Automation with CNC system
Automation is an inevitable trend in modern manufacturing. Alongside the powerful rise of the Fourth Industrial Revolution, automation is widely applied to maximize advantages across various industrial sectors, including CNC machining in particular. However, to fully harness the superior advantages of automation with CNC systems, one needs specific knowledge and careful consideration of related factors. The following article will provide readers with fundamental information on the integration of automation with CNC machining.
What is Automation with CNC system?
Automation with CNC systems involves moving workpieces through the production process from machine tools to secondary equipment such as measuring devices or washing stations. Automation reduces human intervention in the manufacturing process, enhancing the utilization of machine tools. It's an essential way to maximize the potential of your CNC machines.
Automation helps achieve process repeatability in CNC machining operations using CNC technologies such as CAM software. Nowadays, CNC automation technology allows engineers to manufacture parts with less operator intervention through machine simulation and offline programming.
The two most important aspects of CNC automation are: Automated Production Planning and Resource Management and Automation of Motion and Physical Operations
Automated Production Planning and Resource Management
Automated production planning and resource management requires software capable of transforming manufacturing orders (e.g., from ERP systems) into a continuously updated plan of what will happen during the production process and when. By managing production resources such as raw materials, NC programs, and tools, the software can predict and preemptively address any issues. It also guides operators to take timely and appropriate actions. This empowers production managers with complete control and facilitates meeting real-time deadlines more easily and with less stress.
Automation of Motion and Physical Operations
Automating motion and physical operations requires automation hardware such as robots, enabling systems to execute manufacturing (machining) according to plans in real-world scenarios. This involves transferring machining pallets or directly handling workpieces. Additionally, the system can manage the physical movement of cutting tools and integrate supporting processes like grinding, washing, measuring, and marking. This level of automation is well-understood and deeply ingrained in the context of CNC production, but it's only one side of the coin when exploring best practices.
It's important to note that while production planning and resource management can be automated independently of actual operations, the greatest benefits are realized when these are integrated.
For more information on VISC's CNC automation projects, please refer to their applications here.
What can be automated in each process?
Automation of production planning and resource management
The coordination of humans, machinery, and IT systems operates as one system. In practice, this means features such as:
- Automated flow of information between different data systems and machinery or components.
- Proactive and continuous updating of production plans based on manufacturing orders and their priorities.
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Automating the retrieval of orders from ERP
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Guiding operators to always perform actions at the right time
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- Processing the production 'recipe' for workpieces
- Managing complex production stages in the manufacturing process
- Proactively managing resources against the production plan and reporting on deficient resources.
- Fixtures, pallets, and clamps
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Raw materials
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NC programs
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Cutting tools, tool data, and processed goods
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Reporting and analysis
- Production and machinery KPIs such as utilization levels, OEE, availability…
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Viewing order progress Inventory / work in progress
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Production event history and traceability
- Automated documentation (paperless production)
Automation of Motion and Physical Operations
Hardware automation can replicate stable processes efficiently and with very high accuracy. In practice, this can involve activities such as:
- Moving workpiece pallets (non-stop) to/from machine tables.
- Automatically loading/unloading fixed objects using robots.
- Directly transferring blanks to machine tables or workholding fixtures.
- Automatically adjusting or changing workholding fixtures.
- Making changes to grips and tools within robots.
- Moving tools into tool storage containers.
- Moving workpieces to/from secondary machining support processes such as:
- Deburring
- Washing
- Heat treatment
- Washing (again)
- Marking
- Polishing
- Measurement
- Managing and transferring raw materials
- Managing and transferring finished goods
The development process of automation with CNC systems
Below is the sequence of methods applied in the manufacturing process along with the limitations of each method. The advent of CNC automation has helped overcome these limitations and marked a new milestone for the manufacturing industry.
Manual Production: CNC machines were initially used infrequently.
The first approach involved traditional workshops without automation, where one operator controlled 1-3 CNC machine tools manually. While robust, this method had clear drawbacks. Machines typically operated for only 1000-2000 hours out of 8760 annual hours due to manual setup, manual production planning, process instability, and occasional shortages of raw materials or tools.
Overall, this resulted in longer lead times, occasional quality issues, and incomplete fulfillment of production requirements.
Final outcome: Production processes only added value for a fraction of their potential operational time.
Traditional CNC Automation: CNC machines operated most of the time.
The second type replaced human operators with robots. This significantly increased machine utilization, as robots/cranes could supply materials to machines nearly 24/7. However, this approach also encountered substantial challenges. Continuous machine operation sometimes outpaced efficient handling of resources and tools or intelligent management of production orders relative to machining capacities. In other words, production planning and resource management became bottlenecks rather than utilizing maximum production potential. Before automation, clock-speed production was slower and processing could be done with a simple pen and paper or basic Excel sheets.
Final outcome: Machine tool usage could be increased by replacing (some) operators with (multiple) robots, but this often caused related issues in production or resource management, limiting full production potential.
Smart CNC Automation: Machines do the right job, at the right time - all the time.
In CNC automation, all benefits from automated operation of moving parts are combined with the advantages of automated production planning and resource management.
Production orders (e.g., from ERP systems) establish production "speeds" and synchronize everything around them. Production management software knows all necessary resources and machining capacities, prompting operators to perform correct actions at the right times. Moreover, it actively alerts if planned activities cannot be executed. To facilitate production managers' work, production plans are automatically updated based on changes such as rush orders (skipping production requests) or machine breakdowns (reallocating work to other capable machines).
Final outcome: Overall, the production process consistently does the right job at the right time - all the time. This means optimal machine usage, low scrap rates, fast lead times, fewer errors, and high quality.
What is the benefits of Smart CNC Automation
Fast Production Speeds and Quick Turnaround Times
Automating CNC machines increases and maximizes their operational time because they can handle multiple tasks simultaneously. These machines produce products faster and more efficiently compared to conventional machines. They require less supervision from operators and lower labor costs. CNC-machined parts are sold more quickly, thereby influencing increased demand for them.
Reduced Production Costs
CNC automation solutions ensure cost-effectiveness of labor and machinery throughout the production process. One machine operator can manage and monitor multiple machines, reducing production costs. Besides lowering production costs, CNC automation also minimizes risks and prevents accidents, thereby reducing other legal responsibilities. CNC automation enables higher revenue at reduced prices, contributing to long-term profitability for your business.
Consistent Quality Control
CNC automation helps manufacturers produce products with consistent quality, ensuring that customers receive the high-quality products they seek. Customers support manufacturers investing in CNC automation technology expecting the highest possible product quality. Automated machines operate continuously, producing the same product with equivalent quality day and night. They only require regular maintenance to ensure their longevity.
What enables the automation of CNC machining processes?
Automation is increasingly enhancing production efforts and workflows through the integration of various programs and notable innovations. These include:
Hardware in CNC machining
Despite CNC machines being quite costly, they offer significant benefits. Generally, CNC technology automates the machining of various parts using different types of equipment. There is a rich array of machine types to choose from, including 3, 4, or 5-axis machines.
5-axis machines are customized CNC milling machines that offer superior machining capabilities and flexibility. These CNC machine tools are user-friendly and highly efficient. They require regular programming and maintenance to ensure their long-term viability. However, the software interface must be fully integrated with the CNC machine.
Software in CNC machining
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