Knowledge Hub

Solves: CNC lathes loaded and unloaded by hand: one operator per machine, and the night shift cannot run

• What CNC lathe loading and unloading is
• Why a lathe needs automated loading and unloading
• The complete loading and unloading sequence
• Robot or gantry robot
• Automating a single machine
• How one robot serves two machines
• One robot serving three machines, and multi-machine lines
• From gripping to repeatable clamping
• Automatic flipping and second-operation clamping
• How automatic clamping is done
• How cycle time is calculated
• How to keep production running through the night
• Whether different part sizes can share one cell
• Machine fit and brand compatibility

Solves: Machining centers clamped, loaded and unloaded by hand, and the handover between operations

• What machining center automation covers
• How the full sequence runs
• Which machines it suits
• Choosing a machine vise or a hydraulic fixture
• Multi-face machining and automatic flipping
• How to lay out a multi-machine line
• How clamping accuracy is held
• In-line inspection after machining
• Machine communication and signal retrofits
• Typical system configurations

Solves: Drill & tap centers run short cycles and large batches, and the repeated load and unload motions eat into the cycle

• Why drill & tap centers suit automation
• How the overall structure is put together
• Robot configurations
• Gantry configurations
• Keeping feeding in step with the cycle
• Locating and clamping
• Unloading and sorting
• Designing one robot for two or three machines
• Specifying the end effector
• Signals and safety

Solves: A robot without stable feeding: frequent refills and limited continuous running

• What automated part storage is
• Why a storage magazine is needed
• Eight common storage structures
• Choosing the structure
• How storage capacity is calculated
• How continuous production is achieved
• Using it with lathes
• Using it with machining centers
• Working with the robot
• Working with the vision system
• Feeding a multi-machine line
• System composition

Solves: How the part is actually moved: choosing robot or gantry form, payload and travel

• Robot or gantry: how the decision is made
• Five system configurations
• Choosing the robot
• Choosing the gantry
• Payload and working envelope
• How the part is gripped (end effector)
• Running different part sizes on one line
• With lathes / with machining centers
• Flipping and second-operation clamping
• Safety systems

Solves: Loose parts cannot be located, so someone places them by hand and consistency depends on the operator

• What vision-guided flexible feeding is
• Why it is needed
• When vision is not needed
• Choosing between 2D, 3D and AI vision
• The complete sequence
• System composition
• Feeding formats and buffering
• Grasping and pose correction
• Specifying the end effector
• Handling hard-to-grip parts
• How sample-part validation is run
• Changeover between part sizes

Solves: Batch inspection is done piece by piece by hand: night capacity sits idle and records depend on the operator

• What an unmanned inspection workstation is
• Where it sits in the production line
• Workstation architecture
• Sample storage and scheduling
• Sample identification and numbering
• Robot pick and place
• Vision and LIBS inspection
• Judgment and sorting
• Data and reports
• How unattended running is achieved
• Overnight batch inspection
• Exception handling

Solves: Building inspection into the production flow instead of sampling and reworking afterwards

• Where inspection sits in the line
• What can be inspected
• Dimensional inspection
• Hole diameter and hole position
• Appearance and scratch inspection
• Character and code reading
• In-line or off-line
• System composition
• Light sources and illumination
• How accuracy and tolerance are defined
• Sorting OK from NG
• Inspection data and traceability

Solves: Not buying a few robots, but re-planning the flow of parts, machines and data

• What plant-wide automation planning is
• Why planning comes first
• Assessing the current state
• Part flow and process analysis
• Logistics planning
• Machine layout
• New plant or retrofit of an existing plant
• Retrofit priorities
• Six upgrade levels
• Combining business lines 01–08
• Cycle time and capacity calculation
• Buffering and logistics buffers
• Phased implementation
• Planning is not procurement