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Large Scale Architectural Milling Automated by KUKA 6 Axis Robot |
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| Starting point / Task definition |
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| The customer required a solution for large scale tooling and prototyping for molding architectural and industrial parts needed a large format machining system capable of handling a 5-axis CNC process. The system had to be capable of milling pieces as large as 50‘ wide by 12‘ high, with the ability to machine smaller more detailed sculpture type pieces. Highly accurate milling was needed for different material hardness, often moving between foam, wood, fiberglass, composites, etc. In addition to machining, the process required projects to be sprayed with a gel coat on the foam mold parts, then having fiberglass material applied through a chopper gun. |
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| Implementation / Solution |
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| Robotics Solutions, Inc. supplied a customized version of their standard RMC 100-RTSL machining cell. The 100-RTSL system utilizes simple innovative design, keeping the operator in mind by providing a quick and versatile changeover from part to part. All tool lengths and measurements are handled by a laser tool setter and programmed through a CAM system, similar to a standard machine tool and maintaining all the flexibility of a 6 axis KUKA robot. The Guy Martin Design System used the KUKA KR100 L80HA robot mounted on a KL-1500 linear axis with 13 meters of travel. When machining detailed full 3D type concepts the system relies on a rotary table using the eighth axis of the KUKA control. Depending on the project, the system can run with or without the use of the rotary table. The Guy Martin Design system operates like a 5axis CNC machining center powered by Delcam PowerMill CAM software. The tool paths generated in the PowerMill allow the most complicated and intricate parts to be machined by the RMC cell, maintaining the fastest industry programming times. The Guy Martin Design system also included a 10 station tool changer that follows the robot on the linear axis, allowing tools to always be within reach. The resin spraying and chopper gun systems are integrated into the head of the robot saving space and time during application changes. |
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| System components / Scope of supply |
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| The KR 100 L80 HA is used mounted on a KL-1500 Linear axis. |
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| Results / Success |
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| The new Robotics Solutions, Inc. milling cell has given Guy Martin Design a system capable of producing parts of various sizes and materials with the speed, precision and detail to handle any future projects while reducing the time and space required from other solutions. When asked about the process with KUKA Mr. Wenzel stated, “The depth of knowledge and service of the KUKA Robotics team stands behind our purchase. We did not see this level of service or willingness to explore non standard applications with other robotic companies." |
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| Industry |
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Rubber, plastics
Other industries |
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| Application |
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Painting, surface treatment
Application of adhesives and sealants
Other coating operations
Machining
Machining
Other applications |
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| Customer |
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| Guy Martin Design |
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