Robot Automation of High-Mix/Low Volume Part Production

To automate the high-mix/low volume part production needed in job shop operations, Hurco Companies, Inc. (Indianapolis, IN) connects the latest CNC machining center technology with collaborative robots, multi-axis serial robots and pallet systems from Erowa, Universal Robots, FANUC robots, Online Resources, and Industrial Controls & Automation. For example, a collaborative robot can 3D scan a part, generate a solid model to create a tool path, and then a 5-axis VMX30Ui trunnion table machining center will cut the head from cylindrical aluminum stock, or a 3-axis VM10i CNC will cut the profile into a brass coin. Both CNC machine tools are connected to fully automated robot systems coordinated by a centralized job management system.

“Automation integration used to be more expensive and difficult because you had simple I/O connections and needed to reprogram a PLC when changing parts,” explained Dr. Paul Gray, the manager of path planning, front-end design and R&D for Hurco. “CNC manufacturers and automation providers have been working together to provide seamless integration between the CNC control and the robot control. With software systems talking to each other over an Ethernet connection, users can now bundle all aspects of the job together. We have created a new level of flexibility and simplicity in part change-over in production cells.” This includes the introduction of 3D Import with 3D DXF technology, where the user can simply load the file they receive from their customer directly into the control, eliminating the need for extra steps.

“When we introduced the DXF Transfer option in 1992, it was a real game changer for the end user because many shops received DWG or DXF drawing files,” recalled Mike Cope, a product technical specialist for Hurco. “This made it very easy to transfer the files to the CNC machine tool and use them to create their programs on the shop floor right at the machine. It also eliminated incorrect data being entered, or ‘fat-fingering numbers’ as we say in the shop. Today, it is common for shops to receive solid models of the parts that they need to produce, and even paper prints are becoming obsolete.” This is why 3D Import was developed: It includes 3D DXF technology that displays all of the geometry that the CAD system outputs, including splines.

“With 3D DXF, the user can select the bottom of a contour and the Z-axis depths will also be automatically input into the conversational block,” noted Cope. “All previous versions of DXF translators only displayed lines and arcs data, and were only useful in 2D – no Z-axis data was translated. But 3D Import (the solid model portion) automatically creates the necessary Transform Plane data blocks in conversational programming for five-sided programs.

Hurco Companies, Inc., One Technology Way, Indianapolis, IN 46268, 317-293-5309, Fax: 317-328-2812, www.hurco.com.