MILLING ROBOT: SELECTING THE RIGHT SOLUTION FOR YOUR MANUFACTURING NEEDS
Your manufacturing process may be completely transformed by milling robots, which can also save costs and increase output and quality. Your human staff may concentrate on more difficult duties by delegating repetitive milling chores to these autonomous robotic arms—they are accurate, adaptable, and tireless workers.
What is a milling robot and how does it work?
Automated milling systems known as milling robots employ robotic arms to carry out milling operations such as material drilling, shaping, and cutting. Usually, they are made up of an articulated robotic arm, an arm-mounted milling end-effector, or “end mill,” and a control system that directs the arm’s motion.
Common uses for these devices include component deburring, polishing, trimming, and cutting. The robotic arm‘s end-effector, also known as “end-of-arm tooling,” is available in a variety of sizes and forms to suit a range of applications.
The ideal milling robot for you will rely on your demands and financial situation. Take into account the size and composition of the workpiece, the necessary precision and repeatability, the payload capacity, the number of axes of motion, and the installation space. A collaborative robot is usually the preferred choice when operating in close proximity to humans because of its built-in collision detection capabilities, which greatly increase safety in situations where humans and robots interact. Additionally, collaborative robots have smaller payloads. Conventional industrial robots usually need specialized programming, although they can manage heavier payloads.
The advantages of using milling robots for automation
Using robots to automate your milling processes offers several significant advantages. First of all, milling robots have the ability to work continuously for 24 hours a day, seven days a week, which boosts output and cuts down on lead times. Because they consistently execute the same exact actions, they also offer consistency in quality. Benefits of automating your milling operations include:
- Removing the possibility of worker damage from heavy machinery operation or exposure to toxic gasses. They are able to operate in hazardous conditions for people, such as very hot or chemically charged surroundings.
- Reprogrammable highly adaptable systems can carry out different milling jobs as needed. Robots can be quickly deployed to several milling stations and can quickly swap between various milling equipment. You may mill anything from prototypes to large-scale production runs because to its versatility.
- Lower expenses as a result of less waste, increased throughput, and a decrease in personnel overhead. A significant return on investment may be obtained from milling robots, particularly in manufacturing environments with strong demand.
Your milling operations can be automated to guarantee constant quality and productivity. While the robots take care of boring, repetitive chores, your employees may concentrate on more complex work.
Why milling robot end-effectors are important
Your milling robot requires the appropriate end-of-arm tooling in order to function. take into account the kinds of materials, tolerances, and production quantities when assessing end-effectors for milling robots.
High-frequency spindle (HSK)
The ideal choice for efficiently machining aluminum and plastics at high speeds is a high-frequency spindle. Capable of reaching speeds of up to 60,000 RPM, the HSK spindle excels in rapid material removal. To ensure optimal performance, safety, and compatibility between the precision spindle and the robotic system, a customized mount and interface are essential components when integrating the HSK spindle with your robot.
Milling spindles
The milling spindle is the most popular kind of end-effector used by milling robots. Rotating tools called spindles are used to handle reamers, end mills, sanding disks, and drills. Robots can carry out drilling, cutting, grinding, and sanding tasks thanks to milling spindles. Spindles are offered in a range of power ratings and speeds, from 3,000 to 40,000 RPM, to accommodate a variety of materials and milling applications.
Tool changers
A few milling robots include tool changers that let them automatically swap between different end-effectors for optimal versatility. Tool changers include a rack that can accommodate many end-effectors, including sanding disks, saws, and drills. The robot may do many jobs by autonomously releasing one end-effector and grabbing another from the tool changer.
Your unique milling and automation demands will determine which end-effectors are best for your milling robot. To find the finest choices for grasping, cutting, grinding, sanding, and component manipulation, talk about your application with professionals.
How to pick the ideal milling robot for your manufacturing facility
A few important things to think about while selecting a milling robot for your firm are as follows:
The quantity of axes
The robot’s mobility ranges and directions are indicated by the number of axes. For complicated 3D surface milling, a Five-Axis or Six-Axis robot provides more flexibility and dexterity. Generally speaking, a three- or four-axis robot can only mill prismatic or flat pieces. To figure out how many axes you need, take into account the intricacy of your pieces.
Type of milling
There are two main kinds: surface milling, which is used to create smooth, uniform surfaces, and material removal milling, which involves removing excess material to create a desired shape. While surface milling may frequently be achieved with a simple grinding disk, material removal milling robots typically require a revolving cutter as their end-effector. Some robots are adaptable enough to handle both milling procedures with ease.
Capacity of payload
A robot’s payload capacity is its maximum weight capacity. Select a robot whose payload is greater than the combined weight of the end-effector, any necessary fittings, and your heaviest workpiece. Your pieces will not be able to be milled by a robot whose payload is too small.
Accuracy and repeatability
Look for a robot with great precision, which indicates how near the robot can come to a programmed location, if you want exact milling. For consistent outcomes, repeatability—the robot’s capacity to go back to the same spot—is crucial. The expense of increased precision and repeatability increases, therefore only make the investments necessary for your application.
You may select a milling robot that will work best for your particular industrial application in terms of performance, accuracy, and cost by weighing these important variables.
Applications of robotic milling in several industries
Numerous significant sectors that have profited from automating their milling operations can use robotic milling.
Automotive
Precision components used in automobiles are largely produced via robotic milling. Brake rotors, engine blocks, gearbox housings, and other vital components are machined by milling robots. Because of the large number of units produced, robotic milling is required. In addition to lowering expenses, automating milling improves uniformity and quality.
Aerospace
AircraftHigh accuracy and incredibly tight tolerances are required in aerospace production. Turbine blades, wing components, and fuselage sections may all be produced by milling robots. For aeronautical parts, their repeatability and precision are crucial. In this dangerous business, robotic milling lowers waste and increases safety.
Consumer goods
Robotic milling is also beneficial for many consumer items. Milled components are used in appliances, recreational equipment, electronics, and other gadgets. Robotic milling is required because consumer items are produced in large quantities. Additionally, robotic milling enables producers to meet consumer demand and launch new goods more quickly.
For accurate and efficient manufacturing across sectors, robotic milling has become indispensable, whether for high-volume parts or crucial components. All types of factories stand to gain from automating their milling operations.
Next steps
Your manufacturing floor may be completely transformed by milling robots, which also increase output, effectiveness, and quality. Now that you are aware of the many kinds of Milling robots, end-effectors, and applications, you may search the market for a robot that will meet your unique production needs.
Ask plenty of questions, speak with suppliers, and request demos. Investing in automation will pay off handsomely when you can produce parts more quickly, precisely, and economically.
If you are interested in milling robots and automation or want to know more about how to improve production efficiency, please contact Robotnext today for advice and cost support. Details via hotline: 0909 914 837.
