CNC Machinery Solutions Automation, a division of CNC Machinery Solutions and the exclusive distributor of Doosan Robotic’s collaborative robots in the UK and Ireland, has recently introduced two new innovative cobot ranges (series) into the market.

The new A-series and H-series, comprising six new models in total, have significantly strengthened CNC Machinery Solutions Automation’s cobot line-up and, in conjunction with the M-series (comprising four models) previously launched in 2018, will help CNC Machinery Solutions Automation reinforce its market position and profile as the ‘go to’ specialist provider of collaborative robot technology systems and solutions.

A-series

The A-series, accredited by the international testing and certification organisation – TUV SUD – has a number of USPs, the most notable of these being the cobots’ high-speed, safety, versatility and affordability.

The series comprises four different models: the A0509, A0509s, A0912 and A0912s, and boast a payload capacity from 5kg to 9kg, and a reach from 900mm to 1200mm.

A-series cobots feature an advanced safety algorithm that makes them ideal for operating in a wide range of manufacturing and production environments, and takes collision detection sensitivity and safety beyond existing levels.

The cobots are fast with impressive speed and acceleration characteristics. A-series’ joint (axis) speeds are twice that of competitor cobots currently available on the market.

Says Peter McCullough, CNC Machinery Solutions Automation’s Product Manager (Doosan Robotics):

“Cobot operating and processing speeds are important. They help reduce cycle times and, as a consequence, improve customers’ productivity levels which, in turn, impacts (positively) on their ROI.”

Two of the A-series cobots (A0509s and A0912s) are equipped with force sensor technology which increases their application potential to include delicate tasks requiring ‘human- like’ dexterity such as polishing and intricate assembly operations.

H-series

The new H-series cobots are half the weight (75kg) of comparable cobots in their class resulting in low inertia and enhanced safety. H-series cobots are also the most powerful on the market.

There are two models in the series – the H2017 and the H2515. The H2017 has a payload capacity of 20kg and a reach radius of 1700mm, the H2515 has a payload capacity of 25kg and a reach radius of 1500mm.

Both models are equipped with six torque sensors integrated on their (6-axis) arms which if/when detecting any changes in force or pressure causes the cobots to stop in their tracks.

Continues Peter McCullough:

“Safety is critically important. Torque sensors help shut down the cobot immediately once torque thresholds have been exceeded, preventing injury to humans or to the cobot itself.”

New A-series and H-series cobots, along with existing M-series models are all available to view at CNC Machinery Solutions’s, recently opened, Automation and Turkey Centre located at the company’s Campus facility in Leamington.

Concludes Peter McCullough:

“The cobot market is fiercely competitive. Many cobots on the market are very similar to one another and can be classed as ‘me too’ products.

“The new cobots from Doosan Robotics are innovative and different: they offer customers game changing, best-in-class speed, versatility and safety.”

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Somerset-based Watson Gym Equipment, one of the world’s leading manufacturers of specialist strength training equipment used in high-end PT gyms, has recently invested in two new Doosan machine tools and a Doosan collaborative robot (cobot) from CNC Machinery Solutions – the exclusive distributor of Doosan machine tools in the UK and Ireland.

Watson Gym Equipment, created by owner and managing director Simon Watson in 1999, acquired its first Doosan machine – a large-capacity Puma 4100MB lathe – in March 2020.

The 15“ chuck box guideway Puma 4100MB is a rigidly-designed and built machine suitable for a range of heavy-duty machining operations including interrupted cutting. The Fanuc 0iT-controlled machine is equipped with a high-torque 30kW/2,000rpm spindle, a servo-driven tool changer (12-position) and driven tooling capability (7.5kW/4,000rpm).

Since being installed the lathe has been used to machine the company’s Pro Olympic weight plates which are made from solid marine grade stainless steel.

(Weight plates are the flat discs located at either end of a weight bar to create a barbell or dumbbell used for weight training).

The Puma 4100MB investment

The acquisition of the Puma 4100MB lathe had an element of serendipity about it.

In late 2019 Watson Gym Equipment had approached its existing CNC machine tool supplier to discuss the best way to ramp up production of its weight plates in order to meet increased demand.

Initial discussions centred around the acquisition of a new large-capacity vertical turning lathe to machine the components but, with an anticipated delivery time approximately six months after order placement, the company decided to consider alternatives and approached CNC Machinery Solutions for help.

Says Simon Watson:

“We were clearly aware of CNC Machinery Solutions and knew that the company had a good reputation in the market for the technology it sold and the after-sales services it provided.

“We approached them to see if they could help with our specific machining capacity issue and, after an in-depth discussion, they recommended the Puma 4100MB – a large-capacity horizontal lathe that was available from stock, and that could be delivered and installed (virtually) immediately.

“Mills took the time to understand our business and bought into our business model and what were trying to achieve. They pointed out potential tooling interference issues that could occur by going down the vertical turning lathe route and, instead, demonstrated the productivity and flexibility benefits that we could expect to gain from investing in the Puma lathe. All of which, incidentally, have been correct.”

Weight plates

Watson weight plates can be supplied to customers in a range of standard sets (i.e.150kg, 250kg, 350kg and 500kg) with individual plates weighing between 5kg and 25kg.

All weight plates are machined to high accuracy and exacting surface finishes. They feature powder coated end plates that can be customised if required (i.e. with a customer’s logo or brand), and are supplied with a lifetime warranty.

A quick look at Watson’s weight plates, just one product range in its extensive portfolio, demonstrates the company’s commitment to quality and continuous improvement, and goes a long way in explaining its continuing growth and success.

Explains Simon Watson:

“It’s relatively easy, and cheap, to manufacture weight plates from mild steel and then zinc- or nickel-plate them to give a professional looking finish. However, after a short period of time, and through constant use, they will lose their lustre and the coating will peel, chip or discolour.

“Our business model is focused on manufacturing high-quality, high-performance and competitively-priced premium products and equipment that look the part and that stand the test of time. That’s why we use stainless steel for our weight plates.”

Stainless steel is also used for the company’s range of popular and best-selling (class-leading) dumbbell handles.

The Lynx 2100LSYB investment

In early 2020 Watson Gym Equipment, with demand for its dumbbells at an all time high, made the decision to increase its in-house production capacity and approached CNC Machinery Solutions for guidance.

Of particular concern was how to increase production of the company’s heavy-duty dumbbell handles which are available in different lengths (12” to 22”) with a 30mm grip.

Explains Simon Watson:

“Dumbbell handles are not complex components. They are machined from bar and cycle times are short.

“To meet increased customer demand we needed additional turning capacity… and we needed it fast.

“Having already established a good working relationship with Mills through the acquisition of the Puma 4100MB we approached them again with our requirement, and they recommended the purchase of a Doosan Lynx 2100LSYB lathe and a Hydrafeed bar feeder.”

The 8“ chuck/ 65mm bar capacity Lynx 2100LSYB is a compact, multi-axis turning centre equipped with a high torque main spindle (11kW/4500rpm), a sub-spindle (5.5kW/6,000rpm), a Y-axis (+/- 52.5mm) and driven tools (3.7kW/6,000rpm).

The machine is ideal for small part production and is fast, accurate and reliable.

The machine and bar feeder were installed at Watson Gym Equipment’s facility in early May 2020 and its production capabilities have recently been significantly increased still further with the recent addition and integration of a Doosan M1013 collaborative robot (cobot) which was delivered and installed later in the month.

The cobot, with its 10kg payload and 1.3m reach radius, is positioned in front of the Lynx lathe and is programmed to unload the finished parts (dumbbell handles) once machining operations have been completed.

Says Simon Watson:

“The job and machining process were ideal for automation. We can set up the job and leave the machine running unattended and overnight. As a consequence we have improved our productivity significantly and, because we have effectively removed the labour component from the process, have reduced the cost per part as well.”

Future developments

Watson Gym Equipment is constantly innovating and improving.

Plans are well underway to increase the company’s floorspace by an extra 22,000 square feet with the building of a new machine shop adjacent to its existing facility in Frome.

The new facility is expected to be completed by the end of the year (November/December 2020) and will house all the company’s CNC machining operations, including a new CNC Machinery Solutions ‘SYNERGi 25’ automated manufacturing cell.

The cell comprising a Puma 2600SY lathe (with Y-axis and sub-spindle capabilities), a 25kg high-capacity industrial robot, an automated two-way drawer system (for stacking storing and loading workpieces and finished components), a 17” touchscreen HMI, locating plates, pneumatic grippers and SICK safety systems has been specified and ordered to help the company meet growing demand for its word-class, indestructible dumbbells.

Says Simon Watson:

“Automation is the key to increased productivity, operational efficiency and improved competitiveness. The SYNERGi 25 cell will help us increase throughput and reduce bottlenecks, and enable us to exploit lights-out, unattended operations still further.

“We will be working with CNC Machinery Solutions’s automation specialists in the next few weeks and months to create and prove out a bespoke manufacturing process at their Automation and Turnkey Centre in Leamington prior to it being delivered to, and installed in, our new facility.

“In the past six months we have developed a strong and positive working relationship with CNC Machinery Solutions based on integrity and trust. The technologies they are able to supply and the added value consultancy they provide are helping us optimise our performance…making us fitter for the future.”

The post Fit for the future. appeared first on CNC Machinery Solutions.

So, what exactly is collaborative robotics and how does it differ from traditional robotics?

Peter McCullough, Product Manager (Doosan Cobots) at CNC Machinery Solutions Automation brings us up-to-speed with the latest developments and applications in the healthcare and medical devices’ sectors.

“Despite anxiety-led headlines about robots coming for our jobs, collaborative robots are designed to work with and alongside operators and technicians, rather than replace them — making it possible to build work processes that incorporate the strengths of both humans and robots.

“Unlike traditional robots, cobots don’t pose a threat to human safety. Marked improvements in vision and sensor technology have made it possible to program cobots to stop working if a person is too close. Also, cobots are much lighter and smaller — some the size of a desk lamp. They’re significantly less expensive, easily programmable and quick to set up too.

Cobots are transforming the Healthcare Industry

“With the clear potential for streamlined processes, repeatable safety measures and a more efficient workforce, many in the healthcare and medical device sectors have also been quick to accept the future of collaborative robotics.

“Particularly encouraging is the development in the following areas.

Laboratory Testing

“Copenhagen University hospital is using cobots to pick up, sort and load blood samples for analysis. These cobots utilise vision programming by first picking up the sample, placing it in a bar code scanner, and then sorting the sample based on cap colour.

“Once a tray of the same colour is full, a second cobot places them in a machine for analysis. The pair of cobots handle 7 – 8 tubes of blood per minute or about 3,000 samples a day, ensuring that 90% of sample results are ready within one hour.

“This quick turnaround has resulted in positive patient outcomes. Out-patients can now receive results during their initial consultation rather than making an extra return trip to the hospital. Also, in-patients have same day results available by morning rounds, so physicians are reviewing accurate and up-to-date information.

Patient Care

Terapio, a cobot developed by researchers at Toyohashi University of Technology in Japan, is designed to give critical time back to busy nurses by providing bedside monitoring for patients and automatically updating electronic medical charts.

“With the ability to follow medical staff to each patient’s room and automatically upload vital signs to charts, nurses are relieved of administrative tasks and able to focus on patient care.

“Another cobot greeting patients at their bedside is RIBA (Robot for Interactive Body Assistance) that has a friendly bear-like face. Developed by RIKEN-SRK Collaboration Centre for Human-Interactive Robot Research and Sumitomo Riko Company, RIBA is working to serve the growing elderly population in Japan by lifting patients out of beds and wheelchairs — relieving care workers who can often sustain injuries from lifting patients up to 40 times a day.

Surgery

“One of the more familiar cobots in the surgery world is the da Vinci System, built with robot arms and high-tech cameras to assist surgeons during operations. The da Vinci’s arms translate surgeon hand movements into smaller, more precise movements, allowing for less invasive procedures.

“Over 1 million patients worldwide had a da Vinci procedure in 2018 — a great example of early adoption of cobots in the medical field, spanning many different types of surgeries.

“There are also other types of robots currently being used in surgery. Accuracy’s Cybnerknife system delivers radiation therapy to cancerous tumours that utilise a pre-programmed treatment plan and can correct for movement in real time. Two multi-centre studies looking at Cyberknife treatment in prostate cancer patients showed a 97 – 100% success rate for low-risk patients and an 88 – 97% success rate for intermediate risk patients, both exceeding the success rates of conventional radiation therapy.

“Recently, we’ve also begun to see robotic applications in the complex field of brain and spinal surgery.

“Sebastian Koga, M.D., medical director of the Neuroscience Institute at Ochsner Health System is now assisted in surgery by Modus V, which was developed by Synaptive Medical Inc. The cobot provides a high-resolution view of the area being worked on by tracking surgical instruments in-use and then automatically moving its high-powered microscope to accommodate the surgeon.

“Stryker/Mako has also begun doing total knee arthroplasty (TKA) utilising a cobot system to reduce axis misalignment. Bone cuts are 5 times more precise with the system, which results in final component positions being 3.1 times more precise overall. The Mako Total Knee Robotic-Arm Assisted Surgery has also demonstrated soft tissue protection by improving the surgeon’s vision during cutting in regards to ligament disruption, reducing the need for tibial subluxation or patella eversion (which results in quicker recovery and improved function).

Medical Device Manufacturing

“India-based Aurolab, which manufactures cataract surgery kits and intra-ocular lenses use cobots to optimise their manufacturing processes.

“The cobots perform tasks such as material handling and careful picking and moving of the components — pivotal for the delicate process of manufacturing the lenses. After introducing eight cobots, Aurolab has seen a 15% increase in product output.

Applications Outside Healthcare

“With a smaller price tag and little expertise required for installation, even small and mid-size businesses are quickly finding ways to automate work processes with the help of cobots. And adaptation is happening across a multitude of industries.

Automotive

“As an industry with a lot of potentially dangerous tasks, automotive manufacturers are among the earlier early adopters of industrial robotics. They’ve also been some of the fastest to integrate cobots into their operations. For example, with improved vision technology, cobots are performing visual inspections to detect defects in machine parts — proving more accurate than the human eye.

Fulfilment centres

“Amazon fulfilment centres and several online grocery stores are using cobots to fill orders, saving workers the trouble of walking from shelf to shelf in the warehouses. Similarly, leveraging cobot technology, Chinese e-commerce company JD.com recently constructed a warehouse, which fills 200,000 orders a day with only four workers on site.  

Food service

“Axium Food Inc., a mid-size food manufacturer, is using cobots to perform repetitive tasks that

in the past have caused human injury such as carpal tunnel. In the restaurant industry, where staff turnover is notoriously high, restaurants have begun adding cobots to the grill line to meet high demand — most famously, Flippy the burger-flipping cobot, began work at Caliburger (USA) in March 2018.

Industry predictions

“As cobots continue to meet the needs of the medical device and healthcare industries — providing high success rates and positive patient outcomes — we expect to see accelerated adoption rates.

The post Collaborative robots: The present and future for medical device and healthcare applications. appeared first on CNC Machinery Solutions.

Whilst some manufacturers may be waiting for the lockdown to be lifted before they fully explore automation’s potential in their workplaces. Others have ‘bitten the bullet’, and are actively investigating how automation, and specifically robotics, can help them remain productive and profitable now…and in the future.

Prior to making any investment in robotics manufacturers need to make some fundamental decisions – one of the most important being the type of robotic system that’s right for them.

In this article Peter McCullough, Product Manager (Doosan Robotics), explains the differences between Industrial and Collaborative robot technology, for those manufacturers preparing to take the plunge.

“In the post-pandemic world manufacturers, across all industries and sectors, will no doubt be exploring the potential of automation and robotics and whether they are an investment worth considering.

“If and when they do they’ll be faced, early on, with an important question: What type of robot is right for my operation and application?

“Most component manufacturers will have external partners and suppliers (as well as in-house resources) who can help guide or even spec the system but, even if that’s the case, it’s a good idea to have a baseline understanding of the technologies and terms involved to help navigate the waters and ask to right questions.

“The first decision is a fundamental one: Industrial vs. Collaborative robots?

“Industrial robots are what most people imagine when envisioning a robot on the shop floor – a big, heavy robot, caged off toiling away welding car chassis after car chassis twenty four hours a day with no worker in sight. These ‘industrial’ robots complete dull, dangerous and repetitive tasks quickly and more accurately than workers ever could.

“Collaborative robots (cobots) are a more recent development where robots work alongside humans rather than replacing them. Cobots, like their industrial counterparts, are designed to perform receptive, monotonous or error-prone tasks – freeing-up time for an operator to devote to more complex, creative and value-adding tasks.

“It is estimated that by 2025 cobots will comprise 34% of total robot sales, and these estimates were provided before the coronavirus outbreak. (Much of this growth is anticipated to occur from those SME companies who, operating in High-Mix/Low-Volume (HMLV) production environments, realise the flexibility and productivity-boosting potential of collaborative robot technology).

“For SME’s understanding the strengths and limitations of both robot types is critical to chart a successful future. Choosing the wrong type can restrict future growth and be expensive; choosing the right course can ensure more efficient production processes and reduce costs immediately and long into the future.

Robots: Speed and power

“One of the main advantages of industrial robotics is the speed they can perform complex tasks, and the payloads they can handle: both exceed that of cobots. Because industrial robots are often integrated into more specialised manufacturing systems than cobots – they can deliver significant productivity gains.

“However, because of the speed and force provided by industrial robots, substantial safety systems are required to ensure that safety is maintained. The integration of such powerful systems – and the safeguards required – come with a higher price tag than cobots.

Cobots: Enhanced abilities

“Although cobots operate at lower speeds and payloads than industrial robots their (relative) low cost, inherent safety and flexibility, easy integration and operation and ‘collaborative’ nature means (application dependent of course) that they can deliver significant productivity improvements and a fast return on investment.

“The innovation in the cobot sector, not just from system manufacturers, but also from accessory, software and end-of-arm tooling suppliers has widened their appeal and application potential.

“The capability and acceptance of cobots is clearly increasing, and as countries emerge from coronavirus lockdowns and work restrictions, it is likely that adoption and use of the technology will grow exponentially.

Making the right choice

“So, how can you determine whether an industrial robot or collaborative robot is best for your manufacturing operations?

“The first step is to determine exactly what you want to accomplish – be it increased production and output, increased worker safety, reduced scrap levels etc. – and where you intend (i.e which part of your operation) to deploy your automation system.

“Next talk to organisations and experts who can help you realise your objectives, and offer sound and insightful advice.

“(Here at CNC Machinery Solutions Automation we can supply manufacturers with tried and trusted industrial and collaborative robot systems and solutions – and both can be seen in action at our Technology Campus facility in Leamington).

“Lastly undertake an audit to see which robot solution makes the best financial and operational sense for your needs – now and in the future.”

The post Cobot vs. Robot: Which is right for you? appeared first on CNC Machinery Solutions.

Industrial robots integrated into flexible automated manufacturing cells are a key enabler of Industry 4.0 and the Factories of the Future.

They can revolutionise conventional industrial processes allowing manufacturers to increase productivity and achieve higher quality with lower costs.

Despite the clear and much publicised advantages of automation, and how it can help companies prosper and grow – there appears to be a perceived ‘issue’ with its widespread adoption in the UK.

Indeed recent reports suggest that the UK manufacturing companies lag well behind their European counterparts (and competitors) in embracing automation and integrating it within their manufacturing operations. This is especially true of SME’s where a lack of knowledge and a ‘fear’ of ‘all things robotics’ is not unusual.

Says Tony Dale, CNC Machinery Solutions’s Technical Director:

“A major problem affecting the widespread adoption of automation amongst UK companies is a belief that it cannot be easily applied to their businesses or integrated into their work practices, or that the technology itself is too complex and too expensive.

“ CNC Machinery Solutions, through our highly-skilled engineers and years of experience project managing and delivering complex turnkey projects for customers, have addressed many of these concerns with SYNERGi 25 – our new, innovative, cost-competitive and easy-to-use automated cells.

“The cells are simple to install…simple to set up and simple to operate. They are powered by our own (proprietary) SYNERGi software and are high-productivity solutions designed to take the complexity out of automation.”

About SYNERGi 25 Automated Manufacturing Cells

SYNERGi is the generic brand name of CNC Machinery Solutions Automation’s flexible, automated manufacturing cells, and SYNERGi 25, denoting a 25kg robot payload capacity, is the name of the specific standard automated cells held in stock by Mills.

SYNERGi 25 systems are versatile and scaleable, and can be integrated with new Doosan lathes, machining centres and mill-turn machines – significantly increasing their productivity. They can also, (model of machine and year of manufacture dependent*) -:

• be retrofitted to customers’ existing Doosan machines*:
• be custom-designed and built to meet customer’s specific application requirements:
• be expanded to operate with more than one Doosan machine tool.

At the heart of every SYNERGi 25 cell, is a sophisticated and intuitive HMI (Human Machine Interface) – the driving force of the automation system.

The HMI is user-friendly and secure, and is logically designed. Navigation between HMI screens is clear and straightforward, as are the system’s menus and graphical user interface.

Says Heath Redman, CNC Machinery Solutions’s Operations Director:

“The HMI is process driven and operators cannot get lost in the system or hit a cul-de-sac. Input entry errors or omissions do not take place enabling the cells to operate productively and optimally with limited training.”

To ensure process reliability the HMI also incorporates a wide-range of quality control, monitoring and inspection features and capabilities.

SYNERGi 25 cells comprise a range of standard equipment that includes:

• a high-capacity industrial robot
• an automated two-way drawer system for stacking, storing and loading workpieces and machined components
• a 17” touchscreen
• an inspection and parts’ ejector conveyor
• locating plates
• pneumatic 2- or 3-jaw grippers
• integrated SICK safety systems
• industrial robot fencing

Optional equipment includes a parts turnover station, a higher payload capacity industrial robot, a 7th-axis robot transfer unit rail, floor scanners in lieu of hard guarding etc.

Continues Heath Redman:

“If you are looking to embrace unmanned and lights-out operations – SYNERGi 25 automated manufacturing cells integrated with Doosan machine tools are the ideal and proven high-productivity and high-efficiency manufacturing solution.”

The post Good news on the Automation front! appeared first on CNC Machinery Solutions.

CNC Machinery Solutions has, through its recently-created Automation Division, supplied leading precision engineering specialist – Cambridge Precision Ltd (CPL) – with a high-performance Doosan collaborative robot (cobot).

The Doosan M0617 cobot, equipped with ONRobot electrically-driven two finger parallel grippers and Schunk vices, was installed in the company’s 24,000 square foot facility in St Neots in July 2019 where it has been integrated with a Doosan DNM 6700 vertical machining centre to create a flexible and highly-productive automated manufacturing cell.

The cobot performs machine tool tending operations i.e. loading workpiece billets from a loading table into the DNM 6700 and, after the machining operations have been completed, unloading the finished machined components and positioning them back on the table. By creating the manufacturing cell, comprising the cobot and a 5-axis machining centre, and by creating new programs for different jobs, CPL is pushing the boundaries of human:machine collaboration.

The company manufactures complex parts and undertakes mechanical and electrical assembly for a number of customers operating in specialist markets. Quality and lead time fulfilment are critical, and CPL constantly looks for ways to improve performance, support its work-force and delight its customers.

Says Nick Raven: CPL’s General Manager:

“The cobot helps to free-up skilled labour by handling repetitive and less profitable tasks. Robbie (the cobot) has been welcomed by the team, and has enabled team members to focus on other manufacturing and assembly demands.”

The milling cobot cell is able to operate 24/7. Since installation it has been digitally programmed to handle more than 20 different projects and the company estimates that, from a standing start two months ago, over 5000 prismatic parts have been manufactured in the cell.

The cell, supported by a number of CPL’s partners, including tooling specialists MA Ford, Guhring and Alpha-CAM, and metalworking fluid experts Q8Oils, is the company’s first investment in advanced robot technology.

The results achieved to date suggest that it will not be its last.

CPL, celebrating its 25th birthday this year, is committed to innovation and continuous improvement. These twin strategies, evident across all of its operations, help explain the continuing growth and success of the company and why it is so highly-regarded by its large and diverse domestic and international customer base.

The company has a history of investing in the latest and most advanced machine tool and ancillary technologies and has, at its disposal, a range of multi-axis machining centres and multi-tasking turning centres to machine high-precision and often complex parts for its customers in the Scientific Laboratory, X-Ray, Medical Device and Research Instrumentation sectors and industries

A majority of the machines used by CPL are Doosan machines supplied by CNC Machinery Solutions and a significant proportion of these have built-in automation.

Says Nick Raven,

“We are keen automation advocates. Recent machine tool investments in our dedicated turning cell include machines with a twin spindle, twin-turret configuration, as well as lathes with sub-spindles, driven tools and Y-axis capabilities.

“A number of our (eight) lathes have integrated bar-feeders that help facilitate continuous production.”

It’s a similar story with CPL’s milling cell where the company has, over recent years, invested in a number of 5-axis machining centres to help it improve operational efficiency and increase productivity levels.

A visit to Mills

It was indeed a visit to CNC Machinery Solutions’s facility in Leamington earlier this year by CPL representatives to look at the latest Doosan simultaneous 5-axis machine in action when the potential of a cobot investment was realised, and where the impetus behind the cobot acquisition began.

Explains Andrew Barnard, CPL’s Milling Supervisor:

“We had arranged to see the new Doosan DVF 5000 5-axis machine integrated with an automatic workpiece pallet changer (AWC) at Mills. During the visit we were introduced to the new Doosan cobot range, and saw one of the models performing pick and place operations.

“We liked what we saw and could immediately see that this type of technology could be employed to good effect back at CPL, increasing our ability to meet challenging production issues and lead-times.”

CPL had considered investing in an industrial robot previously but had not been able to justify the high investment cost or identify applications that complemented its skills development or capital equipment strategies.

The fact that the M0617 cobot has a small footprint and does not need to be caged-off made it suitable for CPL’s environment, acceptable to the workforce and cost-effective in terms of the value it delivers.

 The investment justification

Prior to investing in its first cobot CPL undertook a comprehensive feasibility study and cost justification exercise.

Explains Andrew Barnard:

“We were looking to achieve an 18 month payback on the cobot investment and we believed we could do this by moving one of our existing machining centres, the Doosan DNM 6700, out of our milling unit into a newly-created automation area where it would be integrated with the cobot.

“The new cell configuration would help us increase the DNM 6700’s production capacity (i.e. the number of hours it could be used cutting metal) and profitability (i.e. autonomous machining with minimal operator intervention).

“As long as we could supply the cell with components that were the right size and weight, and in sufficient batch quantities (ideally 200 to 300), we were confident that we could make it work.”

This recent example illustrates the productivity gains that CPL is experiencing with its cobot investment.

Example

65 small aluminium blanks are positioned on a peg table next to the cobot and adjacent to the DNM 6700 machining centre. The cobot is programmed to pick up each blank in turn and load it into the machining centre where it is machined to completion. (Cycle time for each part is 8 minutes 20 seconds).

Once machining operations have been completed the cobot takes the finished component from the machine and places it back on the peg board, and then loads a new blank into the machine.

By starting the machining operations at 5.00pm the entire batch is machined, overnight, in 9 hours – without any manual intervention.

The Doosan cobot

The cobot acquired by CPL is a Doosan M0617 which has a 1.7 metre reach, a 6kg payload capacity and features high-torque sensors on its (6-axis) articulated arm. It was supplied to CPL with controller, a base unit and teaching pendant.

The cobot was set up by CNC Machinery Solutions Automation application engineers and training was provided to CPL on-site.

Conclusion

Says Nick Raven:

“It’s still early days but we are delighted with the cell’s performance, and the decision to invest in collaborative robot technology has been justified.

“As with any investment in new technology there is a definite learning curve involved but, thanks to Mills, it wasn’t that long or steep. We are appreciative of the relationship we have with Mills and, I believe, we are both benefitting from the learning this journey provides.

“Such has been the positive impact of our first cobot that we are considering investing in a second in the near future and further developing our use and application of digital automation and artificial intelligence.”

The post Another first for Cambridge Precision! appeared first on CNC Machinery Solutions.

CNC Machinery Solutions has, through its recently-created Automation Division, supplied Coventry-based Arrowsmith Engineering, part of the AS.G Group, with a high-performance Doosan collaborative robot as part of a wider £200k investment made by the company to help it increase its productivity levels and maintain its competitive edge.

The robotic cell installed at Arrowsmith’s 20,000 square foot facility comprises a new Doosan DNM 4500 vertical machining centre equipped with a 4th-axis unit and a M0617 cobot with a 1.7m reach radius and 6kg payload capacity equipped with a Schunk Co- act EGP-C electrically-driven two finger parallel gripper.

The cell is being used to ramp up production of a precision engine part that Arrowsmith manufactures for customers in Spain and the US. through adopting ‘lights-out’ production, the cell operates 24/7 enabling the company to manufacture and supply 200 components every month to these customers.

Integrating a collaborative robot into the process has had a dramatic impact on productivity and machine shop efficiency, and has negated the need for Arrowsmith to invest in a second machine tool.

Comments Jason Aldridge, Arrowsmith Engineering’s Managing Director:

“The cell has significantly increased capacity levels (by up to 50%) and is helping us capitalise on the 20% growth we (as a company) have experienced over the last 12 months – growth that has seen our annual turnover soar to £7.5m.”

He continues:

“Some manufacturers, especially here in the UK, are reticent about investing in automation and believe that it has a negative impact on jobs. I don’t subscribe to this view. If anything automation makes us more competitive and successful enabling us to recruit more people into skilled jobs.”

The cobot cell is Arrowsmith’s first investment in robotics.

Operating around the clock it has made the machining process for the engine parts less labour intensive as an operator is no longer required, on standby, to load and unload parts into and out of the machine.

Says Jason Aldridge:

“The cell has made us 15% quicker and has given us a 50% capacity boost already which, in anyone’s book, is a fantastic return on investment.”

It is against this backdrop of improved productivity and efficiency that Arrowsmith has recently approached staff at CNC Machinery Solutions Automation to investigate the potential for automating more and different processes at its facility.

Discussions to date have included the feasibility of investing in a Doosan cobot to serve two machine tools to create an autonomous and flexible automated manufacturing cell, and the potential of a cobot to undertake part inspection operations.

Comments Peter McCullough, Product Manager (Doosan Robotics):

“The cobot cell at Arrowsmith Engineering provides ample evidence (if any was needed) of the significant benefits component manufacturers can expect to achieve from automated machine tool tending operations.

“The installation of the Doosan M0617 cobot is one of the first in the UK and, judging by its positive and immediate impact on Arrowsmith’s productivity, it won’t be the last.”

Says Jason Aldridge:

“We are keen advocates of automation.

“Automation shouldn’t be seen as something that only the big boys do… SMEs can access it cost-effectively and we need to ‘grasp the nettle’ in order to bring the UK’s productivity up to, and in line with, our international rivals.”

About CNC Machinery Solutions Automation

CNC Machinery Solutions Automation is a division of CNC Machinery Solutions responsible for driving sales of the company’s industrial and collaborative robot systems and solutions.

CNC Machinery Solutions Automation is the exclusive supplier of Doosan Robotics’ cobots to manufacturers in the UK and Ireland.

There are four cobots in the Doosan range. All cobots feature high-torque sensors on their (6-axis) articulated arms, and have impressive reach (up to 1.7 metre) and payload capacity (up to 15kg).

The cobots can be supplied with application-specific end-of-arm tooling and, in addition to a cobot arm, feature a state-of-the art controller, a mobile base unit and a teaching pendant, plus a range of options and extras.

About Arrowsmith Engineering

Arrowsmith Engineering, established 50 years ago, is a precision turning, milling and grinding specialist that providing high-quality components made from titanium, nimonic alloys, stainless steel, exotic metal and engineering plastics etc., to aerospace OEMs and Tier 1 companies.

The company, which has been supported by Coventry University and Coventry City Council on its latest investment, supplies parts that are used all over the world in aerospace engines, landing gears and air frames.

It has been able to overcome the prevailing market uncertainty to boost its export business by 400%, thanks mainly to delivering world class manufacturing performance, with ‘On Time In Full’ at 98.5% and quality running at 99.95% for the past twelve months.

This level of continuing operational excellence has seen it recently secure the Supply Chains for the 21st Century (SC21) Silver Award for the third consecutive year, which has contributed to it becoming one of the first company’s to be entered into the Competitiveness & Growth Programme.

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