Through a technology partnership that breaks new ground in the machine tool industry, Siemens offers an automation solution for the busy, multi-tasking, small to mid-sized machine shop, as it combines a digital twin of the software and programming of its popular SINUMERIK 828 CNC, working in tandem with a KUKA robot, to simplify the operation and programming in part handling for the machine tool operator.
Bringing the concept to life during a recent tradeshow, KUKA Robotics Corporation demonstrated the same control and its robot working in tandem with a SYIL vertical milling machine. The machine featured the SYIL R1 machine-tending automation package, developed with one of KUKA’s System Partners, Waybo, which seamlessly integrates the pick-and-place, part articulation and communications with the CNC onboard.
The goal of the program, according to Frans Buikema, Chief Marketing Officer at SYIL, is to offer the small and midsized shops an entry point into automation without major capital investment. Likewise, as Ron Bergamin, Key Technology Manager for Machine Tool Automation at KUKA, added, the ROI can be very short, as this automation advancement allows the addition of a lights-out second or third shift at job shops of almost any size. Automation is the key and this cooperative engineering venture has opened a new chapter for small to mid-sized machine shops.
“The benefits of this development for the busy job shop are many. Setup, programming, operator interface and diagnostics are all improved with the SINUMERIK Run MyRobot /Handling application, as it easily incorporates the KUKA robot with the SYIL machine tool,” said Tiansu Jing, Product Manager, SINUMERIK CNC systems. The teach-in functions are implemented through the SINUMERIK Operate HMI system on the control, while the proprietary SINUMERIK Run MyRobot /Handling capability of the CNC seamlessly integrates with the KUKA robot control.
Jing further noted that since there is no need to learn robotic programming, start-up time is reduced and the robot’s separate control pendant is eliminated, simplifying the operator’s task. The SINUMERIK control’s HMI is used to operate both the machine tool and the robot tender, with all commands and operating conditions displayed on a single screen. He also added that the greatest value for the busy job shop comprised the system’s ability to integrate robots on all its machines, while economizing the learning curve for all the operators. This entire cooperative venture between Siemens, KUKA, and SYIL made this advancement possible, Jing said.
“Machine builders can now offer robotics from KUKA PLC mxAutomation, a universal PLCopen-certified PLC interface. It allows the user to program and operate all important robot functions directly in a busy shop’s familiar control environment,” said Bergamin.
Jing further added that the Run MyRobot/Handling application allows the machine builder to offer robotics as another option, at a far more affordable price than in the past, as all the engineering effort has been substantially reduced.
“We saw a resident robotic talent gap as well as price resistance in the smaller machine shop sector and decided we needed to pursue a solution,” said Philip Peloso, Business Development Manager for Machine Tool Automation at KUKA. “We turned to our Official System Partner, Waybo, presenting them with the facts. This solution would be an entry-level venture, addressing the 75 percent of the job shops who currently have no robotic automation on their floors. We sought to present them an easy-to-use, robust system that allowed quick changeover for the busy shop doing multiple jobs or families of parts during the day,” he added.
Peloso cited the key value proposition: “All meaningful controls and diagnostics were to be displayed on the CNC, thereby reducing or eliminating all the previous roadblocks for the shop personnel.” All the motion control of the grippers, pick-and-place functionality, and communications with the CNC on workholding are seamlessly transmitted from an application layer on the KUKA robot, so all commands are configured and programmed to take instructions directly from the CNC.
“Working with Waybo, we developed the automation around the robot. A new interface layer, run through our standard mxAutomation software, allowed the robot control from the Siemens CNC, so a single pendant is all that’s required to run the SYIL machine tool and the robot package. All diagnostics are under the hood,” Bergamin further added.
Frans Buikema of SYIL highlighted this development from the machine builder perspective. “We’ve long had automation in our company’s vision and roadmap for the future. As we focus on the small and mid-sized machine shop world, we constantly encounter the lack of skilled labor, the price resistance and the shortage of robotic knowledge in this sector of the machine tool market,” he said.
SYIL currently designs and builds CNC milling machines, CNC turning centers and CNC Swiss type lathes. According to Buikema, “This development with Siemens and KUKA represents our own entry into robotics and we plan to expand the use of such packages onto all our machine offerings very soon.” He called the implementation of the SINUMERIK 828D CNC with Run MyRobot/Handling “… a real game changer, because it enables us to start creating more automation packages and make them accessible to our audience, the small to mid-sized machine shops.”
The SYIL R1 machine tending system, incorporating the KUKA robotic technology, is currently offered as a standard package by the machine builder, for parts up to 3kg (6.61 lbs.), a payload of 6.7kg (14.77 lbs.) and a reach of 901 mm (35.47 in). It offers an IP65/67 rating for harsh operating environments. It facilitates the loading and unloading of metal parts from the cutting zone and workholding devices being utilized, plus it is quick to install and easy to operate from the SINUMERIK 828D control. The R1 system from SYIL removes the manual and repetitive tasks for a CNC machine operator by automating the load/unload process. It is an ideal solution for high-mix, low-volume tasks and can be fully integrated with parts conveying systems, bins, and pallets.
In addition, the SYIL R1 system features an “everything on one screen” format, integrating the robot’s programming and operation in the SINUMERIK 828D control, using NC G-code and robot teach-in function for programming. This makes it very easy for machine tool operators to learn and use. All the robot diagnostic data is shown on the same HMI as the machine, allowing the entire automation cell to be monitored without the need for a second pendant.
According to Buikema, the SYIL R1 automation package can be installed and fully operational in less than one day.
This article was contributed by Siemens (Elk Grove Village, IL). For more information, visit usa.siemens.com/cnc .
