Following a large investment in a gear hobbing machine, the EMS production team were looking for a way to maximise the machine’s output and therefore achieve the best possible value from the investment.

Pete Daly, Production Engineer at EMS, explains: “The Affolter gear hobbing machine was a substantial capital investment for us; to maximise our return on the investment, we considered various ways of increasing production outside of the normal working hours. A cobot was the best solution.”

Automating the process of feeding blank parts into the Affolter machine would optimise the productivity and efficiency of the cell.

Having made the decision to automate with a collaborative robot, EMS looked into a range of solutions on the market and ultimately chose a UR5e from Universal Robots, supplied by UR+ Platinum Partner RARUK Automation.

“After obtaining quotes from several cobot suppliers, the decision to go with UR was based on ease of use and programming, the support offered and price,” Daly says.

Universal Robots 6-axis robot arms are designed to work safely alongside human operators, with a range of reach and payload capacities available depending on the cobot model. These robots are popular due to their ease-of-use and flexibility to be re-deployed to suit production needs.

In order to ensure that the automation process went as smoothly as possible, EMS conducted in-house testing and 3D modelling before the cobot was installed.

“From receipt of cobot to shop floor implementation was around two months,” explains Daly. “The reason for this was, we built a replica of the machine loading system in our R&D lab to test different methods and smooth out any potential issues. The whole setup was then installed on the machine.”

RARUK Automation has a dedicated Technical Support team, offering support on-site and over the phone, as well as certified training and feasibility trials.

“I have used the support a few times and they have always been able to help,” remarks Daly.

Adding that his overall experience with RARUK Automation has been positive, Daly says: “Everything has been very good. Very straight forward with good communication.”

Overall, implementing the UR robot has been beneficial for EMS for a range of reasons, including improved product quality. For instance, using the collaborative robot during the day enables the skilled operator to perform more frequent quality checks, making the process more efficient whilst keeping quality standards high.

Production staff at EMS have had a positive reaction to the robot, Daly says: “Staff were informed that the purpose of the cobot was, primarily, to extend the working hours of the machine, and secondly, to relieve the operator from the more tedious duties. Not to replace people, as is often the worry when people hear the word ‘robot’. Now staff have seen it working and can see the benefits; we have been met with positivity.”

Lastly, the primary goal of increasing productivity and continued output after working hours has been achieved, enabling EMS to maximise its ROI on both the gear hobbing machine and the robot.

Looking ahead, EMS may consider implementing more collaborative robots. Daly remarks:

“We have a couple of other projects where we feel the use of another cobot might be beneficial.”

Visit the RARUK Automation website for more information

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A standout feature of Shibaura Machine’s exhibit will be a fully automated production cell, where the TVM900 6-axis robot will seamlessly integrate with the advanced EC75SXIII injection moulding machine. This live demonstration will showcase real-time production of plastic business card cases.

The SXIII series is an all-electric line-up of injection moulding machines designed for high-speed, energy-efficient operation. With 16 different models tailored to varying tonnage requirements, the SXIII features the V70 controller for smooth integration, optimised cycle times and enhanced productivity.

The injection mould machine will collaborate with the TVM900 robot – one of Shibaura Machine’s comprehensive ranges of 6-axis robots. With a 900 mm reach and 20 kg payload capacity, robots in the TVM range offer rapid, smooth motion control and high repeatability.

Complementing this, the RoboPrint printing head will accurately transfer logos and designs onto the moulded plastic parts, demonstrating the potential of robotic integration for speed and efficiency.

“Robotic integration in injection moulding is transforming the industry,” explained Nigel Smith, managing director of TM Robotics, the premier Shibaura Machine robotics distributor in Europe. “By automating repetitive tasks, such as part handling, assembly and quality control, manufacturers can meet rising demand while maintaining consistent quality – all of which contribute to a faster return on investment.”

Dr. Georg Holzinger, executive vice president of Shibaura Machine Europe, added: “As a trusted Japanese manufacturer with over 75 years of experience, Shibaura Machine was one of the first to develop all-electric injection moulding machines in the 1990s. Today, its machines are engineered for unmatched precision, energy efficiency and reliability. This technology, working alongside our industrial robots, demonstrates our commitment to providing complete solutions for the plastics sector.”

Additionally, Shibaura Machine will showcase its TV1000 6-axis robot. With a 1,000 mm reach and 10 kg payload capacity, the TV1000 excels in material handling, assembly, machine tending and packaging applications.

Visit the TM Robotics website for more information

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Designed by DOMA Automation and integrated by Tera Automation, the Infinifeed uses a unique parallel belt conveyor system with opposing motion. This innovative design, equipped with diverters and a 2D vision system, ensures seamless part feeding and sorting.

The system addresses the common challenges related to industrial parts feeding. It can handle diverse shapes and sizes by leaning on advanced vision technology to detect, select and manage parts feeding. This eliminates the need for multiple feeders for different components or challenging programming for diverse parts shapes.

The Infinifeed is not only technologically advanced but also exceptionally user-friendly. Its integrated app allows for remote control, configuration, and real-time monitoring, making it accessible to operators without the need for specialised skills.

Users can easily capture images of objects to be handled, mark gripping points and send the information to the vision system. The speed of the belts can be fine-tuned to match production requirements and instant notifications on any operational issues ensure uninterrupted performance.

Built with advanced hardware to enhance operational efficiency, the Infinifeed eliminates physical barriers for smooth part circulation and simplifies the system with the app as the sole user interface. Magnetic removable shells and sides make maintenance and cleaning straightforward, while the adjustable inclination of the belts accommodates different workpiece sizes and weights. Optional enhancements include illuminators for better visibility and electric pistons for optimal part distribution and tilting.

The Infinifeed system is designed to meet the needs of various industries, including aerospace, automotive, electronics, medical, fashion accessories, water fittings, mechanics, electric components and more. It offers numerous benefits to manufacturers, such as easy integration and straightforward setup that reduces downtime and seamlessly integrates into existing production lines.

The user-friendly interface with intuitive controls and programming makes it accessible to all operators. Precision feeding ensures consistent and accurate placement of components, and high-speed performance boosts throughput and minimises cycle times. Continuous connectivity with real-time alerts and remote-control features keep users updated and in control.

“The Infinifeed, powered by Shibaura Machine represents the next step in industrial parts feeding,” explained Nigel Smith, managing director of TM Robotics, the premium distribution partner of Shibaura Machine industrial robots. “The new system provides manufacturers with a powerful tool to enhance productivity and efficiency, while leaning on the exceptional robotic power of the THE SCARA robot series.”

The THE series is the latest generation of SCARA robots from renowned Japanese manufacturer, Shibaura Machine. The series is meticulously designed for assembly and inspection applications and includes four sizes in its line-up. The THE400, THE600, THE800 and THE1000 cover arms lengths of 400mm to 1000mm respectively, fulfilling a range of applications for fast-cycle automation.

THE robots can be purchased as standalone automation or integrated into machine builds, OEM solutions and systems integrations like the Infinifeed. TM Robotics’ team of robotic experts can provide support and consultation on how Shibaura Machine robots can be applied in a range of industries.

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The idea was sparked by the need for a device for the growing needs of the family-run business, founded by Tony Thompson 30 years ago, and also supported by his two sons, Matthew and Daniel. Their development of collaborative robot applications, based on a Universal Robots robot, was so successful for them they decided to perfect and market it to external customers, calling it the CoboTend. Now, a partnership with SICK UK has enabled effortless safety without sacrificing productivity for the CoboTend, a step that has been vital to the product’s continued development.

Through its Cobots Online machine tending automation portal, sales of the CoboTend have become a major contributor to ALM’s business and are expected to double to potentially 80 units in the next 12 months. The Cobots Online portal also offers UR-based robot solutions for sanding and welding.

The CoboTend integrates a UR robot into a self-contained and lightweight trolley unit that can be wheeled and secured at a machine in a matter of minutes. A hydraulic mechanism lifts and lowers the wheels and firmly locks the trolley in its new position using floor cups. End-effectors and grippers can be then replaced at the touch of a single button depending on the required machine operation.

Safety with productivity

Two SICK nanoScan3 Pro safety laser scanners are positioned at opposite corners of the CoboTend’s trolley cabinet. Together, the two laser scanners provide 360 degree coverage around the robot, enabling it to slow to a safe speed when a person enters the outer of two fields and to stop only when the inner field is breached. This means that the Cobot can continue to operate safety and dynamically based on the proximity of the person rather than simply stopping if anyone gets too close, ensuring maximum uptime and productivity.

Optimising safety with maximum productivity has been an essential element in the continuous development of the CoboTend. The partnership with SICK has enabled Cobots Online to offer machine safety set-up in just a matter of minutes.

ALM’s Commercial Manager Matthew Thompson explains: “Machine shops like ours are busy places crammed with plant and machinery, and there is not much space in between them. Conventional robots, guarded in cages, would just take up too much room. So, to automate our machine tending we needed a safety system that would enable a robot to operate at speed for most of the time avoiding frequent stops and manual restarts, meanwhile protecting the safety of personnel passing nearby.

SICK nanoScan3 Pro with SBot Speed – URCap

The SICK nanoScan3 Pro safety laser scanner is very easy to integrate thanks to the SBot Speed – URCap, an easy-to-use safety system that combines SICK and Universal Robots safety technology.

The sBot Speed – URCap is an intelligent safety system which is designed for ease of set-up and intuitive operation. The sBot Speed – URCap was developed by SICK in collaboration with Universal Robots to provide a means to safeguard a robot application whilst achieving high productivity.

It is easy and fast to set up using smart field definition and field teach-in. Simultaneous scan data and automatic field fusion provide feedback though the GUI displayed on the robot pendant to enable set-up, diagnostics, commissioning and validation.

The circular fields, measured from the centre of the robot base, are generated automatically by the system following the teach-in process, which identifies the robot’s surroundings in seconds, including any stationary objects in the monitored area. The safety system is integrated via SICK’s Flexi Soft controller, which fits neatly within the unit’s cabinet.

Designed by users, for users

“Until we began working with SICK, with earlier versions of the CoboTend we had to set up the safety systems using a laptop and more complex software,” Matthew Thompson continues. “It took a lot longer, and the software was much less easy to use than it is now.  Now, we can combine effortless set-up with peace of mind for our customers.

“The SICK safety is part of the CoboTend’s ultimate appeal: It has been designed by people who use it and understand it. We have developed it for our own efficiency, to get a direct benefit from it. There are other systems out there, but they are developed by robot manufacturers, and not actual users like us.”

The ultra-compact SICK nanoScan3 Pro measures 101 x 101 x 80 mm and is just eight centimetres tall. Despite its size, the nanoScan3 Pro packs in all of SICK’s latest safety laser scanning technology advances, including SICK’s safeHDDM (High Definition Distance Measurement) scanning and evaluation technology. It enables the highest level of responsiveness when safely adjusting a machine’s speed and direction, even under challenging industrial conditions such as where there are bright lights, sparks, dust and dirt.

The SICK nanoScan3 Pro is a Type 3 device (IEC 61496-3) and can be used in combination with the sBot systems in safety functions up to SIL2 (IEC 62061)/ PLd (ISO 13849).

Return on investment

Just like many of the high-mix, low-volume manufacturers that use the Cobots Online serves, ALM Engineering is seeing the need for further automation using freely-accessible robots as essential.

Recruitment is getting increasingly difficult and costly, especially since the Covid pandemic, says Thompson. Using cobots also frees up personnel for less mundane and repetitive tasks and reduces the requirement for overtime during busy periods. Cobots Online customers hail from a diverse range of industries from kitchen manufacturers to automotive and aerospace.

“At ALM, we move our CoboTends around all the time,” Thompson continues. “They can do one job in the morning, and another in the afternoon. We can turn the lights off on a Friday and leave them running all weekend.

“Given the price of labour, a CoboTend has a maximum pay-back period of two years. Once our customers have one machine, it’s often not long before they return to buy another one.”

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The mobile workstation is moved within the plant for use on various machine tools, depending on the production requirement. The island consists of a station with a removable carriage for loading and unloading blanks, a collaborative robot and control console. In addition to safeguarding the mobile workstation, HT Robotics were also looking for an option to regulate access for three different operators – a maintenance engineer, supervisor and operator.

Regulating access to the mobile workstation from HT Robotics guarantees that only authorised operators can control the mobile workstation. As a result, with the access permission system PITreader S, critical situations due to misuse are avoided. For example, the maintenance engineer can make manual interventions, the supervisor can create codes and production sequences and the operator can start or stop the production cycle.

What’s more, flexible area monitoring was implemented around the mobile workstation with the PSENscan safety laser scanner: should an operator approach, PSENscan identifies this and forwards the information, so that the speed of the cobot is adjusted. Once the workspace is free again, the cobot returns to full speed.

These functions are controlled using the myPNOZ modular safety relay, as this evaluation unit is quick and simple to use. In this way, HT Robotics offers its customers a flexible workstation that includes a holistic safety concept – and thus guarantees productivity when loading CNC machines.

Benefits at a glance

• All components in the safety solution support the workstation’s flexible concept.
• Fewer downtimes, as only trained personnel have access to the system.

The PITreader S communicates with various systems via OPC UA

“This application enables the machine to be operated via a central interface,” said Paolo Bertello, project manager at HT Robotics. “In doing so the system is completely flexible: with PITreader, the machine can change operation from the manipulator to final processing, through to quality control. That’s three tasks in one solution.”

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With Flexxbotics, next generation machining environments using robotics with HURCO equipment achieve higher yields, greater throughput and increased profit per part.

Flexxbotics’ patent-pending FlexxCORE technology enables robots to securely connect and communicate with HURCO machinery in the smart factory to provide more powerful, flexible and open robot connectivity than previously possible. Flexxbotics is compatible with HURCO’s MAX5 CNC control system used on HURCO machines including the TM/X Series and VM/X Series.

“We understand the complexities of robot-machine communications, and that when robots are unable to communicate with the CNC machines they are tending quality issues occur and the efficiency gains are minimal,” said Tyler Modelski, co-founder and CTO of Flexxbotics. “That’s why Flexxbotics’ powerful capabilities give the robots the ability to optimise the operation of each machine.”

In addition to compatibility with HURCO MAX5 CNC control, Flexxbotics is compatible with a wide range of open standard protocols including OPC/UA, MTConnect, Modbus-TCP, TCP/IP, Ethernet/IP, and DeviceNet along with FOCAS2/FOCAS, MELSEC, Profibus/Profinet and other proprietary controllers and interfacing protocols.

Flexxbotics workcell digitalisation is the backbone of the Smart Factory, delivering robot-driven manufacturing at scale with autonomous process control for advanced machining operations. Flexxbotics’ SaaS/hybrid architecture also runs both online and offline so production continues with or without internet access, and Flexxbotics works with existing business systems such as CAD/CAM, SCADA/HMI, IIoT, MES, ERP, PLM and others for complete synchronisation.

A full set of bidirectional communication, transform and routing capabilities are available in Flexxbotics for the robots and HURCO machinery that are connected including loading PLC programs, sending instructions, updating parameters and status awareness depending on the equipment’s capabilities so the robots drive the machines in the smart factory.

“We believe that the robots must not only communicate with the machinery in the smart factory, the robots must control and command the machines for maximum efficiency and production optimisation,” said Tyler Bouchard, co-founder and CEO of Flexxbotics. “What we’re doing with the Flexxbotics solution is enabling next generation machining operations to embrace robot-driven manufacturing at scale.”

The UK is currently the world’s sixth largest economy and eighth largest manufacturing nation . But despite being the third biggest aerospace manufacturer, and boasting a world-leading premium automotive sector, there remain concerns around labour shortages and our low productivity rate. These issues are – and always have been – linked to automation.

In order to remain competitive, industrial companies need to produce more goods, to a higher quality and in less time. Since the first industrial revolution through to the current fourth iteration, automation has been proven to boost productivity. Yet whereas the UK was once the world leader in its adoption, we now rank a lowly 25th in the world for robot density, with 98 robots per 10,000 workers. Germany, the leader in Europe, boasts 415.

There are some signs of improved take-up, however; 2,534 new robots were installed in the UK in 2022 – 54% more than in 2015. But the productivity gap persists and reluctance to invest in automation is still a major challenge, especially among SMEs. Much of the lingering reluctance is around a long-held fear of automation, largely based on myths that are well past time for busting. Here, we counter seven of the most popular misconceptions around robotics and explain why there’s never been a better time to make the move to automation…

Myth #1: Automation solves everything

Automation is not a magic bullet. If a manufacturer is looking to solve a bottleneck, then automating the process will just mean parts arriving at the bottleneck faster, exacerbating the issue. And nor will problems with quality and consistency be solved simply by installing a machine.

Instead, factory owners should seek advice from an automation expert, such as FANUC or one of our system integrator partners, about their exact needs and what they want to achieve. We can help to identify problems with existing processes and advise on how best to employ automation to deliver the required objectives: greater efficiency, shorter cycle times, more consistency and higher quality, leading to improved competitiveness and profitability.

Myth #2: Automation is too complicated

It really doesn’t have to be. Businesses can start small, with simple functions such as a palletising/depalletising cell, and progress from there. Our automation experts can help identify where manufacturers can get a good return, quickly.

When it comes to operation, this doesn’t have to be complicated, either. FANUC’s user-friendly software tools – such as FANUC Ladder III, FANUC PICTURE and C-Executor – feature command systems with drop-down menus and choice paths that look comfortingly familiar, making them extremely user-friendly.

Myth #3: Automation will replace valued employees

The right automation solution will replace tasks, not people. The best way to approach a robotics project is to look at what is happening already and identify ways to do it better. Automating processes that are dull, dirty or dangerous helps reduce staff injuries and overcome quality issues born of boredom, freeing up employees to take on more value-added tasks. This can improve staff retention rates, boosting morale and positively impacting productivity.

Automation can also help to capture experienced employees’ expertise. A successful project will involve talking at length to the people who carry out the task and discussing with them how to do it better. By actively engaging shop floor workers, their expertise can be retained. This last point is particularly pertinent, given that almost one fifth of employees in the UK manufacturing industry is aged 55 or over, with 20% of the workforce set to retire within the next decade.

Myth #4: Why fix something that isn’t broken? Our current equipment has been working fine for decades…

Great! There’s no reason why embracing automation should require any company to ditch their current equipment, especially if it is working well. FANUC robots are regularly integrated into existing lines, complementing older machinery to enhance working practices and increase efficiency and boost productivity. What’s more, these modern alternatives are designed to last for decades.

Not only are today’s automation solutions fast, consistent, flexible and adaptable, but they are also extremely reliable. Older machinery can require more maintenance to keep it running, meaning more time offline and resulting in unproductive downtime and growing repair costs. By contrast, advanced condition monitoring has almost completely eliminated unforeseen breakdowns and unnecessary part replacements in modern robotics, enabling longer service intervals and increased uptime. F

ANUC’s robots are known for their outstanding reliability with an eight-year mean time between failures, while our CRX collaborative robot (cobot) series boasts eight-year zero maintenance. Failure to update and invest in new technology erodes competitiveness and ultimately risks putting a company out of business.

Myth #5: We lack the in-house skills to programme a robot

The amount of knowledge and expertise that businesses already have on site often comes as a surprise. If employees are used to setting up CNC equipment, they will find it much easier to set up a robot. FANUC software does not require in-depth knowledge of coding. Simple drop down ‘nesting’ menus with standard procedures and a range of Yes/No choices make today’s advanced automation systems far simpler and more adaptable than previous iterations, and easily capable of being programmed by in-house staff.

In addition, we offer training, either at our UK headquarters in Coventry or at customers’ premises, as well as a dedicated after-sales support team for any queries that may arise throughout the robot’s lifespan.

Myth #6: Any automation system we install will quickly become obsolete

Robot technology and tasks, such as pick, turn and place, have been around for decades. What has changed is control software and the tools that can be attached to them. Robotic tools will last at least as long as ordinary tools but deliver far more value throughout their lifespan.

Regarding operating software, this is supported at FANUC with ongoing, automatic upgrades, including to cybersecurity processes. Our lifetime support promise ensures that we will continue to upgrade, support and repair our products for as long as the customer wishes to use them.

Myth #7: Automation is prohibitively expensive 

The key here is only to buy equipment appropriate to need and to focus on the total cost of ownership, rather than the initial purchase price. By speaking with an experienced automation provider, manufacturers can ensure that their system is not over-specified, and that it will deliver a good return on investment over the planned lifespan of the installation.

The UK government is encouraging the purchase of capital equipment with annual investment allowances that enable machinery costing up to £1,000,000 to be fully offset against profits in a single year. And the rise in corporation tax means that tax reliefs are now even more valuable. In addition, banks and finance companies offer a range of financing packages, including leasing, that can spread costs by offsetting them against taxable revenues.

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The CubeBOX systems integrate with control units and robots, irrespective of manufacturer or communication protocol and enable the automated loading and unloading of CNC machines. The CubeBOX system is characterised by its lean and flexible design, comprising a workpiece stocking area and a robotic arm, with the key differentiator being its powerful CNC programming software, RoboCAM.

All CubeBOX systems are integrated with RoboCAM, Tezmaksan’s automation software. RoboCAM simplifies the integration process, eliminating the need for prior robot programming knowledge. Operators can easily upload product placements with drawing files and RoboCAM translates these into a language that the robot can understand and execute.

The CubeBOX system’s primary benefit is its uninterrupted operation. Capable of running 24 hours a day, night shift efficiency can improve by 50 per cent compared to manual CNC tending. This heightened productivity enables manufacturers to optimise their production output – ultimately reducing lead times and enhancing overall efficiency.

The most popular model, CubeBOX Blues DR, comes with essential standard equipment, including a 6-axis industrial robot, dual light curtains for safety, adjustable drawers, safety fence with interlock, gripper sets and RoboCAM automation software. Additional options include CubeBOX Servo Door automation and tool changer.

The CubeBOX Pallet Pool can manage up to 24 pallets and 16 tools using a single unit. Pallets are arranged in a compact circle in front of the machine and a 6-axis robot handles the loading and unloading process – resulting in reduced operator intervention.

Another model, CubeBOX Blues RT, is designed for use with lathes and vertical machining centers. This system employs two pallets for part loading and can tend to one or two CNC machines. An important advantage of this model is its capacity to stack two pallets on top of each other, enhancing throughput without requiring additional factory space.

An additional Tezmaksan model is the CubeBOX Space Cabinet, equipped with three drawers for storing products. These products are efficiently unloaded by a 6-axis robot. This setup minimises the need for frequent restocking and the ergonomic design of the CubeBOX Space Cabinet allows easy access to the drawers when restocking is required.

“There are ten different models in the CubeBOX range and the system can benefit any company utilising CNC machines,” explains Hakan Aydogdu, general manager at Tezmaksan. “Manufacturers quickly notice performance and output improvements, with the ROI typically ranging from six to twelve months. Given these compelling advantages, it comes as no surprise that we’ve already secured contracts in 36 countries.”

With the CubeBOX series already delivering benefits to sectors such as automotive, casting, aviation and metalware manufacturing, its significance is clear. Tezmaksan’s advanced technologies represent a pioneering stride in the world of automation and delivering innovative solutions to meet the evolving needs of today’s manufacturers.

Visit the Tezmaksan website for more informtation

CubeBOX is a series of automation solutions that enable operator-free production in machine tending. Developed by Tezmaksan, the systems integrate with any control unit and any robot of the user’s choice — regardless of manufacturer or communication protocol and can support the automated loading and unloading of CNC machines.

Among the launches at EMO is the CubeBOX Pallet Pool, also referred to as Pallet Tower and Pallet Changer. The system is used for automation of CNC machining centres with limited floor space and can manage up to 24 pallets and 16 tools with just one unit. Pallets are arranged in a compact circle in front of the machine, using a 6-axis robot to load and unload into the system. The equipment significantly reduces reliance on operators for loading and unloading and can enable up to 24-hour operator free operation.

Other demonstrations include the CubeBOX RT Stacker (RT-S). The RT-S is suitable for lathes and vertical machining centres. The system uses two pallets for part loading and can tend one or two CNC machines. A key advantage of this model is the ability to stack two pallets on top of each other, enabling higher throughput without an increased factory footprint.

Lastly, Tezmaksan will exhibit the CubeBOX Space Cabinet. This model boasts three drawers for holding product which is unloaded using a 6-axis robot. Using this system, an operator does not have to regularly restock the system. When restocking is necessary, the CubeBOX Space Cabinet’s ergonomic design allows drawers to be rolled into a reachable position for easy parts supply.

“Automating the loading and unloading of CNC machines can have significant financial, efficiency and productivity rewards,” explained Hakan Aydogdu, general manager at Tezmaksan. “CNC machining requires high precision and accuracy and improper loading and unloading can result in misalignment or damage to the workpiece – that is not to mention the time dedication required for physically handling parts.

“Another consideration is operator skill and availability,” Aydogdu added. “CNC machines are designed for continuous operation, so minimising downtime by reducing operator reliance is crucial.”

The company asserts that the CubeBOX can increase night shift productivity by up to 50 per cent, enabling an average return on investment (ROI) of just eight months.

All CubeBOX systems lean on RoboCAM – smart automation software from Tezmaksan. RoboCAM allows operators to integrate CubeBOX with any accompanying robot with no prior robot programming knowledge required. An operator simply uploads product drawings and RoboCAM translates these into a language the robot can understand and action. This software will be demonstrated alongside all three CubeBOX launches at EMO 2023.

“RoboCAM and CubeBOX are essential technologies for the flexible and serial production system model – an engineering style that Tezmaksan has pioneered for several decades,” added Aydogdu.

Tezmaksan’s presence at EMO Hannover 2023 will offer attendees first-hand demonstrations of the three new CubeBOX systems. Visitors will also have the opportunity to discuss their requirements with the Tezmaksan engineering team, who can provide consultation on automated technologies for machining.

After first considering a cobot solution, Mitre Plastics has instead, with Fanuc’s help, commissioned a faster, more cost-effective, and more flexible industrial robot system, helping the company to fulfil its contract with a major customer.

Located in north-east England and boasting a 50-year history, in 2019, Mitre Plastics was invited to quote for producing a high-volume part with a brass insert for a white goods manufacturer, requiring a repeatable, high-speed insert loading solution. To get an idea of how the part could be produced on its existing Fanuc ROBOSHOT α-S220iB injection moulding machine, Mitre Plastics asked an unnamed automation supplier to scope out a conceptual solution.

“They suggested using a collaborative robot in conjunction with our existing injection moulding machine and three-axis robot to handle insert loading,” recalls general manager Michael Breckon.

However, as an existing Fanuc injection moulding customer and therefore confident in the company’s automation knowledge and expertise, Mitre Plastics decided to seek Fanuc’s advice before committing to the cobot purchase. “When we took the proposal to Fanuc to discuss providing additional hardware and integration work for the solution, it raised questions over how it would work in practice,” says Michael.

The review highlighted a number of limitations with the proposed solution, with Fanuc’s engineers concluding that this application was not wholly suited to a cobot. Fanuc’s senior integration engineer James Pointer explains why: “Firstly, collaborative robots are intended to work unguarded, but in this case, a guard was required, adding cost.

“Secondly, the proposal was to mount the cobot on the moulding machine at head height, which would not comply with health and safety guidelines. And thirdly, cobots are inherently slow, whereas the key with injection moulding is to minimise mould open time for maximum productivity.”

A seamless partnership

Instead of a cobot, Fanuc proposed a simpler, faster, more efficient and more flexible solution, comprising a six-axis robot cell. To assist in this alternative approach, it engaged Hi-Tech, its long-term strategic partner for injection moulding handling and integration. The two companies worked seamlessly to devise a solution that involved replacing the existing three-axis robot with a side-entry six-axis robot.

This would take four inserts from a bowl feeder, enter the moulding machine through the side door, place the inserts into the mould in the correct orientation, demould the finished component and conduct post-mould checks – all within the specified cycle time. “With the aim of reducing cost and complexity to the existing system, we designed a self-contained industrial automation cell,” says James.

With all parties happy with this concept, Fanuc then simulated the cell on its proprietary ROBOGUIDE software and completed cycle time studies to determine the optimum robot model for the best price/performance ratio over the system’s lifetime.

“ROBOGUIDE allows us to investigate how different specifications can influence life cycle. These simulations told us we needed a 1.8m reach and a 35kg payload to accommodate the actuation and sensors needed for a double-sided gripper, which led us to the M-20iD/35,” says James.

Flexibility foremost

Flexibility was also an important consideration in this project as, although the contract was large, other work still needed to be kept on the moulding machine. This made a six-axis robot ideal, as James explains: “As the name suggests, with a three-axis robot you have three axes of movement: up and down, left and right, forwards and backwards, so when the gripper comes down you can’t change the angle.

“A six-axis, in comparison, gives you full rotation and therefore free movement. For the manufacture of plastic parts with over moulded inserts, this freedom of movement is invaluable, as precision and accuracy are key to successful production.”

While the new proposal seemed ideal, one problem with a change in approach at this stage was that the original cobot solution had already received capex approval. However, this concern was soon assuaged when the new system came in at a similar cost, as well as giving Mitre Plastics six-axis robot capability and the option of re-tasking the three-axis robot elsewhere in the factory. Hurdles overcome, the cell was installed just before Christmas 2021, ready for production start-up in mid-2022.

“This was a long-term investment that supports the company’s ongoing commitment to technical development. It also demonstrated our commitment to the customer and gave them reassurance that we can take their requirements and translate them into a reliable and efficient manufacturing system,” says Michael.

Six-axis reservations

Despite the company’s faith in Fanuc, at the outset of the project, Mitre Plastics harboured doubts over its ability to handle the six-axis robot. “We’d been aware of six-axis technology for some years but were concerned that it was difficult to programme, that our staff wouldn’t have the necessary skills and that we would end up relying on external expertise,” says Dave Veal, technical manager at Mitre Plastics.

However, Dave is pleased to report that these doubts were unfounded: “The programming software has evolved; we’ve found it to be straightforward and logical. Plus, the assistance we’ve had from Fanuc has been excellent – our engineers have been able to pick up the phone and get on-demand support whenever they’ve needed it. What we have now is a better solution. We’re really starting to see the benefits of six-axis technology.”

For Mitre Plastics there is a further advantage associated with using a six-axis robot on this application, relating to gate removal. A secondary operation performed by the three-axis robot had been the removal of gates (plastic left on the mould) using pneumatic cutting tools; however, this required several cutters set at different angles.

“The six-axis has given us greater flexibility when removing gates from products. Instead of having to use several different cutters set at different angles we can now offer the part to one cutter alone. That makes quite a difference in terms of costs and changeover time,” says Dave.

“We would certainly consider Fanuc for any injection moulding or robotics project in the future and would definitely look at six-axis versus three-axis robot technology when designing a general purpose cell,” he adds.

Michael concurs: “We are always looking to develop our capabilities through technology – we must, in order to remain competitive. That includes pushing harder on the technology on and around the moulding machine to produce parts to customer specification every cycle and minimise labour requirements. The robot is becoming the central hub for the thinking around the machine and the more sophisticated the robot, the more we can do to remain competitive,” he says.

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