Integration of automated processes in CNC series production
The automated loading of CNC lathes with parts enables consistent machine utilization with reproducible clamping conditions. In combination with a camera-based recognition system, automated chuck cleaning and mechanical pre-alignment, the SherpaLoader®T88 automates stable series production on a DN Solutions Puma GT3100 LM. The process minimizes manual intervention, reduces production fluctuations in the machining process and maximizes spindle run time.
Robot-assisted CNC Machining on a DN Solutions Puma GT3100 LM
The material flow in this machining process is divided into a raw parts pallet and a finished parts pallet. This makes it possible to provide raw parts in stacks to save space. The SherpaLoader®T88 is equipped with two three-jaw centric grippers to ensure the safe transport of parts. With the integrated camera-based recognition system, the robot arm detects the position of the raw parts on the raw parts pallet. This reduces the need for manual loading of the Pallet and the machining process can be adapted to changing production conditions with minimal effort. Controlled by camera recognition, the robot grips the first blank with the blank gripper and positions it on the alignment station. This mechanical pre-alignment ensures repeatable positioning and secures the clamping position of the parts in the system. After alignment, the blanks are transferred to the chuck of the DN Solutions Puma GT3100 LM. Before the workpiece is clamped, the robot automatically cleans the chuck with compressed air. This measure removes chip and coolant residues from the clamping surfaces and ensures constant clamping conditions. This ensures consistent component quality and reduces the amount of maintenance required for the Clamping Devices. The blank is then automatically clamped and the machining process begins. During the machining process, the robot picks up the next blank from the Pallet and positions it on the alignment station. The implementation of synchronous processes reduces non-productive times, increases the spindle running time and enables a continuous process sequence. Once Machining is complete, the SherpaLoader®T88 automatically cleans the finished part with compressed air before it is removed with the finished part gripper. In the same way, the chuck is cleaned again before the next raw part is clamped.
Automation of front and rear end machining in a DN Solutions Puma GT3100 LM single-spindle machine
The semi-finished parts are deposited in two stages, with the integration of a turning station. First, the semi-finished part is removed from the processing machine and placed on a gripping station. The finished part is then gripped by the robot from the other side, rotated and placed on the finished part pallet in a defined position. As soon as the initial Machining of all raw parts has been completed, the clamping device in the DN Solutions Puma GT3100 LM is converted. The finished part pallet serves as Raw Material Staging for Machining the backs of the components. This sequence enables structured further processing and automation of the front and rear sides on a single-spindle machine.
Robot-assisted CNC series production with integrated safety on the DN Solutions Puma GT3100 LM
Automated handling with camera-supported component recognition, mechanical pre-alignment and continuous chuck cleaning ensure constant production conditions. The dimensional accuracy of the parts remains stable, variances are reduced and rejects can be minimized. At the same time, manual activities are minimized. The automated cell on the DN Solutions Puma GT3100 LM therefore supports economically scalable series production with consistent quality and high system availability. The highest safety standards are always met. The entire automation unit is equipped with safety-related monitoring systems. There are safely monitored hinged doors on the loading side, as well as on the rear of the processing machine. Robot Positions and speed are also continuously monitored. The doors to the work area of the SherpaLoader® T88 are equipped with locking devices. The devices prevent the operator from entering the work area when the robot is clamping a Part in the Gripper that could injure people if it falls.
