The integration of robotic systems with used CNC machines has become a key strategy for improving automation and productivity in the ever changing landscape of manufacturing. In this article, we explore the intricacies and advantages of robotics and used CNC machinery working together, offering a complete guide for manufacturers who want to improve their manufacturing processes.
Understanding CNC Machines and Robotics
By integrating robotic systems with your existing CNC machines you can increase manufacturing efficiency and flexibility. Robots are well suited to repetition with accuracy and do well with material handling, assembly, welding, and inspection. Coupled with CNC machines they facilitate operations, cut short cycle times and enhance production consistency.
Popular Robots for CNC Automation:
Fanuc M-10 Series:
- Suitable for machine tending tasks, compact robots.
- Specifications: Repeatability of ±0.03 mm, reach up to 1,633 mm, payload up to 12 kg.
ABB IRB 2600:
- Ideal for material handling applications, high speed robots.
- Specifications: Maximum payload of 20 kg, maximum reach of 1,650 mm, repeatability of ±0.04 mm.
Universal Robots UR Series:
- Collaborative robots (cobots) for safe interaction with human operators, for machine tending.
- UR5e Specifications: Reach of 850 mm, repeatability of ±0.03 mm, payload up to 5 kg.
- UR10e Specifications: Can transport up to 12.5 kg, reach of 1,300 mm and repeatability of ±0.05 mm.
Halter CNC Automation’s LoadAssistant:
- Robots loading systems to be seamlessly integrated with CNC machines for manufacturing automation.
- Features: The machine is compatible with several types of CNC machines, capable of producing workpieces in different sizes and weight, as well as designed for easy integration.
Once these robotic systems are integrated with your CNC machinery, they can offer a more efficient and scalable manufacturing process that is faster, less expensive to operate.
Benefits of Integrating Robotics with Used CNC Machines
The integration of used CNC machines with robotic systems provides several compelling benefits. The right combination of machines and robots can deliver dramatic gains in productivity, accuracy, safety and cost efficiency.
Increased Productivity
Robots can slash downtime for tasks like loading and unloading parts, inspecting finished goods and transferring materials from one machine to another—thus boosting productivity. This enables manufacturers to produce many parts in short time and with no compromise on quality.
Example Integration:
CNC Machine: Haas VF-2
Specifications:
- Travel: 762 mm x 406 mm x 508 mm X, Y, Z axis
- Spindle Speed: Up to 8,100 rpm
- Tool Capacity: 20+1 tools
Robot: Fanuc M-10iA
Specifications:
- Payload: 10 kg
- Reach: 1,420 mm
- Repeatability: ±0.08 mm
Benefit: Continuous operation with minimal human intervention and increased throughput and reduced cycle times are made possible by automating the Haas VF 2 with the Fanuc M 10 iA robot.
Improved Accuracy
However, robots are known to be precise and consistent. When coupled with CNC machines, they can guarantee that parts are put and aligned the right way, decreasing the possibility of human mistake, and enhance the general quality of the completed item.
Example Integration:
CNC Machine: Mazak Quick Turn 250
Specifications:
- Maximum Swing: 695 mm
- Spindle Speed: Up to 4,000 rpm
- Power: 26 kW
Robot: ABB IRB 2600
Specifications:
- Payload: 20 kg
- Reach: 1,650 mm
- Repeatability: ±0.04 mm
Benefit: ABB IRB 2600 has high repeatability which enables it to load and unload parts into Mazak Quick Turn 250 with high accuracy and less scrap.
Enhanced Safety
Because of that, robotic systems can perform hazardous tasks that can harm human workers. For instance, robots can lift heavy objects, work in risky conditions and fulfill job which are highly specific in the absence of favorable working circumstances.
Example Integration:
Robot: Collaborative Robot Universal Robots UR10e
Specifications:
- Payload: 12.5 kg
- Reach: 1,300 mm
- Safety Features: Built in sensors, force limited joints
Benefit: The cobot UR10e can work safely with human operators without extensive safety fencing. From part handling to machine tending, robots can perform these tasks and significantly reduce the risk of workplace injury, giving human workers a chance to focus on higher value work.
Cost Efficiency
The upfront cost of robotic systems may seem quite high, but the long term cost savings can be dramatic. Robots work 24 hours a day without a break and reduce labour cost and eliminate overtime. They can also help to increase the life of used CNC machines by automating maintenance tasks.
Example Integration:
CNC Machine: Haas VF-4
Specifications:
- Travel: 1,270 mm x 508 mm x 635 mm (X-axis, Y-axis, Z-axis)
- Spindle Speed: Up to 8,100 rpm
- Tool Capacity: 20+1 tools
Robot: This robot is a Fanuc CRX-10iA (Collaborative Robot).
Specifications:
- Payload: 10 kg
- Reach: 1,249 mm
- Energy Efficiency: Low power consumption
Benefit: The Fanuc CRX-10iA cobot operates energy efficiently, lowering operating costs. By working consistently without fatigue, downtime and labor costs are reduced saving a lot of money in the long run.
Steps to Integrate Robotics with Used CNC Machines
It is a complex process of integrating robotic systems with used CNC machines, that calls for careful planning and execution. This integration does more than just automate, it also improves production efficiency. Manufacturers must go through several critical steps in order to successfully merge these technologies, each of which builds on the previous one, in order to create a seamless and effective operation.
1. Assess Your Needs
The first and foremost thing to do when integrating robotics with used CNC machines is to assess your current manufacturing processes. This entails thoroughly probing your production line to find those zones that stand to benefit the most from automation. Search for tasks which are repeating, labor consuming, time consuming and prone to human error. For example, if the majority of your operators’ time is spent loading and unloading parts, or where there is a bottleneck in material handling, this is where automation should be utilized.
Think about the particular results that you want to get from automation — it can be increased production throughput, product quality, decreased operational expenses, or increased workforce security. Clearly defining your needs and objectives will allow you to tailor the integration process to the most impactful areas, and get a better return on investment.
2. Choose the Right Robot
Choosing the right robotic system is a key decision which makes or breaks the integration. The robot must be able to work with your used CNC machine and do the task you want it to do efficiently. Key factors to consider include:
- Payload Capacity: The robot should have the ability to handle weights of parts or tools, it will manipulate.
- Reach: A sufficient arm length is needed so the robot arm can reach all necessary points within the workcell, all the way through loading area of the CNC machine.
- Speed and Precision: For one application, you may need a robot that provides high speed for greater productivity, or high precision for applications requiring exacting accuracy.
- Environmental Conditions: Think about how any environmental factors which might influence the performance of the robot, such as temperature, dust or moisture.
3. Integrate Control Systems
In order to synchronize operations, there is a fundamental need for a seamless integration of the control systems between the CNC machine and the robotic system. Here we also ensure that the two systems can communicate with each other, and in many cases this requires the addition of software or another control system between them.
- Communication Protocols: Two – use standard industrial communication protocols, for example Ethernet/IP, Modbus or ProfiNet to make reliable data exchange between CNC machine and robot. These protocols facilitate real time communication for coordinated movement and operation.
- Software Integration: A middleware or custom software is implemented to bridge any gaps in machine to robot compatibility. This software is a translator that aligns the commands and feedback signals between the two systems, so that they work together.
This phase is where you should work with control system engineers or automation experts with experience at integrating the robotic systems to CNC machines. Configuration of the control interfaces, linking the synchronization routines, and coping with communication problems become possible on their help and support.
4. Build Workcells
The interaction between the CNC machine and the robot is crucial to be optimized and designing an efficient workcell is vital. The layout of the workcell must allow steady work flow, maintain safety, and then achieve maximum productivity. Key considerations include:
- Safety Measures: A secured environment with use of safety fencing, light curtains, etc. should be installed. These barriers prevent unauthorized persons access to the robot operating area and helps reduce the probability of accident. Emergency stop buttons and safety interlocks should be implemented, such that, if a situation where a safety breach may occur is detected, the operations immediately stop.
- Ergonomic Layout: Set up the equipment in the workcell to make the workflow easier. Place the CNC machine and robot in such a way that the distance parts have to travel is minimized, thus decreasing handling time. Make sure that material storage areas, conveyors and other peripherals are arranged in a way that helps to ensure efficient operation.
- Optimizing Workflow: We’ll examine the operations sequence to see where bottlenecks can be brought to bear. Change the robot workcell design to accommodate parallel processes where possible so that the robot can do work while the CNC machine is scheduled to be in cut. The parallelism can greatly cut cycle times overall.
- Accessibility for Maintenance: The workcell should be designed to allow easy maintenance personnel access. The plant should have adequate space available to allow routine inspection, repair, and adjustment without disturbing production.
When you meticulously plan the workcell design, you build an environment that promotes operational efficiency, high safety standards and future scalability.
5. Train Personnel
The key to successful integration of robotics with CNC machines is your personnel. Training programs that form a comprehensive process for training your team for effective operation and maintenance of the integrated system are therefore necessary.
- Operator Training: This teaches the machine operator how to interact with the CNC machine control as well as how to communicate with the robotic controls. Part of that includes understanding the regular operating procedures of the equipment, it’s safety procedures, and hopefully basic troubleshooting techniques. Operators must be able to begin and end processes, modify operating parameters, and react to system alerts.
- Programming Skills: Teach each programmer how to program the robot for any range of tasks. Some of this may include learning certain software’s that the robot uses to create or modify instructions for the robot, or even learning specific programming languages. The robot can be optimized in many ways by skilled programmers and adapted to new tasks and improve over time.
- Maintenance Training: Make sure that robotic system’s mechanical and electrical components are known by maintenance staff. Routine maintenance activities, diagnostics, as well as repair procedures should be covered by the training. Knowing the robot’s maintenance requirements will prevent downtime and will extend the equipment’s lifespan.
- Safety Training: Stress safety with automated systems. The personnel should know of potential hazards, safety features and emergency response procedures.
The investment made in personnel training not only improves the effectiveness of the integrated system but also helps create a continuous improvement, innovation culture in your organization.
Technical Considerations
Several technical issues need to be taken into account when integrating robotic systems with used CNC machines to enable a trouble free and efficient operation. These considerations are essential to achieve optimal performance, to meet safety standards and to guarantee long term reliability of the integrated system.
Communication Protocols
For such synchronized operation requires effective communication between the CNC machine and the robotic system. For efficient part cycle times, both systems must access data from one another to coordinate tasks such as part loading, machining, and unloading. Some of the common industrial communication protocols used to make possible such connection are Ethernet/IP, Profibus, and Modbus.
- Ethernet/IP: The high speed communication capabilities and compatibility with many industrial devices make this protocol widely used. Real time data exchange is possible which is necessary for time sensitive operations in CNC machining and robotics.
- Profibus: Profibus is well known for reliability and especially robustness — even in environments where interference might occur. It works with many devices and can deal with complex communication networks.
- Modbus: Modbus is one of the oldest communication protocols and is very simple and easy to implement. For basic applications requiring features of newer speed protocols is not required.
Elsewhere, where CNC machine and robot system employs a distinct or incompatible protocol, intermediate devices (protocol converters, gateway modules) are utilized to overcome protocol differences. Additionally, it will be possible to develop custom software solutions or middleware to translate and map signals over communication between the two systems and to translate commands and feedback back and forth between them.
Safety Integration
Giving robotics to combine with CNC machines creates new safety problems that require careful managing to manage personnel and equipment. Comprehensive safety measures need to be implemented to avoid accidents and also safely conform to widely used industrial safety standards as ISO 10218 for robot safety and ANSI/RIA R15.06 for industrial robots.
Emergency Stop Systems
Emergency Stop (E-stop) system is required to stop operations immediately in case of an emergency. Both the CNC machine and robotic system E-stop circuits should be interconnected such that when the E-stop is activated on one device, the other will stop as well. With this, there’s coordination so that one machine doesn’t continue running while the other stops, which can result in collisions, or some overall hazardous scenarios.
Light Curtains and Sensors
However, presence sensing light curtains, safety scanners and other presence sensing devices are very effective at detecting human entry into hazardous areas. By integrating these sensors in the workcell these sensors can halt the operations automatically in the workcell if a person breaches the defined safety zone from the robot or CNC machine. For example:
- Light Curtains: They emit infrared beams that, if interrupted, immediately stop. These are perfect for protecting access points to the robotic cell.
- Safety Scanners: It uses laser technology to monitor a 360 degree area. Warning zones and safety zones are programmed in, in which they respond in graded fashion based on proximity.
Furthermore, safety rated soft axis and space limiting features can be included in the robot’s control system to limit the robot’s movement within defined boundaries reducing the chance of unintended interaction.
Physical Barriers and Fencing
Another critical aspect of safety integration, is installing of robust physical barriers and safety fencing. These barriers keep unauthorized or accidental entry out of the robotic workcell. Safety interlocks on access gates can stop operations when opened, and only allow the system to be safe before anyone enters the area.
Collaborative Robots (Cobots)
For collaborative robots (co bots) that are designed to operate in the same workspace as a human, without minimizing with significant guarding, identifying, configuring, and programming appropriately is critical to maintaining a safe operation. Built into cobots are safety features such as force limiting and speed reduction when a human is near. This doesn’t negate the need for a full risk assessment though, as there may still be hazards involved.
Power and Electrical Requirements.
Stable and efficient operation of the CNC machine and the robotic system depends on ensuring that the power and electrical requirements of both are met. Equipment can malfunction, perform sub optimally, or even damage machines due to inadequate or unstable power supply.
Power Supply Compatibility
- Voltage and Current Requirements: Make sure you be able to provide the systems with the right voltage and current that the supplies have available. Many industrial robots and CNC machines need three phase power at specific voltage levels (e.g. 480V or 600V). Transformers or power converters may have to be used to bring the supply into line with the equipment requirement.
- Power Quality: To maintain consistent power quality, implement power conditioning equipment like uninterruptible power supplies (UPSs), voltage stabilizers, and surge protectors. It guards electronic components sensitive to voltage fluctuations, transients and power outages.
Electrical Infrastructure Upgrades are the most common type of upgrade. - Wiring and Cabling: Find out if the existing wiring and cabling infrastructure will be able to carry the traffic surge due to the robotic system. In some cases overloading may require upgrade to higher capacity cables or dedicated circuits as they comply with electrical codes.
- Grounding and Bonding: Grounding and bonding are what keep you safe and prevent electrical noise from contaminating communication signal. Make sure that all the equipment is grounded correctly in accordance with National Electrical Code (NEC) or local regulations.
- Control Panels and Enclosures: New or modification of the control panels may be required for the integration. They should be designed so that the control hardware for both systems will fit, with space allowed for future expansion. Appropriate Ingress Protection (IP) ratings for the operating enclosure should be maintained (e.g. dusts, coolant exposure).
Energy Management
- Power Management Systems: Using energy management solutions can enhance power usage and be a cost saving. These involve such things as programmable logic controllers (PLCs) that orchestrate start-up sequences to prevent power spikes, and energy conserving components like variable frequency drives (VFD), or motors.
- Thermal Management: Cool coming and venting control consoles and how to prevent the heating of the equipment. Among other things, this may mean installing air conditioning units, heat exchangers or fans.
Compliance with Standards
Electrical compliance with standards and regulations is mandatory. The integration complies with international and State standards like NFPA 70E for electrical safety in the workplace and IEC 60204-1 for safety of machinery electrical equipment.
Common Applications
The versatility of integrating robotics with used CNC machines is widespread across all manufacturing sectors and increases efficiency, precision, and flexibility. Manufacturers can tackle the needs of modern production with automation of key processes and the best utilization of existing equipment. Robotics and CNC machines always work together and some of their most common applications are described below.
Machining Operations
Robots play an important role in automating loading and unloading processes of parts from CNC machining operations. This automation replaces manual intervention; minimizes downtime; and improves throughput. Precision and consistence in handling raw materials and finished parts enables such robots to realize higher productivity and raise product quality.
Benefits:
- Increased Machine Utilization: CNC machines can run continuously, 24 hours a day, without operator breaks, and robots can operate continuously.
- Consistency and Precision: Automated handling also ensures that each part will be loaded and positioned correctly, minimizing production errors and unwanted scrap rates.
- Safety Improvements: Robots take over repetitive, and possibly dangerous, work reducing the risk of work place injuries.
Example Application:
A Fanuc M-20iA robot is integrated into a manufacturing facility using a Haas VF-2 CNC milling machine for automated part loading and unloading. The robot takes raw material blanks from a feeder system and puts them into the CNC machine. The finished part is removed by the robot after machining, and placed on an outbound conveyor. This setup increases production rates and enables the facility to run unattended during off peak hours.
Assembly Lines
Robots connected to CNC machines in assembly lines increase the manufacturing process efficiency by doing tasks of part inspection, assembly and packaging of the product among others. With their ability to perform tasks with extremely high repeatability and precision, they help ensure consistency and quality – very important in industries where quality standards cannot be compromised.
Benefits:
- Quality Assurance: Vision systems on robots can perform real time inspection of machined parts, finding defects before the parts leave the production line.
- Efficient Assembly: They can assemble complex components with precision, and do it much faster and with fewer errors.
- Scalability: Systems can be easily scaled up to satisfy growing production demands by automated systems.
Example Application:
The Mazak Quick Turn 250 CNC lathe is used by an automotive parts manufacturer along with an ABB IRB 4600 robot on an assembly line. In addition to unloading machined components, the robot also inspects using integrated sensors. The defective parts are automatically separated, so only quality products go to the next stage. After that, the robot assembles parts with other parts, simplifying the production process and keeping the quality high.
Material Handling
Material handling is a very important aspect of manufacturing which is defined as the movement, storage, control and protection of materials during manufacturing process. Robots are good at doing things like picking, placing, and transferring parts from one machine or station to another. When combined with CNC machines, they increase workflow and decrease time and labor involved in material transport.
Benefits:
- Workflow Optimization: By flowing materials continuously, robots reduce bottlenecks and increase efficiency as a whole.
- Labor Cost Reduction: Automating material handling reduces the use of manual labor and thereby reduces costs of operations.
- Inventory Management: Inventory systems can take advantage of robots, and utilize them to track stock levels and material usage in realtime.
Example Application:
An automated guided vehicle (AGV) system and robotic arms are integrated into a large scale manufacturing plant to transport material between CNC machining centers. AGVs are used to mount robots like the KUKA KR 10 R1100 to pick up raw materials from storage and deliver them to CNC machines like Okuma GENOS M560-V mills. Following machining, robots deposit completed products at the subsequent processing station or packaging area. Due to the integration, handling is now minimal; errors are lowered and the production cycle is faster.
Overcoming Challenges
Although integrating robotics with used CNC machines presents many advantages, manufacturers will face a number of challenges that must be overcome for a successful implementation. Maximizing the return on investment and long term operational efficiency requires first understanding these obstacles and develop strategies to overcome them.
Initial Investment
The initial cost of buying and integrating robotic systems is also one of the biggest challenges. This investment is more than the robots themselves, but costs of system integration, software, training and likely infrastructure updates. However, for small to medium sized enterprises (SMEs), these financial demands are significant enough to discourage them from adopting automation technologies.
Justifying the Upfront Costs
But the upfront expense can be justified by long term savings in labor costs, higher productivity and better product quality. Without fatigue, robots can operate at any time day or night, allowing for higher throughput, as well as more consistent output. The cost savings are achieved by reducing human error, which, in turn, reduces waste and rework.
Cost-Benefit Analysis
A thorough cost benefit analysis is necessary to judge the viability of the integration financially. When evaluating the worth of using robots, this analysis should account for the initial costs (including purchase price of robots, integration services, training and modification of infrastructure) and operational savings deriving from labor cost reduction, downtime, error rate reduction. Similarly, the opportunity for additional revenue with higher production requirements and the capability to manage more complicated projects will also be under consideration.
Exploring Financing Options
Installing a Fanuc M-20iA robot with a used Haas VF-2 CNC machine would be costly at the beginning. But the automation could potentially double the machine’s output, and thus speed up the return on investment. Manufacturers can use different financing techniques to overcome the financial problems. Through leasing, today, you can get lower initial costs and also, maintenance services, minimizing the upfront capital spend. Some of the investment pressures may be alleviated by government grants and incentives for the adoption of advanced manufacturing technologies. In addition, automation can be phased in slowly, so that the costs are only gradually incurred and the company has the ability to transition to the new technology gradually.
Complexity
The process of integrating can be inherently complex and indeed requires a great deal of expertise and planning. Compatibility requirements between robot and CNC machine need to be ensured, robot programming for a specific task is needed, and kinematics computation is needed.
Using the Synergy with the Expertise
It is important to work with experienced professionals that have both experience with CNC machines as well as robotic systems. A customized solution can be developed by the system integrators to assist the manufacturer in designing the integration that fits the manufacturer’s specific needs. Programming and configuration is instrumental in telling the robot what to do, what it’s programmed to do and its configuration to move the robot, to communicate with the CNC machine and safety systems. Moreover, they also play an integral role in testing and validation that the integrated system performs as we expect before a large scale deployment.
Investing in Staff Training
Effective investment to manage the complexity of the new system is to train the existing staff. This includes teaching machine operators how to work with the robot and CNC machine, teaching maintenance personnel the skills needed to service and troubleshoot the robotic system, and developing in house expertise to modify and optimize robot programs as the production needs change. The nurturing of the workforce so that its skill set strengthens that not only helps it to easily move to a new platform but also creates a culture of a continuous improvement and innovation in the organization.
Standardization Simplified
Integrating complicated instruction sets and interpreter generation is greatly simplified by the use of standardized interfaces and modular components. Also, by using robots and CNC machines that use common communication protocols such as Ethernet/IP or Profinet, compatibility problems can be kept to a minimum and configuration simplified. Modular solutions also allow for the easier upgrade and scalability, which allow the manufacturing system to change as needed with production requirement without large overhauls.
Maintenance
To stay at optimal performance and long lifespan, robotic systems need regular maintenance. Without maintenance, downtime, productivity is decreased as well as increased repair costs.
The first step is to establish Preventive Maintenance.
Preventive maintenance schedule is essential for robotic system to be in top condition. As part of the schedule, updating the robot’s software to the latest version with every update should be on the schedule – per performance improvements, security patches, and any other changes. This should also mean inspecting mechanical parts for wear and tear (gears, belts, bearings, …) and keeping the robot taking precise movements by calibrating sensors and actuators from time to time. Since contaminants can cause sensitive components to heat up and cause a build up of dust and debris, it must be cleaned on a regular basis so it can prevent the buildup.
Effective Maintenance Planning is a key element of a successful maintenance program.
Maintenance planning is the process of setting up the maintenance activity in such a way so that maintenance activities do not disturb the production schedule. An inventory of critical spare parts is kept, to prevent downtime when repairing parts, as replacements are available and delivered quickly without the need to order parts first. For tracking the system’s health, identifying recurring patterns as a sign of imminent problems, and recreating the bugs in the most sudden cases, detailed records of maintenance activities, issues seen, and took corrective actions on have to be maintained.
Remote Monitoring Implementation
By selecting remote monitoring systems you will be able to detect potential issues before they cause the failure. The connectivity features of advanced robots provide real time monitoring of performance metrics, including cycle times, temperatures, and error codes. Data analytics for predictive maintenance is used by manufacturers to predict when components will fail, so that they can be replaced proactively and unplanned downtime can be reduced. Abnormalities are detected immediately and you are alerted so you can respond quickly to resolve issues before they become problems.
Conclusion
A strategic investment in automation by adding robotics to used CNC machines can greatly improve productivity, accuracy and safety in manufacturing operations. There are challenges to be overcome, but the long term benefits make this integration a worthwhile investment for any manufacturer who wants to stay competitive in today’s fast paced industrial landscape.
Through the proper selection of CNC machines and robotic systems, and by considering technical issues in integration, manufacturers can develop efficient, automated production lines that produce high quality products reliably.
Additional Resources
Here are some additional resources:
- National Institute of Standards and Technology (NIST) – Robotics and Intelligent Systems: NIST Robotics
- SME (Society of Manufacturing Engineers) – Automation Resources: SME Automation
- IEEE Robotics and Automation Society: IEEE RAS
By leveraging the power of robotics and CNC technology, manufacturers can create more efficient, productive, and sustainable production environments that drive innovation and growth.
