Maximize Profits with a 24/7 CNC Automation Cell: Dual-Chuck Lathe & Robotic Loader in Action!
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- เผยแพร่เมื่อ 26 มิ.ย. 2024
- To make serious money in the CNC machining industry you have to perfect the process. Halter Automation coupled with DN Solutions CNC machines are a perfect match to complete your automation process.
For more information on Halter Automation:
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00:00 Manufacturing and Automation
00:45 Loading Turnstacker
03:03 Programming Halter Automation
04:32 Machining Op 1
05:38 Tips for Automation Ease
07:08 Robot Integration Process of Machining
08:16 Safety Features for Halter Automation
08:55 Halter Automation Powered by Fanuc Robotics
09:25 Unattended Machining Continuously
09:43 Staying Competitive in Today's Industry
Speeds & Feeds:
UPPER TURRET
TOOL 1 OUTSIDE ROUGH TURNING
HOLDER: .750" STICK TOOLING
INSERT: CNMG432MP KCU10B
SFM: 500 / IPR: .010
TOOL 2 INSIDE FINISH TURNING
HOLDER: KM32 MODULAR / 1.260” STEEL BORING BAR
INSERT: CNMG431FP KCU10B
SFM: 650 / IPR: .004
TOOL 4 INSIDE THREADING
HOLDER: .625” CARBIDE BAR
INSERT: 16UN ID THREADER
SFM: 400 / IPR: .0625
TOOL 5 OUTSIDE FINISH TURNING
HOLDER: KM32 MODULAR / OUTSIDE TURNING
INSERT: CNMG431FP KCU10B
SFM: 650 / IPR: .004
TOOL 6 HOLE CHAMFERING (LIVE TOOL)
HOLDER: DUO-LOCK SOLID COLLET
TOOL: .375” 4 FLUTE CHAMFER TOOL
SFM: 325 / IPM: 16
TOOL 7 HOLE MILLING (LIVE TOOL)
HOLDER: ER25 COLLET
TOOL: HARVI I 1/4" ENDMILL
SFM: 230 / IPM: 25
LOWER TURRET
TOOL 1 OUTSIDE ROUGH TURNING
HOLDER: .750" STICK TOOLING
INSERT: CNMG432MP KCU10B
SFM: 500 / IPR: .010
TOOL 3 OUTSIDE FINISH TURNING
HOLDER: KM32 MODULAR / OUTSIDE TURNING
INSERT: CNMG431FP KCU10B
SFM: 650 / IPR: .004
TOOL 4 RADIAL DRILLING (LIVE TOOL)
HOLDER: ER25 COLLET
TOOL: .375” FLAT BOTTOM DRILL
SFM: 165 / IPM: 12
TOOL 6 INSIDE ROUGH TURNING
HOLDER: 1.25” STEEL BORING BAR
INSERT: CNMG432MR KCM25B
SFM: 450 / IPR: .012
TOOL 10 INSIDE FINISH TURNING
HOLDER: .750” CARBIDE BORING BAR
INSERT: CPMT3251LF KCU10B
SFM: 650 / IPR: .004
TOOL 12 AXIAL DRILLING
HOLDER: DRILL FIX PRO 2XD 1.2189”
INSERT: DFPR110406MSO KCMS35 / DFPR120405MSI KCMS40
SFM: 550 / IPM: .0045
#Machining #Machinist #Engineering - วิทยาศาสตร์และเทคโนโลยี
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Considering I've spent the last 10 years at several factories running machines from the 80s-early 00s, including a tape memory machine still running today, I look forward to the opportunity to try this new technology in the 2050s
Thanks for putting into words exactly how i feel about my job.
Странное дело, коллеги: я работаю в России на станках с ЧПУ - и эти станки у нас на заводе современные: самый старый - это HAAS UMC-750 2018 года выпуска.
И роботы FANUC давным-давно установлены.
thats the thing about this field, some people go into it thinking every shop is like this but its simply not true, most job shops are dirty and the machines are worn to hell and back, and convincing management to invest in equipment or maintain what they have is like talking to a tungsten brick
tbf this is just a nicer version of rather old stuff, at my previous employer we had a a Fastems pallet system attached to all our machines along with 2 CNC lathes one of which being about 50 years old that was fully automated with a robot parts changer attached to the Fastems system so we just had to load up normal pallets with parts and it would run 24/7 as long as the tooling held up. That system was from the early 00s.
Thats a really cool set up , dual chucks , op 1 , op 2 , etc .. One thing comes to mind .. when I was a highschool kid who got a summer job in a shop in Ireland I was the robot , cut the blanks on the saw , and when the program for op 1 was up and running I would load the lathe , run op one , learn to change offsets etc . Its how I learned about cnc .. Automation is great for the bottom line .. the balance sheet , but I still think a little old school production running will teach the newbies of the business from the ground up ... keep up the good work guys.. keep teaching ..
Some times think this automation removes the drudgery from running machines. But rather than having your skilled guys / girls loading the machine. Get someone young in. Start them off loading then tip changing inspecting the parts. This gives your skilled people time to do the things you pay them for and the operator the opportunity to learn.😊 before you know it they are starting to move on to setting the machines.
Great video Travis and Corey! Automation is a game changer and Halter is top of the line!
Awesome video Travis and Corey! Those Robots arms are Legit!
Travis, great job walking us through that.
DUDE this is so good! Travis awesome job! And Corey these shots are insane! Good job work!😊
Appreciated there passion 😍
Great video Travis. Lots of good information. The Halter robots are great👏
Enjoying your video from Italy Travis and Corey 💯
Lol nice brother! Hope you two are having a blast!
Automating batch work makes alot of sense. It allows you to get more done with less time wasted.
I have one of these coming in a couple of weeks!
Great explanation, Travis!
❤
I don’t know his name but loved the guy in this video, would like to see him allot more on the channel👌🏽
Excellent video! Such a cool process!
Nice video! More parts to shipping = Happy customers.
Amazing, thank you.
You could just use a turn mill with bar feeder, robotics is still good but for this application according to my expertise turn mill is a efficient option
You guys a smart. Be smarter and don’t use universal unless you want to replace motors ever couple months. You have fanucs. Use a CRX. Love the videos!
Vid request: an in depth vid in getting a process dialed to the point you can rely on it for a 8 hour-24hour shift.
All the pitfalls and solutions.
Robots are awesome and can be easy to integrate, but having a machining process that you can wal away from for a day is the real challenge and the barrier that stops many from investing in advanced equipment
I'd love to see a video going over how to multi stream in MasterCAM, just to get more experience in mill turn
Waw excellent work 👍👏
Woww to see the part of 5:38 😮
Mazak has been doing that since the 90s with their multiplexer line
I agree it’s important to stay ahead and automate your systems. But there should be a balance- we don’t want the robots to think for us. See I am for advancements in technology as long as it doesn’t dumb down people. Should always be using your brain and never take the lazy route
Nice trick, dragging the bird's nest off the part with a tool.
Can you get a machine that has a bar feed and then use the robot and stacker as pure unloaded for completed parts?
Less hands on and material handeling.
Yes!
the entire video I was thinking the same thing lol
Yes, they’re called turning centers. They have integrated robots and could be used to load material like in this video as well. They’re also more cost effective than this system. Those robots cost about as much as whole new lathe.
Please make a nut and bolt with the teeths of a 3/8 roughing endmill for funzies.
What brand are those robots???
Thats bad ass 💩
I need to ask tho Why would you need such a system like this instead of just using a Bar feeder?
We have dozens of cells like this at my shop it’s fascination to watch. One arm can keep 3-4 machines going 24/7. Ours are quite old though.
With all of this automation, will per-part-price be competitive with a standard non-automated Chinese shop?
Of course not. American industry is not competitive in the outside world. Any complex product made in the USA is inferior in price to Asian competitors.
I would like to see how that robot works with 2 machines
So when does this same sense? Id imagine for 50 parts itd just be cheaper to have a guy standing close to it changine parts every so often and doing other things in the meantime. Plus what about parts that are tapered? If you regularly have a series of 100+ parts it def makes sense, but for your avg small shop this will probably hardly pay off
I wander what it costs to set something like this up. Say that lathe itself minus the automation was 350K tooled up, wander what the ROI would be compared to hiring a person at say $30 an hr to replace the robot?
I don’t know but let us say the robot costs about 120k - 1 person works 8hr shift - 40hr a week. Let’s say 10month a year (holiday and sick included) so more or less 1700hr per year productivity. But costs times 30$*52*40hr=62.400$ per year.
The robot could work 24/7 - even if this is unrealistic.
365*24hr=8760hr production maximum. The robot is more consistent but slower. Let’s say he make 12hr per day - still around 4400hr productivity.
120k$/4400hr= around 28$/hr
In the first year!!
Sure no electricity and service costs include…
Right parts and enough parts - a robot is a nobrainer
What I've seen of them, unless you have a couple parts that you need to run constantly for 5-7 years, it's cheaper and faster to pay a person.
The robot will not run constantly , it WILL be broken down at some point, and you'll still have to pay someone decent money to attend the robot. They don't just walk into the shop, set themselves up, and run the machine autonomously.
A more realistic look is that robots allow one operator to run a cell of machines while not having to load/unload parts every few minutes on 2-6 machines. That way they can focus on making good parts, not scrambling to load machines.
@@SecondFloorOutdoors-gj8dt sure - but as a small shop owner it’s pretty nice having a second or even a third shift. And if you look at the speeds of the robot, they are slowed down a lot. These are robots built to run 100% 24/7 and couple of years. In this halter or every other builders case, they slow them down to 50% and less wich leads to far longer lifetime.
We have one cell in our factory runing for 10 years. Not 24/7 but still has around 30.000 hours worktime.
@@teekteekteekteek depends on what a small shop is to you. The one I'm at is about 30 people total, we run two shifts. We have a fanuc robot that is overall probably considerably less productive than a person. When it's working it's ok, it lets the operator run another machine, but we call it Joe b/c it loses track of what it's doing and wanders off. We can pretty much only run it when someone is there to watch it. They can be force multipliers, but they're not magic cure-alls. With the upfront cost of the robot, plus the service calls, it would probably be cheaper to pay a kid $15/hr to load a slug, then stare at his phone for 12 minutes.
Can you say bar feeder?
Very nice System, BUT, a big thing which many miss in my expierence, who messures the parts? Yes, good machines can hold tolerances for a certain amount of time, but they will change.
You can do with laser 3D..., but in the video only says the ideal things.
Excellent but expensive
Price for this robot setup? Without the lathe
Reach out to me via email if you’d like a quote. trevor@titansofcnc.com
150-170k for the halter, plus more if you need an auto door and software option/ ladder edits to the machine tool for coms to the robot.
@@funwitharobotthat’s not correct. Halter starts at 100k, depending on the model. This set up is 25% lower as you mention here. By the way, ROI is always under 18 months. Ask one of our experts.
as a web developer, i cry for the users of this 90's user interface. It looks like a toddler designed it on MS Paint 3.11
I used to work for FANUC and I would always cringe seeing our interfaces... I still cringe. Their iHMI system is better than their old Windows CE interfaces, but still looks like a middle school student designed it.
I know it looks dated, but it is fast and efficient, and never fails. We have some newer machines with more pretty UI and sometimes you need to wait 0,5s for each input to register, sometimes second for navigating between modes (seems like nothing but try it for long enough and you will hate it), just because all this pretty interface is heavy for a CNC, as it's not designed for it. And sometimes all this nice interface simply glitches or freezes. I'll gladly keep the fanuc, knowing it responds instantly to any command, knowing it never glitches, and if you dig into it enough you discover hundreds of keyboard shortcuts that makes the interface more fluid and fast, the opposite of today's beautiful touchscreens
@@Orakwan that’s one thing that I do have to say about FANUC. Reliable and support is second to none if you need it.
Right but it’s totally possible to have a modern interface that performs well, they just don’t build their machines that way
@@CNC-Time-Lapse Dude. I work with Fanuc CNCs and Robots and man do I hate the interface. Especially the CNC interface. It's like it's stuck in 1979.
Will never happen in the UK for at least 20 years.
Wages are embarrassing here
I'm sorry, that is a poor example of utilization of man and machine. Could be manufactured with older technology much more efficiently and way less cost.
Jeff I’m sorry but unless you can tell me otherwise, there is not a chance “older technology” can execute a sample cell like this with 24/7 efficiency. There are ways they can optimize this further as well in the matter of minutes. Sure short term cost may be more cost effective but these machines are designed to run light out for years with little maintenance other than putting in new programs for new product. Cost efficiency in the long run with new machines is unrivaled. Sure these machines aren’t cheap but like I said, this is lights out. Turn around time for a larger work cell than this is unmatched.
Great idea,,,,if you have hundreds and thousands sat in bank...great vid tho
24hours in Aisi316... Tell me more about the inserts xD no, really, good commercial of Halter I have a Flextek cell and it's much better.
🤓
Azubiteile 😜
Dang.. button pushers are being phased out. Kinda sad.
Yeah I like to think lifted up to bigger and better things.
@@travisjarrett2355 haha right. Well, its what Ive told all operators Ive trained, you either do something with the knowledge Im providing or risk being left behind. Gone are the days of 30+ machines with operators on each machine. Good times.
no, we become slaves of the robots! Who is going to load/unload/clean the parts?
that robot is handling a highly repetitive task. So not taking over button pushers yet, just the hardest working people.
Make a video groving program in vmc machine Iam form India bro make a video for every body I wating for your groving program video 🇮🇳🇮🇳🇮🇳🇮🇳
Mazak automation system is wayyy better than this old user interface 😂😂
I wish the Mazak control was more of a standard. I can write a progam in 5 mins on Mazatrol, same part would take 30-45mins to do im mastercam.
Still needs a minimum wage Johnny to load the material to start with though , before you all start bleating about job losses .....
And he will smash it up
Pay peanuts get monkeys
All i see is two machinist out of a job with all that automation.
A machinist that lost their job to a robot is one that didn't have a good job to begin with.
@@vintageludwig tbf I get the same hourly rate for humping castings on a machine as I would in oil and gas and the stress that goes with cutting 30k worth of inconel at a time. There is a massive difference between a good job and a good paying job, pros and cons to each one.
There are no people to loose a job… because there are no people wanna work as button pushers - sad but true
*reliable people
@@teekteekteekteek then theres people who can't comprehend the difference between want and need, usually with atrocious grammar.😆
I'm sorry, that example is a poor use of machine and manpower folks go out of business following an idea like that
More job losses
rubbish machine