Enhancing CNC Machining with Industrial Robots

1. Introduction

Modern manufacturing relies on automation to boost productivity, cut costs, and increase competitiveness. Industrial robots play a key role in CNC machining. They handle tasks like loading, unloading, handling, and inspection. These robots reduce manual work. They also improve production speed, precision, and consistency.

Additionally, they expand CNC machine functions. They support multi-process machining, such as measuring, milling, and drilling. This enables 24-hour continuous production. It increases manufacturing flexibility, making it ideal for small-batch, multi-variety production.

2. Feasibility Analysis: Industrial Robots in CNC Machining

CNC machines offer more automation than traditional methods. This makes them a strong foundation for integrating industrial robots. However, tasks like loading, unloading, and quality inspection still require manual work. Robots can replace these manual tasks. They reduce human labor, improve accuracy, and make production more flexible. This ultimately increases efficiency and lowers costs.

3. Applications of Industrial Robots in CNC Machining

3.1 Robots in Machining and Manufacturing

Industrial robots integrated with CNC machines improve automation, precision, and output. This leads to higher product quality. Many robots for CNC systems now feature automatic deceleration. This ensures stability during mass production and maintains machining accuracy.

3.2 Supporting CNC Bending Operations

In CNC bending, robots assist in two main ways:

Flexible Bending Assistance: Robots with force and vacuum suction cups support CNC bending units. They improve automation in flipping frames, positioning tables, and other key areas.
Travel-Axis Flexibility: Robots move along production lines. This increases system adaptability and processing flexibility.

3.3 CNC Machine Tool Press Integration

Robots handle several tasks in CNC press operations:

Material Handling: Robots locate and transport sheets automatically.
Stamping Precision: Robots complete stamping processes with high accuracy.
Stacking & Unloading: Robots move finished products to stacking areas. This supports continuous, organized production.
In fully automated production lines, multiple CNC machines and robots work together. Each robot performs a specific task like loading or handling. This setup improves efficiency and supports complex machining processes.

3.4 Robots in Hot-Die Forging

For hot forging, CNC machines and robots work together to manage high-temperature materials:

Material Transfer: One robot moves heated material to the press.

Trimming Support: Another robot trims and applies lubrication. This prevents adhesion at extreme temperatures.
Robots need regular maintenance to stay functional. This protects them from heat and radiation damage. They also rely on advanced sensors for self-protection. This ensures they operate safely in harsh environments.

4. Building Intelligent CNC Production Lines

4.1 Production Line Components and Layout

The production line setup includes two FANUC CNC lathes, robot guides, PLCs, ABB industrial robots, and loading tables. Each part plays a critical role in keeping the line running smoothly.

4.2 Production Line Operation

The robot loads materials into the machines. After processing, the robot unloads the parts and arranges them neatly. This creates a continuous, cyclic workflow.

4.3 CNC Lathe Modification for Robot Integration

To connect the robot to the CNC lathe, wires link the CNC system to the robot’s I/O board interface. This allows the machine and robot to communicate smoothly.

4.4 PLC-Controlled Robot Movement on Guideways

The PLC (Programmable Logic Controller) controls the robot’s movement along guideways. The PLC program uses FXIN positioning commands. These commands guide the robot to move accurately and perform tasks like loading and unloading.

4.4.1 Home Return Instruction (ZRN)

When the machine loses power, the robot loses its position data. The home return instruction resets the robot to its starting position after power is restored. This ensures accurate operation resumes.

4.4.2 Absolute Position Control Command (DRVA)

The DRVA command controls the robot’s movement. It sets the pulse output, frequency, and rotary direction. This ensures the robot moves precisely and repeats actions accurately.

Emergency stop buttons: For safety, the system includes emergency stop buttons. Button X005 stops the robot, while button X001 stops the guideway.

4.5 Robot Programming

The robot has an ABB DSOC652 I/O board with 16 input/output ports. The PLC connects to output port 7 to control the guideway. Hall sensors detect magnetic field changes. These sensors track completed tasks and ensure the robot counts each process accurately.

5. Conclusion

Industrial robots greatly improve CNC machining. They handle repetitive tasks with speed and precision. This reduces labor costs, minimizes errors, and ensures consistent product quality. Robots enable 24/7 production and support complex processes. This helps manufacturers achieve faster turnaround times, greater flexibility, and stronger competitiveness in today’s fast-paced manufacturing environment.