Automation solutions for Benzinger lathes and milling machines
As a manufacturer of CNC lathes and CNC milling machines, we also offer you a wide range of automation solutions.
Effective cost reduction through economical and productive automation systems. Below you will find an overview of our customised, automated manufacturing processes.
In general, all our machine tools can be automatised.
Effective cost reduction through economical and productive automation systems. Below you will find an overview of our customised, automated manufacturing processes.
In general, all our machine tools can be automatised.
· Part removal via the unloading arm from the counter spindle
· Part deposit directly into a box
*Exemplarily shown on a GOFuture-B3 lathe. Compatible with other machine variants.
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· Part removal via the unloading arm from the main spindle
· Part deposit directly onto a conveyor belt
* Exemplarily shown on a GOFuture-B2. Compatible with other machine variants.
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· Part feeding via a loading shuttle
· Part removal via the unloading arm from the counter spindle
· Part deposit directly onto a conveyor belt
* Exemplarily shown on a GOFuture-BX turn-mill machine. Compatible with other machine variants.
· Material feeding via a bar feeder
· Part removal via the unloading arm from the counter spindle
· Part deposit directly onto a conveyor belt
* Exemplarily shown on a GOFuture-B3 lathe. Compatible with other machine variants.
· Part feeding from a conveyor bunker via a feed rail
· Part removal via the unloading arm from the counter spindle
· Part deposit directly into a box
* Exemplarily shown on a GOFuture-B6 lathe. Compatible with other machine variants.
· Part feeding from a vibratory bowl via a feed rail
· Part loading via the integrated loading/ unloading device
· Part unloading via the integrated loading/ unloading device
· Part deposit directly into a box
* Exemplarily shown on a DOLittle-B1. Compatible with other machine variants.
- Part feeding from a robot via a loading shuttle
- Part loading via the integrated feeder
- Part unloading via the integrated feeder
- Part discharging via an unloading shuttle back to the robot
· Part loading via the integrated feeder
· Part unloading via the integrated feeder
* Exemplarily shown on a GOFuture-B1 lathe. Compatible with other machine variants.
- Part loading via a robot directly into the spindle
- Part unloading via the robot
- Part loading via a robot directly into the spindle
- Part unloading via the robot
- Part loading via a portal directly into the spindle
- Part unloading via the portal directly into the pallet
- Part feeding from a vibrating bowl
- Part loading via the integrated feeder
- Part unloading via the integrated feeder
- Part discharging via the portal directly into the pallet
- Part feeding from a vibrating bowl
- Part loading via the integrated feeder
- Part unloading directly on a conveyor belt
- Equipment chaining
- Material feeding using a bar feeder
- Part unloading via an unlaoding arm out of the counter spindle
- Parts deposit directly onto a conveyor belt
Process-orientated automation on lathes and milling machines - application examples
In order to enable manufacturing companies to produce small precision turned parts economically and reliably in large series, Benzinger develops and realises modular automation solutions for its lathes and milling machines that are specifically adapted to workpieces and machining processes.
Manufacturing companies prefer to produce small components in medium to large series on single or double-spindle lathes. Compared to rotary transfer machines, these lathes require significantly lower investments. They are much easier and more flexible to use for a wide range of component dimensions and geometries. They also require less floor space. Benzinger lathes in particular meet the strict requirements for accuracy and surface quality when manufacturing small components. This applies, for example, to nozzle needles and valves for the automotive industry and medical technology, bearing bushes, shafts and gears for micromechanics and mechatronics for use in miniaturised sensors and actuators. These components are required in series of tens to hundreds of thousands, but not millions, of workpieces per year. There are usually numerous variants in lengths and diameters. This requires flexible production equipment that can be quickly and easily retooled. The lathes and milling machines from Benzinger fulfil these criteria.
Large series require operatorless production
In order for manufacturing companies to be able to produce small components in large series with low unit costs and short cycle times, the machines must work without an operator. Benzinger therefore equips its lathes with fully automated loading and unloading systems and - as an option - with measuring devices and NC programme tracking (Adaptive Control). Feeding with a bar feeder is tried and tested and unproblematic. However, even separate, cut-to-length and pre-machined workpieces require significantly more complex automation solutions. Benzinger uses conveyor belts, pressure hoses, chutes, gates, pick-and-place grippers and robots, among other things, to bring these components to the machining process in an organised manner. These feeding devices are combined with measuring, positioning and orientation stations as required.
For the automotive industry, for example, pre-machined nozzle needles have to be turned conically and milled to a geometrically defined position on the circumference. This is done on a DOLittle double-spindle lathe. The valve needles are about 12 mm long and have a diameter of just under 2 mm. A partial geometry has already been produced at one end. Further machining is dependent on this. The disorganised nozzle needles are first separated in a vibrating conveyor with a separator and fed through a hose. In this way, they reach a measuring and turning station. This is located next to the main spindle of the precision turning centre within the standard machine housing. In a channel, measuring pins on the components recognise the geometry that has already been machined. Depending on this, the nozzle needles are now rotated by 90° on the turning station. In this way, they enter a hose in which they are always fed, end first, into the channel in the spindle passage of the lathe and into the pneumatic precision collet. After machining, a collecting bowl collects the valve needles. A channel guides them out of the working area of the lathe into containers.
The advantages of this automation system designed and realised by Benzinger are its compact and modular design as well as the integration of position detection and orientation of the components. The automation modules, for example the measuring and turning station, can be flexibly set up. This means that they can be set up for a wide range of nozzle needle variants. Individual components, such as the feed hose, can be exchanged on a modular basis and are equipped with a standardised clamping interface. Baffles for orienting workpieces or complete measuring, positioning and turning stations can also be equipped with the standardised clamping interface. Benzinger uses the tried and tested dovetail guide with clamping screw for clamping tool blocks. It ensures maximum repeat accuracy and stable, rigid clamping.
Automation adaptable to several lathes
The modular concept and the standardised clamping interfaces are especially advantageous when working on several lathes. The automation can be easily transferred from one lathe to another. Manufacturing companies can therefore reduce their investment in automation and still work extremely flexibly. If a production batch has to be executed on an alternative turning centre for various reasons, the programmers and machine operators can easily switch the automation from one lathe to another.
Material flow coordinated with machining processes
An especially well engineered automation system has been realised by Benzinger for the finishing of precision rivets for the aerospace industry. The individually fed, approximately 50 mm long components with a diameter of 8 mm must be further machined in a position-orientated manner with reference to a previously cut groove on their circumference. They also have to be clamped at the head in order to machine them at the other end. This is achieved with the automation installed by Benzinger with optical recognition using image sensors. Depending on the image evaluation, the rivets are rotated around their longitudinal axis in a gantry and - if necessary - turned in the feed direction. They are then fed into the collet chuck of the main spindle of the lathes via a chute. This automation system can also be quickly and easily converted for component variants of different lengths and diameters.
In addition, Benzinger realised the integration into the further material flow in the production plant with the individually designed automation that is tailored to the workpieces. This means that the blanks can be removed from individual pallets, inserted and machined and then placed on specific workpiece carriers or pallets. The automation integrated into the lathes also allows the cycle times of different processing steps to be decoupled. Depending on the required manufacturing processes, two-spindle turning centres with simultaneous machining on the front and rear sides or single-spindle machine tools with rear side machining in the counter spindle are ideal. As an option, Benzinger realises measuring stations in the machining area in order to verify individual process steps or to control further machining via zero point corrections in the NC programme. Manufacturing companies benefit from maximum reliability and accuracy. Depending on the individual requirements of the machining processes, components can be buffered. This results in a continuous material flow that minimises the overall cycle times in manufacturing operations.
Future-proof investment thanks to flexible modules
This makes the automation solutions, which Benzinger realises individually adapted to the requirements of the workpieces, machining processes and production environment, particularly advantageous. Thanks to their modular design and standardised clamping interfaces, users can use the automation flexibly. With economically justifiable investments, these automation solutions are also suitable for future production orders with a varying range of components. They are fully integrated into the control concept of the CNC turning centres. This means that the complex automation sequences can be programmed very simply and easily. Users also receive the necessary investment security from the machine manufacturer as their sole point of contact. Benzinger guarantees the same high-quality service for its automation over many years as for its precision lathes and milling machines.