Automation has revolutionized numerous industries and metalworking manufacturing is no exception. Integrating automation systems on CNC lathes not only improves manufacturing efficiency and quality, but also solves many common production problems. This article explores the advantages of integrated automation on CNC lathes, as well as the different types of automation and a comparison between them.
Advantages of automation in CNC Lathes:
Efficiency and productivity: automation reduces downtime, normally dependent on a human factor, and optimizes workflow, ensuring more efficient and consistent production.
Accuracy and consistency: Automation minimizes human error, which translates into parts with higher accuracy and repeatability, ensuring that each part meets exact specifications.
Reduced operation costs: In the long term, automation can reduce operating costs by increasing productivity, minimizing waste and reducing the need for intensive manual labor.
Increased safety: By reducing the need for manual intervention, automation minimizes the risk of workplace hazards, creating a safer working environment.
Types of integrated automation in CNC lathes:
Gantry systems: consists of an elevated bridge with two or more columns supporting a horizontal rail above the lathe. They generally have a moving arm equipped with a gripper that travels along the horizontal rail and lowers to pick up the parts, place them on the plate and unload them. Although there are several design variations, such as the arm shape and number, and gripping method, the operation is essentially the same. Gantry systems allow precise high-speed handling of fixed geometry parts, while taking up little additional space on the lathe due to its compact design and to the material loading/unloading movement above the machine body.

Bar feeders: They are equipment that allows the continuos feeding of bar material, typically cilindrical. They are place adjacent to the lathe and are loaded with multiple bars, which are taken one by one through a calmping system and fed to the lathe through the chuck. For each turning cycle, the bar is fed to a stop determined by the lathe, the lathe grips the bar and begins its operating cycle. The machined parts, once cut from the bar, are usually unloaded with a part catcher or extractor arm that removes them from the machine to a chute or tray. The bar feeder automatically discards the bar remainder and picks up the next to continue the process. This equipment reduces the need for manual intervention and allows the machine to operate unsupervised for long periods of time, which vary depending on their load capacity and supported bar length.

Loading/unloading robots: Their design is generally that of an articulated arm with adaptable gripper jaws to handle parts safely and efficiently. They automate the part loading and unloading process, which significantly improves cycle times and reduces downtime. They take the raw parts from a pallet or conveyor, place them with high precision on the chuck and when the operation is finished, they take the turned part and place it on another pallet or unloading conveyor. To ensure safety and avoid interference in the process they are usually protected by guards in an area adjacent to the machine. They are especially useful in high volume production with diverse geometries as they can be programmed to handle a variety of different parts.

Table comparisson between types of automation
Characteristic | Gantry system | Automatic bar feeder | Loading/unloading robot |
Precision | High | High | High |
Speed | High | High | Moderate |
Flexibility | Moderate | Low | High |
Cost | Moderate | Moderate | Depends on application |
Space requirement | Low | High | Moderate |
Best suited for | High volume, fixed geometries | High volume, cylindrical and polygonal parts | Low to medium volume, flexible geometries |
How to select the appropriateCNC automated lathe?
Each type of automation system in CNC lathes presents advantages and disadvantages, selecting the appropriate type requires an analysis of the production and working environment to determine the one that best suits your requirements. Here is some criteria to consider when selecting an automation system:
Production volume: For high-volume operations with parts that have constant geometry, gantry systems and bar feeders offer a continuos production cycle without frequent interventions, which make them an ideal choice for mass production. The choice between them will mainly depend on the feeding method (bar or stock). On the other hand, if the production involves parts with varied geometries, robots are the most flexible options, since the allow for handling of different type of parts without the need of frequent adjustments.
Part dimensions and complexity: Integrated automation must adapt to the parts's specific dimensions and complexity. In this sense, bar feeders are limited to the cylindrical or polygonal shape of the bar. Contrarily, gantry systems and robots usually have specialized grippers designed specifically for the part at hand, although in general, it is more common to use a robot in applications with larger or heavier parts due to their size availability and integration cost.
Technical support and training: The complexity of automation depends on the system used. In the case of robots, due to their versatility to handle parts of different geometries, more skilled personnel in programming and maintenance are generally required to make adjustments. On the other hand, bar feeders and gantry systems usually require less programming adjustments, as the geometries are more fixed. However, it is always key to evaluate the availability of technical support from the supplier and the ease of training in-house personnel to ensure quick troubleshooting.
Success story: Implementation of gantry system
To illustrate the benefits of integrated automation in CNC lathes, we will consider the cas of a metalworking manufacturing company located in central Mexico. This company decided to implement Takisawa lathes with automated gantry system to boost the produciton of a specific family of parts. This integration allowed them to increase production of that family of parts by 30% without modifying the individual turning cycle times and without increasing costs due to tool wear and consumables.
By eliminating the long pauses associated with operator dependence and minimizing manufacturing errors caused by manual handling, a continuous production flow with consistent quality on every part produced was ensured, optimizing lead time and significantly improving the competitiveness of the operation.
Final considerations and recommendations:
Automation in metalworking manufacturing is more than a trend, it is an essental strategy to compete in a global market.
To invest in a CNC lathe with an integrated automation system, a careful selection must be made based on specific production needs, available space and the type of parts to be manufactured.
Proper lathe selection along with trained personnel to operate and maintain the automation is key to maximizing its long-term performance, and driving the growth and profitability of the operation.
If you are looking to optimize your processes and improve your manufacturing efficiency, we are here to help. We invite you to learn about our CNC lathe solutions with integrated automation, designed to take your production to the next level.
Our team is available to guide you in choosing the most suitable option and solve any technical questions you may have, always adapting to the specific needs of your project. ¡Contact us!
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