Simbiosis × ZF Sachs - Robotic automation
Automatic CNC unloading
Fully automatic unloading of machined parts from a DMG MORI CNC lathe with a Universal Robots (UR) cobot, with operator safety built in.
Results - in figures
Production efficiency up by more than 30%.
Operators moved off monotonous, risky tasks onto higher-value work.
Cycle time per part standardised and cut by up to 25%.
Operator-induced errors reduced to zero.
In this project, parts machined on a DMG MORI CNC machine at ZF Sachs’s production plant are picked precisely by a Universal Robots (UR) cobot and placed at a set position, with no human intervention. A Schunk gripper holds the parts reliably, and a Euchner MGB smart door safety system maximises operator safety. The automation cell raises production efficiency, standardises cycle times and allows uninterrupted 24/7 operation.
01 - Challenge
The challenges
The starting point: what was slowing the line down, putting it at risk or keeping its data in the dark?
- 01Challenge
Precise cobot motion in the tight, confined space inside the CNC machine
- 02Challenge
Keeping the heat of the machined part, and any burrs on its surface, from affecting the grip
- 03Challenge
Uninterrupted, real-time communication between the CNC, the cobot and the safety systems
- 04Challenge
Keeping machine downtime to a minimum while ensuring maximum safety
02 - Solution
Our solutions
Our answer: mechanics, controls and software, built by one team.
- 01Solution
We created custom motion paths for the tight space, using the UR cobot’s 6-axis movement and precise programming.
- 02Solution
We designed custom Schunk gripper fingers to suit the part’s geometry and temperature.
- 03Solution
All the equipment (CNC, cobot, Euchner) communicates over industrial Ethernet protocols.
- 04Solution
The Euchner MGB door switch is integrated with the cobot’s safe-mode functions, so the cobot slows down or stops instantly when the door opens.
03 - Result
The results
The difference measured on the line, and seen by the customer every day.
- 01Result
Production efficiency up by more than 30%.
- 02Result
Operators moved off monotonous, risky tasks onto higher-value work.
- 03Result
Cycle time per part standardised and cut by up to 25%.
- 04Result
Operator-induced errors reduced to zero.
- 05Result
Maximum working safety, with a target of zero workplace accidents.
04 - System
Project highlights
- Automatic part unloading from the CNC machine with a cobot
- Reliable, repeatable part gripping with a precision Schunk gripper
- Operator safety to PLe with Euchner MGB integration
- 24/7 unmanned production capability
- Flexible programming for quick, easy product changeovers
- Fully synchronised with the CNC machine
Technologies used
05 - On site
Project gallery
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The service we provided on this project
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