Robotic Integration Boosts Automated Milling, AM and Part Fabrication

Kuka Robotics is demonstrating a variety of automated solutions from several of its system partners that can streamline part processing and boost overall production output. These systems, all featuring Kuka robots, include the CyberDrawers machine feeding unit from Waybo; entry-level machine and process automation from Mairotec GmbH; automated milling from Robotics Solutions Inc.; and metal additive manufacturing from One-Off Robotics. For part fabrication operations, show attendees can also experience the Mobile Robotic Bending Cell from Bystronic and the Robotic Bending Cell (RBC) from the Gladwin Automation Division. 

For turnkey machine tool automation solutions, Waybo’s CyberDrawers feeding system is designed for turning centers and milling machines. Shops can program the system using an internally designed interface that calculates nearly all of the robot’s movements, and setting up for a production process is quick and easy. Initial installation of the whole system typically takes one day, according to the company.

All Waybo products, including the CyberDrawers are fully modular, compatible with each other and optimize operations while reducing production costs. The cells integrate with current and older machine tools and interface with other equipment such as marking machines, digital inspection machines, saws, grinding wheels and more.

Mairotec is also showcasing its MairoFlex Compact 8, which is said to offer the speed and flexibility of an industrial robot with the benefits of a fenceless solution. The company says that its standard systems are flexible, provide easy entry into automation and are an economical alternative to larger size systems.

The unit provides a reach up to 1,640 mm, increased speeds and high pose repeatability. Its integration with the KR C5 micro controller from Kuka enables maximum performance, connectivity and flexibility. The KR C5 micro integrates into existing infrastructures and can deliver added value through efficient performance for all applications. Mairotec also incorporates Kuka LBR iisy cobots into its MairoFlex iisy solution to maximize flexibility, minimize space requirements, boost performance, accelerate production and lower cost of ownership.

Designed with applicability for several market segments including pick-and-place operations in machining, assembly and handling applications, the MairoFlex iisy and LBR iisy cobot are easily teachable to beginners. 

Robotic Solutions is displaying a robotic milling application that uses a KR Quantec Nano robot and DKP 3 positioner processing a cast part made of hard material. The solution offers users full CNC-type operations including automated toolchangers, tool presetters, hotwire harps, probes, 3D scanners, unlimited file size capabilities and more. The company’s systems are available in sizes ranging from small to large.

Show attendees looking to incorporate metal additive technology into their part processing operations can also experience the Robotic Metal Additive Manufacturing System from One-Off Robotics in the Kuka booth. These systems, using Kuka robots, are designed to improvethe production capabilities of defense, aerospace, research, mold and die and other specialized production sectors.

One-Off Robotic systems aim to address not only the current needs of the industry but also lay the groundwork for future advancements. Its featured system provides high efficiency and supports average deposition rates of 4 kg/hr for wire arc additive manufacturing (WAAM) and variable rates — up to 10 kg/hr — for wire laser additive manufacturing (WLAM), enabling rapid production cycles in both applications. Enhanced control over the melt pool and part density improves the mechanical properties of final products. Its features make it suitable for mold repair applications.

The Bystronic Mobile Bending Robot Cell provides flexible on-demand automation designed for confined spaces and for producing small- and medium-sized parts. Using a KR Agilus robot from Kuka, the miniature-format press-brake cell delivers bending speeds of up to 30 mm/sec — a speed that’s said to be three times faster compared to large press brakes.

In minutes, the company says it can expand either its compact ByBend Star 40 or ByBend Star 80 press brakes into mobile bending cells for manual or automatic operation. This can give shops the flexibility to select the right cell for their particular part bending application.

Gladwin Automation’s RBC is said to require little input from press brake operators while also allowing shops to handle a variety of bending jobs. Equipped with necessary components — from press brake, robot and end-of-arm tooling to offline programming software and material handling conveyors — the cell provides a viable way to maintain or increase output without the effort and expense of additional labor.

According to the company, the cell increases productivity through 24/7 operation, eliminates the need for heavy lifting by operators, improves overall part quality, reduces the risk of scrapped parts and has a user-friendly interface for quick operating and retooling.