Machine tending is the process of using robots to automate tasks associated with operating industrial machines, such as CNC (Computer Numerical Control) machines, metal presses, plastics molding, and metal casting. Machine tending is widely used across various industries—from automotive to consumer goods to aerospace and defense—to enhance efficiency, precision, and safety in components manufacturing.
1. CNC Machining
CNC machines are automated tools that follow programmed instructions to perform precise machining tasks like milling, turning, and grinding. Automated machine tending in CNC machining involves using robots to automate tasks—most often the loading and unloading of workpieces, but also activating the CNC cycle and ensuring machines operate efficiently.
CNC milling is a versatile and precise method of manufacturing. The automotive industry uses CNC milling to manufacture engine blocks, gearboxes, and other critical components. Similarly, the aerospace industry uses CNC milling for high-precision pieces like airfoils, landing gears, and engine parts. CNC milling is also used to produce shafts, housings, and structural elements for a variety of machinery.
In CNC milling, robots handle tasks like loading raw materials into the milling machine and unloading finished parts. This automation increases productivity by allowing the machine to operate continuously without human intervention. Robots can also be reprogrammed to handle different parts and operations, enhancing flexibility.
CNC turning produces cylindrical parts by rotating the workpiece against cutting tools. Medical devices, such as bone screws and joint components, are manufactured with CNC turning. The energy sector also uses CNC turning to manufacture components for turbines and pumps. In CNC turning, robots ensure consistent placement and orientation of workpieces for turning, reducing errors and improving overall equipment effectiveness. The use of robots also enhances safety by keeping human operators away from cutting machinery.
CNC grinding finishes the surfaces of workpieces. CNC grinding is essential in the automotive industry for producing precision components such as camshafts, crankshafts, gears, and other engine parts. Tool and die manufacturers use CNC grinding to create molds, dies, and other tools. In CNC grinding, robots automate the process of feeding parts into the grinding machine and removing finished products. This boosts efficiency and ensures precision and consistency in the grinding process. Automating these tasks with CNC machine tending robots reduces downtime and allows for continuous operation, which is crucial for high-volume production.
2. Press Brakes and Stamping Presses
Press brakes and stamping presses are industrial machinery widely used across various industries. The automotive industry uses press brakes to shape body panels and frames and uses stamping for the crucial formation of terminals, connectors, and brackets. Aerospace uses press brakes and stamping for airframe components. In consumer goods, manufacturers use stamping to shape and cut metal sheets for appliances, tools, and hardware.
Machine tending in press brakes and stamping involves using robots to automate the loading, unloading, and handling of materials during the forming and shaping processes. In press brakes, robots load metal sheets into the press brake, position them accurately, and remove the formed parts after bending. The benefits of machine tending here are that it ensures consistent and accurate bends, reduces the risk of injuries from handling heavy or sharp materials, and increases production speed by operating continuously.
For machine tending in stamping, robots handle loading raw materials into stamping presses, manage the transfer of parts between different stages, and unload finished products. Robots are designed to withstand the high-duty cycles and vibrations typical in stamping operations, and they can be programmed to handle various part geometries and sizes.
3. Injection Molding
Injection molding (or “moulding,” depending on your geography) is often used in the automotive industry to produce plastic components like dashboards, bumpers, and interior trims. In consumer goods, injection molding manufactures toys, appliances, and packaging materials. Parts of medical devices, like syringes, are also manufactured by injection molding.
In the plastics industry, machine tending robots are used to automate the process of loading and unloading molds and handling the finished parts. Robots load raw plastic pellets or other materials into the injection molding machine. The machine heats and injects the material into a mold to form the desired shape. Once the part is formed and cooled, the robot removes it from the mold and places it in a designated area for further processing or packaging. Machine tending robots handle hot and potentially hazardous materials, reducing the risk of injuries to human workers. Automated handling ensures consistent part quality and reduces the risk of defects.
4. Die Casting
Die casting is a manufacturing process where molten metal is injected into a mold cavity under high pressure. This process is used to produce complex metal parts with high precision and excellent surface finish. Die casting is commonly used to make parts like engine components, housings, and other intricate metal pieces. In foundries, robotic machine tending manages the loading of raw materials, such as ingots, into casting machines and the extraction of finished cast parts.
Automated machine tending is important for the die casting industry, already known to have labor shortages and many potential hazards such as high heat and sharp-edged unfinished pieces. Robots can supplement labor where there is a shortfall and take on tasks that are potentially dangerous to human workers.
Qualities of a Good Machine Tending Operation
What qualities make a machine tending system an excellent operation? A good machine tending operation requires a combination of several essential qualities to ensure quality and productivity.
- Flexible: The system should be scalable to accommodate increased production demands and reprogrammable to adapt to different tasks and product variants.
- Precise: A good machine tending system ensures that parts are consistently loaded and unloaded in exact positioning to maintain the same level of accuracy.
- Efficient: The system’s workflow has been carefully considered to streamline processes, reduce cycle times, maximize throughput, and minimize waste.
In addition to these qualities, it is important to remember that machine tending operations are usually pieces of a larger whole for manufacturing a part or even a final product. Therefore, machine tending operations should integrate seamlessly with other material handling systems, deburring or trimming operations, and assembly and test stations. At Wes-Tech, we’ve built innumerable machine tending systems, some of which were standalone operations and many of which we integrated into more robust production processes. If you want to revamp or reimagine a machine tending system, contact us to explore the possibilities of enhanced production with automation solutions.