In September, Tormach demonstrated its automation solution at IMTS by integrating the new 1500MX CNC mill with the ZA6 industrial robot. In a new 4-part video series, Tormach CEO Daniel Rogge shares an in-depth look at how these tools were used to manufacture a microARC 6 motor mount, a high-precision part utilized in the Tormach production line. This video series dives into every aspect of the demo, from setup and programming to handling and inspection, giving an inside look at how Tormach's automation solution is helping reduce the barriers to CNC automation.
The IMTS Demo Setup: Automation and Efficiency in Focus
The goal for IMTS was to showcase an engaging automation process that would capture attention and demonstrate real-world production capabilities. To accomplish this, Tormach used a LiDAR scanner on the ZA6 robot, allowing it to identify workpieces on the table without the need for a structured grid layout. This setup simplifies and speeds up the preparation process while minimizing potential errors caused by part movement.
Tormach wanted a robust part that would draw visitors into the booth with the sounds of machining, making the motor mount for the microARC 6 a perfect choice. These parts weren’t just for demonstration — they’re now used in production at Tormach and were given to customers who visited the IMTS booth.
ZA6 Part Loading: Dynamic Interaction with the 1500MX CNC mill
A key element of the demo was the ZA6 robot’s ability to load parts into the 1500MX. Using custom-designed end-of-arm tooling, the ZA6 could handle two workpieces simultaneously: one blank and one finished. This dual-handling setup required careful coordination between the robot and mill to ensure efficient operation within the confined milling enclosure.
The demo showed how the mill itself assists with tending by moving into position as the ZA6 robot grips a workpiece. This collaborative movement simplifies part swapping, with the ZA6 issuing commands to the mill to position itself for each interaction. For this video demo, the ZA6 was slowed down to allow viewers to see every step clearly, but the setup is capable of much faster operations in a production setting. Through-spindle coolant at 250 inches per minute was used for roughing, with the ZA6 continuing to scan the table for additional parts, creating a seamless and continuous workflow.
Part Scanning with LiDAR: An Adaptive Approach
Unlike traditional setups that require precise part placement in a grid, the ZA6 utilized a LiDAR system — similar to those found in Roomba vacuums — to scan the workpieces on the table. This approach allowed the ZA6 to adapt to any layout, saving significant setup time and reducing the risk of human error in alignment.
The LiDAR scanner scans the entire table, identifies stacked workpieces, and selects them for processing. This adaptability means that operators don’t need to spend time aligning each workpiece on the table; the ZA6 and its LiDAR scanner handle that automatically, providing a user-friendly and flexible automation solution.
The LiDAR scanner on the ZA6 industrial robot scans workpieces on the table.
Tackling Challenges: Chip Management and Robot-Mill Communication
Preparing for IMTS wasn’t without its challenges. Chip management, a common issue in CNC machining, required extra attention due to the high-speed cutting and the through-spindle coolant system. Chips could quickly accumulate in the machine, so measures like a chip fan with through-spindle coolant to clean the workspace effectively were implemented.
Communication between the ZA6 and 1500MX was also crucial. The ZA6 had to be in sync with the mill’s status, which led Tormach to introduce a subroutine that signals the robot when the mill is engaged. This adjustment prevents the ZA6 from attempting to load parts while the mill is still processing, reducing the risk of errors and ensuring a smooth, efficient workflow.
Overcoming Size and Weight Challenges with Custom Tooling
Another unique aspect of the IMTS setup was the need for custom grippers to handle the larger, heavier microARC 6 motor mount. Unlike the smaller parts used at previous events, such as Automate, these motor mounts required more robust gripping mechanisms.
Tormach solved this issue by designing a larger, more supportive gripper that could securely handle the workpiece during rotations. This gripper was initially prototyped using 3D printing, proving to be an effective and cost-efficient solution for the IMTS demo.
The microARC 6 motor mount created with the 1500MX and ZA6 robot automation solution.
What’s Next: Upcoming Videos in the Series
In the remaining videos of this series, Rogge will delve deeper into each step of the setup. Viewers will learn about programming the probing routines used to set G54 and G55 offsets, using the LiDAR system for scanning and part identification, and finally, the role of 3D-printed end-of-arm tooling in the automation process. These videos are designed to make automation more accessible and approachable for those interested in integrating CNC automation solutions.
With Tormach’s commitment to providing accessible, user-friendly automation, this series is an ideal resource for anyone looking to incorporate CNC automation into their workflow.
