A new standardised off-the-shelf robotic automation cell will be highlighted by Devon-based XYZ Machine Tools at Northern Manufacturing 2019 (Stand B52) (www.xyzmachinetools.com).

Robo-Tend, which has been designed by XYZ in collaboration with Manchester-based automation specialist Adelphi Automation, is a robot-based automation cell with a camera vision system that brings robotic automation within the reach of traditional sub-contract engineering businesses.

It is fully compatible with the Siemens ShopMill and ShopTurn controls used on XYZ’s new vertical machining centres and turning centres, and it can be retrofitted to existing models.

The compact stand-alone cell is on wheels and can be moved between machines within a workshop as demand dictates, taking around 30min to be set up and operational again.

The camera vision system makes use of markers on up to four vices on the table of a machining centre, along with similar markers in the component storage drawers.

This means that exact positioning of the components or vices is not critical for efficient functioning of the system.

In line with XYZ’s philosophy of making machine control straightforward, the Robo-Tend operator simply enters the dimensions of the billets and whether they are round or square; the control system then calculates the location pin positions within the drawers, along with the optimum stack height.

The Robo-Tend controller then communicates with the machine’s Siemens control to select the correct part programme, and unmanned operation can begin.

Central to the system is the self-contained Kuka Cybertech KR10 R1420 robot, with a rated total load of 10kg (larger-capacity robots are available, up to 25kg), managed via the Kuka KRC4 compact robot controller.

This operates within a moveable compartment that is in turn attached to the drawer system where billets and finished parts are stored.

The versatility of the system means that it is equally at home servicing a machining centre as a turning centre. Features such as component ‘flipping’ for second-operation work are also available.

Typically, there are four storage drawers in a Robo-Tend system, with each drawer capable of holding 90kg of material.

With the camera vision system identifying the location of the parts in the drawers (opened and closed by the robot), the parts can be loosely placed within the location pins, with the system calculating the actual pick-up point.

Now, with robot and storage units connected, the guards interlock and create a safe working environment for the robot. If access is required to the machine table for setting or maintenance purposes, the robot is ‘parked’ in a safe position and becomes inoperative.

XYZ’s managing director, Nigel Atherton, said: “Robot automation is nothing new, but for many the perception is that it is only suitable for high-volume production environments, such as the automotive sector.

“The XYZ Robo-Tend system addresses this and makes automation viable for lower-volume production.

"The driver for this development was that the availability of skilled labour is a major issue that will not disappear, so the automation of lower-skilled jobs such as machine loading is an obvious way of addressing this for small to medium-size businesses.

“We are confident that we have created a solution that will open up automation to a much wider audience at a very competitive price.

“Robo-Tend provides a versatile, user-friendly and modular approach to companies that need to improve their productivity but are struggling to find the personnel to operate machines.

"Depending on the component, the system can be left unattended for a full shift or even operate 24/7, with the only manual intervention being to restock the raw material in the part storage system.

"Here customers have the option of a second drawer system, which can be pre-loaded and ready to slot into place to further improve set-up time and logistics.”