MARATHON RZ430
CNC hybrid automation for workpiece and pallet handling in a single system.
Many manufacturing companies operate in two different spheres: on the one hand, individual parts and small batches need to be produced flexibly; on the other hand, repeat orders should be produced as efficiently as possible and with minimal operator intervention. Hybrid automation combines both requirements in a single system. By combining pallet and workpiece handling, different production strategies can be integrated into a single system. This results in longer unmanned running times, improved machine utilisation and greater flexibility in the face of changing requirements.
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Automate step by step
Wenn Einzelteile und Serien aufeinandertreffen, steigen die Anforderungen an die Fertigung.
Viele Fertigungen lassen sich nicht eindeutig einer Automationsstrategie zuordnen. Während einige Werkstücke von flexiblen Rüstprozessen profitieren, verlangen andere nach möglichst hoher Ausbringung und langen Laufzeiten. Dadurch entstehen Zielkonflikte zwischen Flexibilität und Produktivität. Typische Herausforderungen sind:
// Hohe Variantenvielfalt
Unterschiedliche Werkstücke und wechselnde Aufträge erfordern flexible Fertigungsabläufe.
// Schwankende Losgrößen
Von Einzelteilen bis zur Serie müssen verschiedene Fertigungsstrategien wirtschaftlich umgesetzt werden.
// Häufige Rüstvorgänge
Werkstücke, Spannmittel und Aufträge wechseln regelmäßig.
// Begrenzte Personalressourcen
Qualifizierte Mitarbeiter werden zunehmend für wertschöpfende Tätigkeiten benötigt.
// Ungenutzte Maschinenlaufzeiten
Pausen, Nachtschichten und Wochenenden bleiben häufig produktiv ungenutzt.
Hybrid automation combines flexibility and productivity.
Hybrid automation combines pallet handling and workpiece handling within a single automation system. This enables different manufacturing tasks to be carried out automatically on the same line. Whilst pallets allow for the flexible organisation of individual parts, repeat parts and small batches, workpiece handling facilitates the cost-effective production of recurring components. The system can switch between the two strategies, thereby achieving high capacity utilisation whilst maintaining a high degree of flexibility.
Hybrid automation does not begin with the robot system.
Cost-effective hybrid automation can only be achieved when the machine, clamping technology, pallet handling, workpiece handling and production strategy are all coordinated. HEDELIUS therefore considers the entire production process rather than individual components.
In addition to its own solutions, automation systems from renowned partners can also be integrated. Standardised interfaces and early-stage project planning result in solutions that produce reliably whilst remaining flexible enough to be adapted to future requirements.
Automation solutions are often categorised according to whether they are geared more towards a high variety of products (high mix) or high production volumes (high volume). Hybrid automation combines both requirements and creates the conditions necessary to handle different production tasks within a single system.
Partner solutions and project management
Reap the benefits thanks to hybrid automation.
Hybrid automation proves particularly valuable where manufacturing companies not only wish to automate a single task, but also need to be prepared for changing requirements. What is therefore crucial is not merely the combination of different handling methods, but the practical impact in day-to-day operations: more usable operating time, greater flexibility when switching between orders, better use of floor space and greater certainty for future investment decisions.
Which hybrid automation solution is right for your production?
Different manufacturing tasks require different automation strategies. Key factors include workpiece size, batch size, the range of variants and the desired production duration without operator intervention. That is why HEDELIUS offers the option of integrating machining centres from the ACURA, TILTENTA and FORTE series with a wide variety of hybrid automation systems.
Three steps to finding the right hybrid automation solution.
Step 1: Understanding | Step 2: Define | Step 3: Flexibly |
We analyse workpieces, batch sizes, repeat rates, product variety and production targets. | Together, we develop a solution that optimally combines pallet and workpiece handling. | The machine, robot system and peripherals are coordinated to ensure stable and cost-effective processes. |
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Playbook
Automation.
Welche Automationsstrategie passt zu Ihren Werkstücken, Stückzahlen und Fertigungszielen? Das Playbook Automation zeigt praxisnah, wie unterschiedliche Automationskonzepte eingesetzt werden und welche Aufgaben sie besonders wirtschaftlich lösen.
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Automation that grows with your needs.
Very few manufacturing companies today can say with any certainty which workpieces, batch sizes and orders will define their day-to-day operations in five years’ time. Markets change, customer requirements evolve and new business areas emerge.
With the HEDELIUS step-by-step model, automation can be scaled up gradually: from a pre-configured machine to largely autonomous production. This means you are not simply investing in a solution for today’s requirements, but are laying the foundations for tomorrow’s needs.
Discover the step-by-step model
Greater flexibility to adapt to changing requirements.
The greatest advantage of hybrid automation lies not solely in longer running times or higher capacity utilisation. It enables different production strategies to be implemented within a single system. This allows companies to remain flexible, even when the range of workpieces, batch sizes or customer requirements change. The advantages are particularly evident in:
greater flexibility in dealing with changing orders
cost-effective production of different batch sizes
flexible response to new customer requirements
less dependence on a single production strategy
long-term investment security
better utilisation of capacity across different order types
Frequently asked questions about hybrid automation systems.
When is hybrid automation a better option than a traditional automation solution?
Hybrid automation is particularly worthwhile when a manufacturing facility wishes to automate both flexible single-part and small-batch orders, as well as recurring production runs, in a cost-effective manner. It combines the advantages of pallet and workpiece automation within a single system, thereby providing greater flexibility in the face of changing requirements.
Is hybrid automation the right solution for contract manufacturers?
Hybrid automation can be particularly appealing to many contract manufacturers, as future orders are often difficult to predict. By combining different automation strategies, production remains flexible and can respond to both new one-off orders and recurring production runs.
Do I need to decide on a production strategy right at the start of the investment?
No. It is precisely those companies with a varied range of workpieces that benefit from hybrid automation, as different manufacturing tasks can be handled within a single system. This ensures that the automation remains cost-effective even if requirements change over time.
How long can the unmanned operating periods last?
The achievable running times depend on the workpieces, tooling requirements, automation system and storage capacity. Depending on their design, hybrid automation solutions can operate across multiple shifts, through the night or for entire weekends without the need for operator intervention.
Can the machine still be operated manually?
Yes. HEDELIUS machining centres with automation interfaces feature a side loading opening. This means that the working area remains accessible from the front and can still be used for set-up work, special parts, inspection measurements or crane loading.
How can I find out whether hybrid automation is suitable for my production?
It is not individual workpieces that are crucial, but the overall production structure. Together, we analyse the range of workpieces, batch sizes, repeat rates, set-up times and production targets to assess whether pallet automation, workpiece automation or hybrid automation represents the most economically viable solution.
Let’s work together to find the right automation solution.
Would you like to find out which automation solution is right for your production? Together, we’ll look at workpieces, batch sizes, set-up processes and available floor space to show you how to achieve more spindle runtime in a cost-effective way. Whether you’re looking for a compact entry-level solution or a scalable automation system, we’ll provide practical advice tailored to your production needs. Simply fill in the contact form below and our experts will get back to you as soon as possible.
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