Coordinated use of CNC machine tools, robots, and related systems

In modern manufacturing, the integration of CNC machine tools, robots, and related systems creates highly automated production lines. Robots handle tasks like loading/unloading workpieces and transporting them between stations, while CNC machines perform precise machining operations. Communication between these components ensures smooth workflow and coordination. This setup enhances production efficiency, accuracy, and flexibility, reducing human intervention and improving overall manufacturing quality. It is widely used in industries such as automotive, aerospace, and metal processing, adapting to various production needs and optimizing processes through data analysis.

System Integration Architecture

• Hardware Composition: Taking the Baoji CK7520 full-feature lathe and the Guangshu GSK RB08 handling robot as an example, the lathe is equipped with a FANUC-0IT CNC system. The robot is fitted with an end-effector for holding workpieces, and the solenoid valve for controlling the end-effector’s action is installed on the robot itself. In addition, two conveyors (one for raw blanks and one for finished products) are used, driven by three-phase asynchronous motors, and equipped with material detection sensors.
• Communication Connection: A PLC is used to process input and output signals logically, facilitating signal transmission and operational coordination, and controlling the conveyors, safety doors, and chuck. The robot receives and sends signals through the DSQC652 input/output board, while the CNC lathe handles signal input and output via the built-in PLC of the FANUC CNC system.

Production Process Coordination

1. Workpiece Loading: Based on the input signal, the robot picks up the workpiece to be processed from the conveyor and accurately places it on the worktable of the CNC lathe. During the process of picking up and placing the workpiece, the robot uses sensors to detect the position and orientation of the workpiece to ensure it is correctly clamped.
2. Machining Process: After receiving the signal that the robot has completed the loading, the CNC lathe begins machining the workpiece according to the preset machining program. During the machining process, the robot can prepare to pick up the next workpiece or carry out subsequent processing on the workpiece that has already been machined, such as deburring or cleaning. At the same time, the robot can also adjust the machining position of the workpiece or change tools in a timely manner according to the machining progress to meet the machining requirements of complex parts.
3. Workpiece Unloading and Inspection: Once the machining is complete, the robot removes the finished workpiece from the CNC lathe and sends it to the inspection equipment for quality inspection. The inspection equipment feeds back the inspection results to the central control system. If the workpiece is qualified, it is sent to the next process or the finished product area; if it is not qualified, it is processed for rework or scrapping.
4. Data Collection and Analysis: Throughout the production process, the robot and the CNC lathe continuously collect machining data, such as cutting force, machining time, and tool wear, and transmit this data to the central control system. The central control system analyzes and processes the data, optimizing machining parameters and adjusting production plans based on the analysis results to improve production efficiency and product quality.

Technical Details and Advantages

• High-Precision Positioning and Control: The robot is equipped with high-precision sensors and advanced control systems, capable of achieving micron-level positioning accuracy to ensure precise clamping and handling of workpieces during the machining process. The CNC lathe itself also has high-precision machining capabilities, and the combination of the two can further enhance machining accuracy and product quality.
• High Degree of Automation: The entire production process, from workpiece loading to machining completion, and then to inspection and unloading, is automatically completed by the robot and the CNC lathe without human intervention. This not only increases production efficiency but also reduces the impact of human factors on the production process, enhancing production stability and reliability.
• Strong Flexible Production Capability: The robot can quickly adjust its working mode and motion path according to different production tasks and workpiece types. The CNC lathe can also rapidly adapt to the machining requirements of different parts by changing the machining program. This flexible production method can well meet the modern manufacturing industry’s demand for multi-variety and small-batch production.
• Data-Driven Optimization: By collecting and analyzing production data in real-time, the system can automatically adjust the production process and machining parameters. For example, it can automatically adjust cutting speed and feed rate based on tool wear to extend tool life and ensure machining quality; it can also optimize production plans based on workpiece machining time to improve equipment utilization.

Practical Application Cases

• Automotive Manufacturing: On the production line for automotive engine cylinder blocks, the robot is responsible for picking up the raw cylinder block from the rack and sending it to the CNC lathe for machining. After machining, the robot removes the cylinder block and sends it to the inspection equipment for inspection. The entire process is automated, improving production efficiency and product quality.
• Aerospace: In the machining of aerospace components, the CNC lathe and robot work together to complete the high-precision machining of complex-shaped parts. The robot not only handles the transportation and loading/unloading of workpieces but also assists the CNC lathe in some auxiliary machining operations, such as grinding and polishing. This cooperative approach enhances machining efficiency and precision while reducing production costs.
• Metal Processing: A metal processing and manufacturing company has introduced a high-performance composite robot system, integrating advanced robot control technology with precision CNC lathe machining equipment. The robot is configured to automatically perform a variety of tasks, including workpiece loading, positioning, clamping, and subsequent CNC lathe machining. This automated process significantly reduces the need for human intervention and minimizes errors and waste in the machining process.