Increased efficiency through automated processes with the POSmill E 1100
The automation of manual process steps in CNC production makes a significant contribution to reducing non-productive times, increasing reproducibility and improving the utilization of machine capacities. The following video illustrates how a production process for Machining both Sides of steel plates on a POSmill E 1100 can be automated by integrating a SherpaLoader® M80. The integration of safety-related devices ensures safe and monitored operation.
Automated CNC Machining with a POSmill E 1100 with the highest safety standards
The entire production cell is equipped with several safety devices that safeguard automatic operation. Mechanical protective elements prevent tampering, crawling under and reaching into the work area. A light curtain on the loading side with 30 mm resolution detects the intrusion of limbs in the sensitive access area; it is safely monitored. There is also an inspection door at the rear, the status of which is monitored to ensure that maintenance access is only possible in a safe state. The speed and position of the robot are continuously monitored so that all safety-relevant limit values are always adhered to during operation. All requirements for permanently safe automatic operation are therefore met.
Robot-assisted blank handling on the POSmill E 1100
The material is supplied via two pallets. The steel plates are located on the unfinished part pallet. They are provided in stacks to increase the capacity of the Pallet. After Machining, finished parts are placed on the finished parts pallet. The camera-supported recognition technology on the robot detects the exact position of the raw parts. This enables flexible loading of the Raw Material Staging without having to place the parts precisely. The robot removes the blank with a two-jaw parallel gripper and positions it on an alignment station. Mechanical positioning against a fixed stop creates a defined alignment. This reduces the variance in the subsequent clamping process and increases process stability. Before transferring to the first clamping station, the robot arm cleans the magnetic clamping plate of the processing machine with compressed air to remove chips and lubricant residues. This increases the reproducibility of the clamping and reduces faults caused by incomplete contact surfaces. The SherpaLoader®M80 then places the blank on the cleaned pole shoes of the POSmill E 1100’s magnetic clamping system and the first machining side is machined. Once the First Run is complete, the robot cleans the workpiece, removes it and places it on a gripping station for turning. The robot grips the part from the unmachined side and feeds it to the alignment station a second time. Defined positioning is also carried out here before the next Machining operation to ensure repeatable clamping conditions. The SherpaLoader®M80 also cleans the second clamping station automatically before inserting the Part into it. The part is then inserted into the second magnetic clamping system, enabling Machining on both Sides and finishing parts without manual intervention. The advantage lies in the complete, continuous Machining with consistent quality and minimized variance in component pick-up.
Synchronized process sequences to maximize spindle running time
Before the back of the current workpiece is machined, the SherpaLoader®M80 picks up the next blank from the Raw Material Staging. This is prepared, positioned on the alignment station and then, after the clamping point has been cleaned, fed to the first clamping station. The overlapping of Machining with the preparation of the subsequent process reduces downtimes and increases the spindle running time of the POSmill E 1100. Both clamping fixtures are cleaned cyclically by the robot arm. This prevents the build-up of chip nests on the contact surfaces and ensures consistent clamping quality. Thanks to this synchronous mode of operation, a large number of parts can be machined in a continuous process without operator intervention. This results in a stable production cycle with high repeat accuracy and low effort in machine operation. Once the machining of both sides of the workpiece has been completed, the SherpaLoader®M88 cleans the Part with compressed air and then positions it on the finished part storage unit. The automated return system ensures traceable storage of the edited workpieces and supports orderly further processing. Thanks to the complete automation, all processing steps can be carried out in a traceable and standardized manner – without manual intervention during operation.
Automated production of a POSmill E 1100 as a contribution to stable processes
Automating the machining process on the POSmill E 1100 with the SherpaLoader® M80 not only enables stable and repeatable production processes, but also reduces the workload of the operating personnel in the long term. Manual routine activities are no longer required, freeing up capacity for higher-level tasks. At the same time, the standardization of processes increases process stability and reduces the susceptibility to errors. The system thus contributes to the efficient use of existing personnel resources and to ensuring production quality.
