Since the world robot reports about more and more robots will enter into the workers and in the years later to determine the production planning with the workers of information already known. While it's no surprise that double-digit percentage growth rates have been achieved, automation remains the core competitiveness of the manufacturing sector. From 2015 to 2019, the robot industry has entered the fast lane of development. According to IFR data, the number of industrial robots to be used worldwide will grow to about 2.9 million units by 2019, up from a record 1 million in 2015.

A robot that automates technical solutions

    Industrial robots, service robots, help robots and humanoid robots have become increasingly visible. Robots are now also available as a direct automation technology in the field of machine tools. Although the automation of machine tools is not a new field, it has become a brilliant new star at the recent AMB exhibition. Mazak, Schuler, Vollmer, Trumpf, Matsuura and DMGMORI are all well-known brands in the market, and all of them have strengthened the integration of automation technology into their respective products.

    Where does the growing demand for automation technology come from? Stuttgart research institutions (IfW) senior engineer Dr ThomasStehle said: "behind the automation technology there is a need to further improve the efficiency of the manufacturing process and economical efficiency of the desire or requirements. At the same time, we should also see the technical advantages of this aspect, such as higher machining accuracy, shortening the main production time and production support time, and improving the safety of equipment.

    However, the user's request was not presented at the recent AMB exhibition. On the contrary, the popularity of this popular display has almost given rise to some sort of doubt that the growing attention to automation of machine tools seems too late.

"For decades, machine tools have been constantly improving, and production efficiency has continued to improve. But in recent years productivity growth has been constrained because of a coherent process, such as loading and unloading and logistics, that have not grown at similar rates. In the aspect of overall productivity improvement, the automatic loading and unloading of machine tools and the delivery of workpieces is a necessary lagging link. UlrichSchneider, program manager for robotics and auxiliary systems at the fraunhofer manufacturing engineering and automation company (IPA), describes the development gap between the machine tool and its environment.

    The products are more and more popular with the market, which can also verify the development trend of automatic machine tool technology. Kuka is a supplier of robotics and equipment and systems technology. "Over the years, Kuka has grown at an annual rate of 50 per cent in the field of machine automation technology, and we are only just beginning. In many manufacturing processes there is also potential to increase productivity without being exploited. Machine tool manufacturers have grasped this development trend and have strengthened our cooperation to provide a complete set of technical solutions to users. "Said AndreasSchuhbauer, market manager for machine tool automation at Kuka.

    The Kuka robot on the MazakIntegrex machine

    It is possible to reflect the development trend of this technology. Mazak, the machine tool maker, first exhibited its cooperation with Kuka in the AMB exhibition. This technology is a requirement for the company's users to a holistic technical solution, which can match the mazakintegrex-i series of machine tools in terms of feature data. Since the 1870 s, Mazak company already has the very strong strength in production automation technology and can provide mature automation system products, such as product Palletech system for machining center. Kuka can provide hardware for the mazakintegrex-i series of devices in the new fully automatic technical scheme, and the production process and interface and process procedures can be developed in Mazak's own design department.

    "A feature of Integrex technology with robots is great flexibility. Integrex series equipment, with its universal processing capacity for parts showing great flexibility and achieve a high quality level, even the small batch production, the same is true, so it's suitable for today's manufacturing requirements. We have seen significant growth potential in this area, and we have expanded our capabilities with the newly established design department in Germany in 2015 to cooperate with such technical solutions." "Explains JohannesBurkart, marketing manager for YamazakiMazak German company. By the combination of Mazak machine tool equipment and robot can generate a complete technology package, because the robot can not only carrying workpieces, at the same time also can be extended to the carrying on of cutting tool.

    The Kuka robot integrated on the MazakIntegrex device can not only undertake the transfer task of the workpiece, but also can be extended to the function of tool handling

    In addition, a variety of special functions can be installed in the robot work station, such as installing an optical or laser system or a processing station that goes to a burr.

Automation also tends to involve a cost problem. "Of course, the cost of investing in a robot workstation can double as a machine tool, so many end users will often be reluctant to invest in automation in the past. On the market, however, there is the coordination &liaision instead is shorter and smaller batch processing requirements, combined with enterprise employee wages and logistics cost increasing, which makes more and more users believe that the need for spending on automation technology. As the utilization of machine tools has been improved, investment in automation technology can often be recovered in less than two years. Schuhbauer has worked to persuade companies that have yet to make a decision. He says: "when you have a wide range of components, it's worth it to use a robot. This is because the robot can effectively use the production auxiliary time and can implement the boring, comb brush and deburring to achieve higher quality than manual work. At the same time, the robot can also assist machine tool work so that the production of machine tool can be improved and the investment recovery period of the equipment can be shortened, which can be shortened to less than one year. Kuka is one of a handful of companies that can benefit from both proprietary technology and systems and equipment know-how. Enterprise internal departments closely illustrates an example in the field of machine tool automation, namely KukaSystems department Flexfellow type machine tools and KukaRobotics LBRiiwa type robot for KukaIndustries department of friction welding equipment for loading and unloading.

    In the Merz machine tool factory, a kukakr-fortec type robot can be connected to four machining centers

    As with all technical integration, automated machine tools raise questions about appropriate interfaces and interfaces. "The biggest obstacle to machine automation is the interaction with existing equipment. Automatic technical equipment on existing machine tools often fails due to lack of software interface and high cost of special matching. Especially in plate processing, the service life of machine tool is very long, and the other auxiliary equipment that matches with the existing technology process is the opposite. Interface problems tend to be a barrier when devices enter the market. Lack of data flow and material flow can enable automation technology solutions to achieve a uniform standard that can be widely applied without special matching. "Says Schneider of IPA.

    The practice of connecting robots to machine tools appears to be closer to success in Fanuc, Japan, because it has established a mature and standardized interface. As a result, the manufacturer of CNC systems, robots and production equipment has effectively become a partner in the automation technology of the factory.

Through simple IO connection, Fanuc - CNC equipment can be compared with Fanuc robot. For this, all other devices can be connected by using a safe plug connection. In machine tools with robot such correlation way, can be directly on the operation of the CNC machine tool interface to see the working state of the robot, or the opposite: because with this "simple connection" function, can pass on the robot control system I - Pendant manual manipulation of the instrument to query the CNC machine tool data. By IO link exchange, ways to realize the I/O signals transmitting data through Ethernet, the simple combination of equipment can be realized and meaningful docking device, such as robot docking with the machine.

    Recently, Fanuc robot has a FLFL - Net interface and an Ethernet interface, so it can realize the docking with the upper level network without problem. This makes sense for larger machine tools, because there will be multiple CNC machines communicating with each other.

    Once the Fanuc CNC connected to Fanuc robotics, query on the interface of the control system of CNC the working state of the robot, and also, because Easyconnection function also allows by robot control system for CNC data query

To further simplify the operation of machine tools and robotic systems, Fanuc has developed RobotConnection (robot connection) function. Once robots have been set up into the system as a whole, the machine operators can use this function in CNC control system, bring up a robot can provide him with the relevant state of all the important information, such as maintenance tasks or alarm information to the menu. He can also select programs and control the robot without using a separate control system to operate the robot.

    In the aspect of machine automation technology, the best coordination between all the components that are incorporated into the connection scope is also very important in addition to the problem of interface matching. Since the 1980s, machine tool maker Vollmer has been working in coordination between automation equipment.

    The ND series robotic system has been in use for about 20 years. Through this kind of loading system, users can not only improve productivity, but also respond to problems such as shortage of professionals. Vollmer has demonstrated new technology solutions for automated machine tools at the last AMB exhibition with its Vgrind360 devices. "Vollmer's technology development is closely linked to our communication and dialogue with users. The idea of a Vgrind360 device automation is derived from such conversations. Then we combine the results of the conversation with our technical experience. Now with Vgrind360 type equipment, tool manufacturers can respond to the demand of increasing hard metal cutting tools and realize continuous production, which can achieve high production output. Vollmer general manager Dr StefanBrand said. For cutting tool machining operations on handle and ship the cutter path atresia stabilization problem of collaboration and position, the company can be on line equipment experience into the automation technology. In the line cutting equipment, the coordination between the parts requires the accuracy of micron level. This technology can be directly integrated into the development of Vgrind360 machine tool equipment.

    Reduce the workload of professionals

    Schuler also introduced his years of work experience in automation in the AMB show. As an extension of the LoadMaster loading system, the enterprise introduced the LoadMasterAssist robot device. "The higher the degree of automation, the higher the productivity, especially for the machine tools that use the LoadMaster loading system to implement the link. A function extension of LoadMasterAssist robot as a loading system for pallets and cargo carriers to undertake the tasks undertaken by former equipment operators. Schuler product manager AlexanderHergl said. This can reduce the workload of professionals and enable them to handle other tasks.

    Trumpf is also aware that machine automation is a topic for the future, and has commissioned IPA to develop the relevant technologies and programmes in a collaborative manner. "The goal of development is fully automatic connection of machine tool equipment in information flow and material flow. In order to be able to in the plank treatment of complex and diverse production environment to provide effective technical solution, Trumpf and IPA company also explores the transitional technology solutions on some automation, the operating personnel in their work can be gained through information connection and support, the existing production process in the case of without expensive automation technology can also be improved." Says Schneider of IPA. The term of cooperation between the two companies is five years. In addition to the direct cooperation approach, the collaboration within the framework of public funded research projects is also discussed. IfW company is also actively explore in the field of machine tool automation subject, both fundamental aspect, also has a directly cooperation with industrial partners mouth, such as machine tool manufacturing companies and robot suppliers and equipment manufacturers, the transfer unit using, etc. If from the original seems to lack of proper connection interface and also need high investment cost become the biggest obstacle, these factors in Kuka Schuhbauer company point of view, in fact there are some other obstacles. The biggest challenge is the coordination of work between project partners. At the beginning of the project, it's not always clear what must be done, and when the project is coming to an end, there's no longer a lot of time to complete the equipment and test.

    Convince users by technical advantage

    In order to reduce the work intensity of the project cooperation unit, Kuka participated in the standardization of common interface of VDW working group. Kuka company's own technical package (such as ready2grip) should also can win more time for the user, namely the integrators in Kuka company can directly order with gripper of robot, the robot equipment to use the site after can be directly put into use. Given the complexity of automation technologies, this forward-looking support for users can be a compelling reason for users to choose automated machine tools.

    "From the point of view, I believe that the urgency of work should be placed on equipment and robot manufacturers here, because they want to make (especially small and medium-sized production) convince users with the right degree of automation of the many advantages of automation of machine tools in." The IfW company Stehle concludes. Equally compelling is the fact that users with automated machine tools are more likely to be represented by industry 4.0, which also has a future meaning. "Automation technology