Lightening the load

Robojob offers two systems: Turn-Assist for turning and Mill-Assist for milling applications with both incorporating Fanuc robots for automated loading and unloading.

The Turn-Assist system allows the unit to be deployed on CNC turning machines of all brands of both existing and new machine tools. The interface is particularly user-friendly and its design requires no specific knowledge of robotics for operation. According to the manufacturer, the Turn-Assist can be set-up in less than five minutes.

With the Fanuc robot set-up in an inclined position, the machine opening remains fully accessible to the operator, as does the swarf tray which provides easy access for machine cleaning and tool changes. The Robojob software even proposes which type of gripper or gripper fingers should be used on the robot.

In a nutshell, the concept behind both Turn-Assist and Mill-Assist is to optimise machine uptime by automating the loading and unloading of workpieces. The Turn-Assist system uses a patented servo-operated stacking table, which helps to make optimum use of space for varying workpiece sizes. Hydrafeed has installed systems capable of handling workpieces as small as 23mm diameter and as large as 450mm, depending on the robot used. These systems can reduce operator costs, improve productivity and consistency whilst also permitting cost effective lights-out production.

Hydrafeed also offers these benefits to customers with machining centres via the Mill-Assist system which is also adaptable to all brands of CNC machining centres. It can be set-up in two ways, front or side; with the latter, users can choose a transparent screen with sliding doors, or an open entrance guarded using a light curtain.

Robojob incorporates a ’cube’ gripper arrangement that can quickly attach various types of grippers, such as adjustable clamp and vacuum. Mill-Assist features a configurable input and reception plate which is suitable for small and medium-sized parts from 23-450mm diameter.

A recent success story saw Hydrafeed install a Robojob system at Jason Hydraulics based in Witney, Oxfordshire, a company specialising in the manufacture of hydraulic cylinders and parts, bespoke hydraulic cylinder design and the repair and servicing of hydraulic cylinders. It manufactures over 45,000 cylinders per year.

Hydrafeed installed supplied a Robojob Turn-Assist 180 system with 10kg payload robot for use on the Jason Hydraulics’ Doosan Puma 2100 turning centre.

“We’ve seen immediate productivity benefits using the new system,” enthuses Steven Moore, production manager at Jason Hydraulics. “The loading and unloading of parts is now fully automated so one operator can now oversee three machines. As a result, our labour costs have reduced significantly.”

Managing director, Conrad Edwards echoes the sentiment: “We’re looking to purchase at least one additional Robojob system for other machines on our shopfloor,” he adds. “On the Doosan Puma lathe, it has allowed complete automation on medium to small batches. Raw material is loaded into the machine to the main spindle and then the part is transferred to the sub-spindle. Then the robot removes the part and loads it onto the machine conveyor. During the same cycle a new billet is loaded into the main spindle keeping the machine spindle uptime to its optimum.”

This is a standard feature of all RoboJob systems where finished components can be placed into a receptacle, conveyor or back on the loading table. RoboJob systems add flexibility to a machine tool by allowing bar feeds to be run or the machine tool used as a standalone machine by simply parking the robot safely.

“We’ve have had a busy year with many installations on a variety of machine tools,” concludes Martyn Page, Hydrafeed’s managing director. “In all cases, our customers were able to increase their machine automation levels – in many instances over and above their initial expectations.

“In recent years UK manufacturers have faced significant challenges: it has become increasingly difficult to recruit skilled staff; batch sizes have reduced; while delivery and lead-times have shortened. To tackle these issues automation is a route many companies are exploring.”

Hydrafeed www.hydrafeed.co.uk