In a recent article in the trade magazine MaschinenMarkt, various factors were named that speak in favor of automating manufacturing processes: On the one hand, there is a lack of manpower throughout Europe. Companies can hardly find workers for simple, manual tasks and certainly not for shift work. On the other hand, product and variant diversity is increasing and quantities are falling. Production must therefore be able to manufacture even small batches economically in rapid succession. What's more: Many customers do without warehousing and want their parts and components »just in time« or »just in sequence«. Delivery times are shortening and must be able to be planned precisely.

No questions left unanswered – with automation solutions from the CHIRON Group
Internal CHIRON Group statistics confirm this development: Five years ago, one in three project machines was automated, today it is seven out of ten. Thomas Marquardt, Head of Automation, names two key questions that he hears more and more often from customers: »Will I still find operators for simple tasks, for second and third shift work, in two, five or ten years' time? And: How can I increase productivity and realize unit cost benefits at the same time?«

Thomas Marquardt's answer to both questions: »In terms of production technology and economics, process automation simply has the greatest potential to save time, optimize unit costs and deploy skilled workers elsewhere for more demanding tasks. We can also see this in our statistics. If automation is used, modules for additional tasks should also be integrated in many cases.«

For the CHIRON Group, the answer to the growing demands is an equally growing portfolio for more autonomy in production – both for new machining centers and existing machines. Starting with integrated automation, for example for workpiece handling on the 715 Series models, and continuing with units for the smallest machine, the Micro5, where the Feed5 handling system takes over the loading and unloading of up to two machining centers. The new DTS (driverless transport system) can also be used to automatically feed and remove workpiece stacks with raw and finished parts.

Standardized or individual? Both!
Standard automation with a Variocell UNO is available in three versions: The smallest version has a footprint of just 1.5 square meters and can be combined with the 08 and 12 Series and can hold 24 pallets weighing up to 10 kg.

The M variant is designed for productive combination with 08, 12 and 15 Series machining centers, now with extended storage capacity for 30 pallets and a total load capacity of 350 kg for even greater autonomy. Parts handling is fully automated, with optional retooling of workpiece gripper jaws and fixture clamping jaws.

The largest Variocell UNO is available in two basic versions: with base frame on the left for the 15 and 18 Series, and the double-spindle machine DZ 16 W, and with base frame on the right for the 16, 19 and 22 Series. The separation of the workpieces provided in layers or as bulk material can be carried out robot-supported with camera recognition by means of bin picking.

In addition to the handling robot and workpiece store, each Variocell UNO automation unit can have additional components added to it: Multiple grippers, turning stations, blow-off stations, simple cleaning, labeling and vision systems are just a few examples from the modular system.

Do you need a complex solution with a high degree of autonomy into which peripheral units will be integrated? A Variocell SYSTEM is designed by the CHIRON Group application exactly as specified in the requirements matrix. Starting with handling systems, gantry or articulated arm loaders, workpiece storage systems for unfinished and finished parts, pallet storage systems, infeed and outfeed systems. And further with a variety of modules for seamless integration: from A for arm loaders to D for deburring to I for inspection systems to W for workpiece storage systems.

In addition, it is possible to automate not only the manufacturing process on a machining center, but also a complex production line – from the provision of the blank to machining, the integration of upstream and downstream processes and end-of-line testing.

Variocell MOVE: Automation is easier and more flexible than ever
The new Variocell MOVE is an automation unit that forms a productive unit with a machining center from the 12, 15, 16, 18, MILL and baseline Series. So far, a typical CHIRON Group unit. But it has one special feature: The unit does not have to be permanent. The compact robot cell with inclined pallet system for intelligent workpiece handling can be combined with alternating milling and mill-turning centers. And provides more autonomy and efficiency exactly where it is needed – for months, weeks or just days.

To ensure that the Variocell MOVE can also show its strengths in short applications, configuration is user-guided and based on predefined matrices via the control panel. They range from the selection of the machining center to clamping devices and gripper configuration to the data of the raw and finished parts and the pick-up and deposit positions on the pallet. Additional functions such as blowing off the device or the finished workpiece are also integrated and easy to select.

Another special feature: In order to keep the unit as compact and mobile as possible while still ensuring maximum safety for the operating personnel, laser scanners form graduated safety zones. If a person approaches, the robot's speed is reduced as a first step. If someone enters the critical area, the system is shut down.

Would you like to know more about how autonomous manufacturing increases productivity and counteracts the shortage of skilled workers? For the CHIRON Group, automation is one of the main themes of their stand at AMB 2024. 

Detailed information on the products – from Feed5 to highly individualized solutions (Variocell SYSTEM) can be found on the Corporate website.