Less than 50 years ago, automated production was still a fantasy. Today, thanks to the emergence of the CNC prototyping services industry, it is as common as a vending machine in an airport corridor. While just a few years ago you had to hire a highly qualified specialist to install a robotic arm loader for you, today many CNC manufacturing devices have preset options that allow you to attach the arm yourself. However, the need for automation in CNC production must be carefully examined since robots are generally very expensive.
When is a robot needed?
Originally, it was believed that CNC automation should be used for monotonous jobs, for high-precision operations that humans cannot perform, and for dangerous production supply chains. Today robots have become cheaper, and I would say that the most important reason to choose robots is this: if you take into account the cost of the robot itself, it will bring you more profit in the next five years than if you didn't buy it. . Basically, add up your costs and profits. Divide the robot's price by five and look at your production plans. If factory automation increases your CNC production so you can create enough new jobs to save a fifth of the robot's price this year, you should definitely buy it.
Arm selection
There are many robotic arms for various automated production purposes. Some of them load or unload parts onto the machine tool, speeding up the CNC process, others can perform welding work, install some elements on a machine, etc. The simplest and most efficient robot for CNC companies (companies with low-volume CNC production) and prototype manufacturers are robotic arms that load and unload parts.
The arms differ in the way they are programmed. Previously, this was a very complex and time-consuming process that was only practical if you had hundreds of thousands of parts or required the highest level of positioning accuracy. Today there are poor people who can learn cycles. As? Well, you basically put them in learning mode and manually move them from the first to the last action. The arm remembers what you did and imitates your actions. The positioning accuracy is not that high, but programming such an arm takes much less time.
The main advantage of a robotic loading arm
Its main advantage is that if you need to make a batch of identical parts on a machine tool, you can fully automate the CNC process, to the point where you can pick up a box of raw parts and go home, come back the next day and have the entire batch. ready. The arm works a second and third shift for you.
What you need to install and configure the arm
So you've considered everything and come to the conclusion that creating a smart factory will benefit your business. Maybe you even bought the arm. And now? Well, both devices must work in unison. The most important factor here is that they can send and receive information between each other. Since the arm works when the machine tool is stopped and vice versa, they don't need to know much about how the other works. They primarily need to receive a signal to start and send a signal when their part of the cycle is complete.
The arm for the machine tool
The arm should start working as soon as the machine tool finishes processing the part and opens the door. He must receive this signal, pick up a blank, move it to the machine tool device, release it and take its ready position. However, there are some nuances to letting go. In some processes, such as turning, for example, the part must be clamped (or held) in place while clamping occurs. So the program will be a little more complex because the arm needs to send the signal to the lathe that it is time to clamp, and the lathe needs to send the signal to the arm that the clamping is complete.
The arm machine tool
How to connect the arm to the machine tool and make them understand each other. If you know mechatronics, you can connect any arm and any type of CNC machine tool. There are several options, e.g. B. Configure via a USB port or connect directly via one of your device relays. Then you can write a small conversion program so that the arm output signal can be understood by the machine tool programming language. For example, the arm sends the signal from an M program to close the door, rather than just an unknown output signal.
However, if you are not a mechatronics engineer, I recommend that you check what type of equipment or control panel the arm you want to buy is compatible with. If your machine tool is not included in the list, I suggest checking with the manufacturer. He will definitely know and can help you set it up. They may even have some manuals that can help your CNC company save some money on technicians.
Programming the CNC machine door
An important feature when setting up automated production for CNC precision machining is the machine tool door. It should open or close automatically. If your machine tool does not have this option, I recommend that you purchase it first. And even if you bought a brand new automatic door, there may be some problems. The most important thing is that opening the door takes some time. So you need to set a delay for the arm to wait, otherwise it will collide with the opening door.
Another serious problem is that when you insert the “Open Door” function into the program and a little later, the control unit may think that the door is blocked because it does not open immediately. If you have this problem with your machine tool, the easiest course of action would be to program your arm to push the door open/close function on the control panel itself (like a human machinist). It's not difficult and will save you a lot of time and effort fiddling with the control panel and door.
How WayKen can help you
We specialize in rapid prototyping services and small batch manufacturing to support the development of new automated CNC product solutions. We have strong production capabilities and excellent supply chains to provide custom CNC machining and rapid injection molds in the shortest lead times. If you are interested in how we can be your strategic partner, please contact us.
