off extension module for producing several semi-finished products from one blank
Alignment station for pre-positioning molded parts for position-oriented insertion into the processing machine
Automation of machine vices without rotary feed-through, with torque-accurate control of the tightening torque
Discover our knowledge portal on the automation of modern CNC machines. Here we share expertise, best practices and practical insights into the use of robotics and CNC optimizations. Learn how innovative technologies such as the SherpaLoader make production processes more efficient and increase competitiveness.
Automation of a Spinner 4-axis CNC machine
When implementing automation solutions in the manufacturing process, specific requirements must be taken into account in order to increase productivity. The integration of the SherpaLoader® into this process illustrates how coordinated technologies can meet these requirements and optimize the production process.
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