Integrated grinding cell: the new automation solution developed with Labormak

Rosa GrindTech and Favretto GrindTech surface grinders can now operate within an integrated grinding cell, an automation solution we developed in collaboration with Labormak, designed for repetitive production, including small and medium batch sizes, and for multi-shift operations.

Previewed at 35.BI-MU on a Rosa GrindTech SILVER 20.9 CN tended by a cell with an anthropomorphic robot, the integrated cell reduces machine supervision, speeds up batch changeover and ensures consistent quality, with less reliance on highly skilled operators.

Our goal was to shift the focus from the precision of a single machine to the productivity of the entire cell, but this required specific expertise. 

For this first project, we therefore chose Labormak as our technology partner, valuing their expertise, flexibility and proximity, as well as their willingness to study each customer’s needs in depth to build tailor-made solutions.

The result is a single cell instead of two separate entities, where our knowledge of the machine and of grinding processes combines with Labormak’s experience in automation, handling and programming.

Three needs, one step-by-step path

The integrated cell stems from three customer needs, starting with the most immediate:

• machine tending, handled by the robotic cell, which ensures continuous loading and unloading with no manual handling and no dedicated operator.

• The second concerns production cycle optimisation, which depends on effective workpiece positioning. To this end, the cell uses gripping and referencing systems designed around each customer’s machining cycle: the workpiece is handled and oriented at every stage, the machine requires no supervision, workpiece zero becomes repeatable with no manual adjustments, and setup is reduced to selecting a recipe.

• Finally, the third need is in-line process control. The integrated machine probe enables in-process measurement and immediate corrections, reducing rejects at the end of the cycle: quality thus becomes part of the process itself, although the system does not replace off-line inspection.

Each need corresponds to a level of automation, forming a true step-by-step path: machine tending is the entry point, to which cycle optimisation and process control can be added according to production requirements.

Technical features

The system features a robotic cell developed by Labormak, equipped with an anthropomorphic robot with a 25 or 35 kg wrist payload. The robot picks raw workpieces from a tower storage system with interchangeable trays, loads them into the machine and, once machining is complete, unloads them and replaces them with the next ones in a continuous cycle.
The grippers, with two or three jaws, in single or double configuration and also available as custom designs, adapt to the workpiece geometry and include air blowing for cleaning. A dedicated interface synchronises door opening, workpiece positioning and cycle start, while dedicated laser scanners ensure the safety of the working area, keeping easy access for tray replacement.
The measuring cycles enabled by the probe integrated into the grinder are developed with dedicated software, based on the specifications of each individual project.

GrindTech Service+, our ecosystem of digital services for machine support and monitoring throughout its entire life cycle, is also available on automated cells.

To assess the automation of your grinder, please contact our sales team at sales@rosa.it.