Uses and Comparisons of In-Machine Automation and Spindle Grippers
Let’s face it: Automation has become a buzzword that everyone likes to throw around, but companies, especially SMBs, struggle to actually implement on the shop floor. The normal options that these companies look at generally fall into one of these three categories:
- Robot or Cobot Integration ($40-$100K)
- Trinity or Erowa-Style Robot System ($200-$300K)
- Pallet Loading System ($60-$100K)
While all of these solutions can get the job done, the reality is that for most small and medium shops, it makes more sense to spend that much money on one or more additional spindles to make more parts, and simply eat the recurring expense of manual labor to load parts one-by-one.
What almost every shop ignores, however, is that they have had a robot in their shop this whole time: their CNC Machine! In this article, we’ll explore the benefits of In-Machine Automation, and we’ll dive into the variety of Spindle Grippers available on the market to turn your Three-Axis VMC into its own robotic-loading platform.
What is In-Machine Automation?
In-Machine Automation refers to using the moving axes already present in your CNC machine to load and unload the stock into and out of your workholding, completely automatically. You can integrate this to various levels of complexity. For instance:
- Single-Operation Part Loading (i.e., Machining Only “Op1”)
- Multi-Operation Part Loading (i.e., Machining Multiple Ops in One Cycle)
Watch this short video below to get an idea of what each of these look:
Why Not Just Create a Giant Fixture of Mitee-Bite Clamps?
This is one of the questions we get the most: If we are going to put a tray to hold parts on the machine, why not just populate that area with pockets for Mitee-Bite or Pitbull clamps?
The truth is that we most often get this question from shops who aren’t ready for automation, usually because they’re prototype shops that haven’t experienced or need to run repeat production. The answer to this is simple: A simple fixture with hundreds of small parts can easily take over an hour to accurately load with parts. And, if you aren’t able to swap that fixture out, you’re going to lose countless lights-out production hours you could otherwise be making chips.
What is a CNC Spindle Gripper?
A CNC Spindle Gripper is the easiest and fastest path to automated production. There’s a couple of reasons that this is the best entry point into automation for VMCs:
- Cost Effective: A Spindle Gripper is less than $1,500
- No Programming or Integration: Since program generation is automatic through our Program Generator and the machine runs standard g-code, there is zero robot integration to handle
- Loads In Tool Changer: Since the machine treats it like another tool, there’s nothing to bolt down and indicate in. Just insert into the spindle and start running automated production.
In-machine automation refers to the integration of automated systems directly into the manufacturing machinery. This technology is designed to streamline processes and reduce the need for human intervention, leading to numerous benefits for manufacturers. A question must arise: "How is this automation done?" It's not a thing beyond imagination because computers play the leading role in the hit play of computer numerical control (CNC) machining.
Spindle grippers are a crucial component of in-machine automation, especially in industries like manufacturing and assembly. These devices are responsible for gripping, moving, and manipulating parts or objects within a machine. Here's how spindle grippers contribute to the ROI of in-machine automation.
With these spindle grippers, the in-machine automation has acquired the highest level of smoothness, consistency, and precision. Furthermore, they’re also credited with being the biggest time-savers in the manufacturing industry.
CNC Spindle Grippers: Game Changers in the Manufacturing Industry
CNC spindle grippers have a crucial role in the manufacturing industry, as they can automate machine parts with the help of specific codes. Spindle grippers come in a great variety with unique features, but CNC spindle grippers lead the way with sky-high precision.
What makes these CNC spindle grippers stand out among all automation tools?
- Enhanced Precision: Spindle grippers, especially the Bypass-Air CNC Spindle Gripper, are designed to handle delicate and intricate tasks with precision. They can pick up, move, and place components with remarkable accuracy, ensuring that manufacturing processes meet stringent quality standards. This precision can result in fewer defects and rework, reducing overall production costs.
- Increased Efficiency: By automating the workpiece handling process, By-pass Air CNC spindle grippers installed with the Instant Solenoid Kit with programmable M-code reduce the downtime associated with manual loading and unloading. This leads to a significant increase in machine uptime, power supply, and overall production efficiency.
- Flexibility: Spindle grippers such as Bypass-Air CNC spindle grippers, TSA (Air) Universal CNC spindle grippers, and many more can be programmed to handle a wide range of workpiece shapes and sizes. This versatility makes it easier for manufacturers to adapt to changing production demands without significant retooling.
CNC Spindle Grippers: A Tool of Precision
Gimble Automation also offers an automated program generator for G-Code, which allows the smooth functioning of gripper systems. This system ensures the precise handling of objects with complete automation or minimal use of manual force. It can perfectly load and unload the machine parts with no or minimal manual effort. These spindle grippers allow for the grasping, tightening up, transportation, and removal of an object.
Let’s dig into spindle grinder types as per their shape and functions.
Bypass Air CNC Spindle Grippers
Gimbel Automation comes up with beforehand solutions for your CNC machines. No coolant or air is a problem because the Bypass Air CNC Spindle Grippers can perform effective loading and unloading with precise automation.
The Air Bypass block is fixed into the Haas spindle over-center toggle lock, resulting in a high grip force-to-weight ratio. This fixation requires just a minute, so it's the easiest installation to date. Despite no air pressure, this mechanism will stay locked, leading to smooth yet superlative automation.
TSA Universal CNC Spindle Grippers
Through Spindle Air (TSA) CNC Grippers are another name for prime automation. TSA CNC grippers speed up the automation with perfect tool placement and convenience. TSA Universal Spindle Grips are gaining popularity because of their smooth functioning, prime accuracy, and minimum time.
TSA grippers take versatility to another level, as they can be a perfect tool for almost all manufacturing businesses. These are perfect examples of "tiny packs with big blasts," as they take the place of a single tool while performing automation with sky-rocketing accuracy.
Gripper Parallel versus Gripper Angular
Concerning the gripper body, the gripper jaws move in a parallel manner. Parallel grippers are more accurate than other styles of grippers in the majority of applications.
The angular gripper jaws open and close in a sweeping or arcing action around a central pivot point. When there is little space or the jaws need to move up and out of the way, angular grippers are frequently employed. The pivot point jaw functions as an over-center toggle lock, resulting in a high grip force-to-weight ratio. Even if air pressure is removed, this mechanism will stay locked.
2 Jaws versus 3 Jaws Spindle Grippers
The most popular gripper, with two long arms, is used to grasp and transport objects, utilizing the least power. But the 3-jaw gripper is more valuable, allowing more contact with the object. Thus, it brings complete accuracy to the installation process.
A CNC spindle gripper can be fixed with versatile parts in a machine, achieving multiple goals instantly. Thus, it's a cost-effective and time-saving tool that makes the heaviest tasks smooth and swift.
Conclusion
In-machine automation and spindle grippers are powerful tools that can significantly enhance the efficiency, productivity, and quality of manufacturing processes. As technology continues to advance, spindle grippers and in-machine automation are likely to become even more compelling, making them essential components of modern manufacturing operations.
