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Customised robotic island for tube turning on two Doosan machining centres

+45% production efficiency thanks to Robo Feed Custom

SECTOR:

Metalworking

Location:

Reggio Emilia, Italy

CUSTOMER

Cerma has been a leader in precision mechanics since 1966, specialising in CNC turning, milling and grinding

REQUIREMENT

Reduce the cycle time of metal tube turning , as the machining process occurs in two separate stages and on two different machining centres.
Compact robotic cell to optimise space

OBJECTIVES

  • To reduce cycle times
  • To maximise the space within the workshop
  • To enhance production efficiency and quality

Since 1966, Cerma has been a leader in precision mechanics, specialising in CNC turning, milling and grinding.

The decision to integrate one of our fully customised RoboFeed models into its machinery fleet was driven by the need to optimise space, while ensuring employee safety, and also to allow the robot to work in perfect synergy with the two machining centres, Doosan Puma 2600 LM and Doosan Puma GT2600. This integration significantly reduced the cycle time from 1 minute and 30 seconds to just 60 seconds.

SOLUTION: ROBOFEED CUSTOM

After the initial meeting with the customer, the Technical Team developed a robotic cell featuring a FANUC M20Id/25 25kg Robot, capable of picking up and machining pipes of various diameters and lengths, with a maximum reach of 1831 mm.

Features of the RoboFeed Custom:

The RoboFeed Custom is a customised cell equipped with a Fanuc M20Id/ 25 anthropomorphic robot for servicing CNC machine tools.

To maximise efficiency and optimise production, our technical team took care of all aspects of the cell, including the robot wrist with two-jaw gripper, robot wrist blowing station and workpiece requalification station before and after loading/unloading from the lathes, and more.

To achieve optimal cycle times, our team constructed a six-rack warehouse divided into two zones to enable the loading/unloading of blanks and machined parts on the operator side without interrupting the machining cycle, while photoelectric barriers on both the robot and operator sides ensure complete safety.

Moreover, to ensure the highest quality workpieces inside the first machining centre, a dedicated internal spindle blowing station was implemented to eliminate chips from the workpiece prior to unloading.

COMPLETE WORKPIECE CYCLE:

  1. The robot picks up the blank from the warehouse;
  2. The workpiece is requalified on a special station before being picked up and inserted into the first machining centre;
  3. The wrist rotates, depositing the blank in the spindle inside the first lathe;
  4. After the workpiece exits lathe 1, the door closes and the machining cycle commences;
  5. The workpiece undergoes cleaning via blowing from inside the spindle to remove swarf and coolant; subsequently, the door of the first lathe opens;
  6. The robot picks up the workpiece;
  7. The workpiece is placed on the requalification station before being picked up by the robot;
  8. The machined workpiece is introduced into the second machining centre;
  9. After the workpiece exits lathe 2, the door closes and the machining cycle commences;
  10. The machined workpiece is picked up and placed on the requalification station;
  11. Finally, the workpiece is stored inside the rack warehouse.
  • cycle time: 60 sec
  • Floor space: 5,720 X 7,370 mm
  • Cell height (highest point): 2,100 mm
  • Total cell weight: 13,000 kg
  • Installed power: 4 kW
  • Power supply voltage: 3 phases 400Vac – 50hZ + ground (no neutral)
  • Pneumatic supply: 6 bar
  • Safety management: safety gates and doors
  • Electrical Safety Management: REER safety PLC
  • Warehouse capacity: 126 pcs.
  • Capacity of each rack: 21 pcs
  • No. of racks in Custom Warehouse: 6

Conclusion: a successful collaboration

This custom solution has allowed Cerma to boost productivity and exceed expectations, demonstrating the effectiveness and practicality of automation in the metalworking industry. To learn more about how you can implement an efficient RoboFeed Custom solution to your machine fleet, contact us for a personalised consultation.

After integrating the RoboFeed robotic cell into our production line, we were able to reduce the cycle time of our machining centres from 1 minute and 30 seconds to just 60 seconds. This significant improvement has dramatically enhanced our production efficiency and output. The cell was custom-designed to meet our requirements, allowing us to maximise space without obstructing any transit areas, thereby ensuring the safety of our employees. We are extremely pleased with the results achieved by the cell and the post-installation support provided by Assistec.

P.R. - Production Manager