More productive machine uptime
Set-up operations are being moved out of the working area. The spindle remains in operation for longer.
CNC pallet automation for increased uptime and flexibility.
With pallet automation from HEDELIUS, you can set up the next job whilst the machine is in production – ensuring stable processes, longer running times and cost-effective production for individual parts and small batches. When the machine is idle, no parts are being produced. This is precisely where pallet automation comes in: workpieces and fixtures are prepared outside the working area whilst the machining centre continues to run. This allows you to reduce non-productive time, ease the workload on your staff and make significantly better use of existing machine capacity.
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Automate step by step
In many businesses, it is not the actual processing that takes up most of the time, but everything in between.
Set-up, clamping, positioning, running-in, inspection: in single-part and small-batch production, there are many interruptions surrounding the actual machining process. Internal set-up procedures, particularly when dealing with changing orders, take up valuable spindle running time. The result is well known: the machine is technically capable, but not consistently productive. Deadlines come under pressure, skilled staff are tied up with ancillary tasks, and it is difficult to schedule additional orders. The HEDELIUS Playbook describes precisely this situation: machine operators often spend too much time dealing with tools, clamping devices and gathering information.
As a result, it is not uncommon for the spindle running time to be less than 40 per cent.
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Pallet automation turns set-up time into productive time.
A pallet storage system is used to prepare the next job whilst the machine continues to operate. Fixtures and workpieces are clamped whilst the machine is in operation. Pallet changes take place automatically. Spindle running time is increased. This brings tangible benefits in day-to-day operations.
Greater predictability
Repeat orders, small batches and pre-arranged orders can be processed in a structured manner.
Relief for skilled workers
Operators are focusing more on programming, process control and complex components.
Unmanned operating times
Depending on the workpiece, the tooling available and process reliability, it is possible to make better use of breaks, off-peak periods, night shifts or weekend shifts.
Cost-effective even for small batch sizes
Pallet automation is particularly suitable in situations where set-up changes are frequent and every interruption avoided has an immediate impact.
Machinery and automation
from a single source.
Pallet automation only works reliably when the machine, clamping technology, tooling, operating concept and process work together seamlessly. HEDELIUS develops machining centres and automation solutions in such a way that they remain easy to operate in day-to-day production.
With side-mounted automation, the working area remains accessible from the front. This is important for set-up work, process monitoring, crane loading and individual parts that are still manufactured manually. It is precisely this combination of automation and accessibility that is crucial for medium-sized manufacturing companies.
HEDELIUS offers a range of MARATHON solutions for this purpose: from the compact 6-pallet storage system to systems with 15, 18 or 22 pallets, as well as hybrid solutions combining pallet and workpiece handling.
ACURA compact or TILTENTA flexible?
Pallet automation works best when the machine and the range of workpieces are well-suited to one another. That is why the first question is a simple one: do you tend to manufacture compact 5-axis parts – or do you need maximum flexibility for large, long and varied workpieces?
ACURA: compact automation
The ACURA is the ideal choice if you want to maximise spindle running time in a limited space. It is particularly suitable for individual parts, repeat parts and small to medium-sized production runs.
Automation is integrated from the side. The working area remains accessible from the front. This is important for set-up work, inspection measurements and special parts that continue to be manufactured manually.
Particularly well suited if you:
- have limited floor space
- manufacture compact 5-axis components
- machine frequently recurring parts
- wish to build up unmanned running times
- want to switch flexibly between manual and automated operation
ACURA is the compact solution for more productive machine time in a small space.
Discover the ACURA range
TILTENTA: flexible automation
The TILTENTA is the ideal platform if your production needs to accommodate a particularly diverse range of workpieces. Long components, larger workpieces, individual parts, small batches and multiple set-ups can all be organised on a single machine platform.
With pallet automation or work area separation, set-up operations can be prepared whilst the machine continues to operate. This ensures a smoother workflow and better utilisation.
Particularly well suited if you:
- manufacture long or larger workpieces
- have frequently changing orders
- require maximum clamping flexibility
- combine individual parts and small batches
- are looking for a single machine to handle a wide range of tasks
TILTENTA is the flexible solution for businesses with a high variety of parts and changing requirements.
Discover the TILTENTA range
Which pallet automation system is right for your production?
Not every automation solution is equally suitable for every production environment. The key factors are the workpieces you are machining, how frequently jobs change, and how much operating time you wish to get out of your machine. Some solutions are designed for compact, repetitive parts and high pallet density, whilst others offer greater flexibility for larger components, multiple clamping operations or changing set-up tasks.
MARATHON SR415
For TILTENTA and flexible 5-axis machining
The MARATHON SR415 automates the TILTENTA 7 via side loading, combining the flexibility of a swivelling spindle machining centre with additional running time from the pallet magazine.
Technical benefits:
- 15 pallet positions
- for components up to 700 mm in diameter
- up to 500 mm clamping height
- side loading
- rotatable loading/unloading station
- suitable for day shifts with individual parts and automated series production during off-peak hours
About the MARATHON SR415
MARATHON SR422
For repeat parts and small to medium-sized production runs
The MARATHON SR422 is designed to work with the ACURA 65 and is suitable for businesses wishing to flexibly automate the production of individual parts as repeat parts or in small to medium-sized production runs.
Technical benefits:
- 22 pallets, each measuring 400 x 400 mm
- 270 kg transfer weight
- up to 500 mm clamping diameter
- up to 400 mm clamping height
- Loading/unloading station as standard
- consistent operating concept with Heidenhain TNC7
About the MARATHON SR422
MARATHON SR518
For larger and heavier components
The MARATHON SR518 is designed for larger, heavier individual parts, whether as repeat parts or for small to medium-sized production runs. When combined with the ACURA 85, it provides a productive solution for demanding 5-axis machining with automated pallet handling.
Technical benefits:
- 18 pallets, each measuring 500 x 500 mm
- 470 kg transfer weight
- up to 700 mm clamping diameter
- up to 500 mm clamping height
- rotatable loading/unloading station as standard
- work area remains accessible from the front
About the MARATHON SR518
MARATHON PL406
Getting started with set-up during active production time
The MARATHON PL406 offers 6 pallet positions and is particularly suitable for businesses that wish to maximise the running time of an ACURA 65 whilst requiring only a modest amount of floor space. For workpieces requiring extended machining times, several pallets can be prepared and processed one after the other.
Technical benefits:
- 6 pallets
- 400 x 400 mm or 500 x 400 mm
- 270 kg transfer weight, optionally 370 kg
- suitable for multiple clamping and clamping towers
- clamping and changing of fixtures in parallel with production time
About the MARATHON PL406
MARATHON RZ430
For long autonomous running times
The MARATHON RZ430 combines a high pallet capacity with robot-based pallet handling. The solution is particularly suitable for businesses wishing to automate the production of individual parts as repeat items, as well as small and medium-sized production runs, with a high degree of flexibility.
Technical benefits:
- up to 34 pallets, each measuring 400 x 400 mm
- 6-axis YASKAWA robot for automated pallet handling
- 88 kg transfer weight, optionally 110 kg
- Up to 400 mm clamping height
- Two rotatable loading/unloading stations as standard
- MultibatchOS pallet and order management
- Tailored to the ACURA 50 and ACURA 65 5-axis machining centres
About the MARATHON RZ430
Here’s how to achieve more productive machine uptime.
Step 1: Analyse the manufacturing | Step 2: Select a | Step 3: Implement the |
We examine your components, batch sizes, set-up times, clamping devices, tooling stock and existing processes. | Together, we determine whether a compact pallet loader, a shelving system or a larger automation solution makes economic sense. | The machine, pallet storage, zero-point clamping, tool magazine and operating concept are designed to ensure that your production runs reliably on a day-to-day basis. |
Take the first step now
Playbook
Automation.
Which automation strategy is best suited to your workpieces, production volumes and manufacturing objectives? The Automation Playbook provides practical guidance on how different automation concepts are used and which tasks they can tackle particularly cost-effectively.
Download now for free
Automation that grows with your needs.
Not every business needs the largest solution straight away. The key is that the automation must be suited to the range of parts, the available floor space, the operating staff and the business objectives. HEDELIUS therefore offers scalable solutions: from ready-to-use machines and compact pallet storage systems to advanced automation concepts. The phased model outlines this path from a machine ready for automation to fully automated production.
Discover the step-by-step model
Significantly greater capacity, using existing staff resources.
Pallet automation does not automatically increase complexity. When properly planned, it reduces downtime and maximises machine uptime using existing skilled staff. The economic benefits stem primarily from:
less internal set-up time
higher spindle utilisation
Longer running times from the buffer
better utilisation of off-peak periods
less downtime between jobs
Reproducible processes
Frequently asked questions about pallet automation.
Für welche Betriebe lohnt sich Palettenautomation?
Für Betriebe mit häufigen Rüstvorgängen, wiederkehrenden Einzelteilen, kleinen bis mittleren Serien oder langen Bearbeitungszeiten. Besonders interessant ist sie, wenn Fachkräfte knapp sind und vorhandene Maschinen länger produktiv laufen sollen.
Bleibt die Maschine manuell nutzbar?
Ja, bei HEDELIUS bleibt der Arbeitsraum durch die seitliche Automationsanbindung von vorne zugänglich. Das erleichtert Einrichten, Kontrollarbeiten, Sonderteile und Kranbeladung.
Muss ich sofort voll automatisieren?
Nein. HEDELIUS bietet vorbereitete Schnittstellen und skalierbare Lösungen. So kann eine Maschine zunächst klassisch genutzt und später erweitert werden.
Welche Lösung passt zur ACURA 65?
Für die ACURA 65 kommen unter anderem MARATHON PL406 und MARATHON SR422 infrage. PL406 eignet sich als kompakte Lösung mit 6 Paletten, SR422 als System mit 22 Paletten für wiederkehrende Einzelteile und kleine bis mittlere Serien.
Welche Lösung passt zu größeren Werkstücken?
Für größere und schwerere Bauteile bietet sich beispielsweise MARATHON SR518 mit 18 Paletten à 500 x 500 mm und 470 kg Transfergewicht an.
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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