Compact Automation Cell for Flexible CNC Manufacturing

Maschinenfabrik Berthold HERMLE AG has introduced the second-generation RS 1 automation system, extending its automation portfolio with a compact robotic cell designed for CNC machining centers. The system combines pallet automation, workpiece handling and adaptive production control to support unattended machining in high-mix, low-volume manufacturing environments.

Modular Automation for High-Mix Manufacturing
The RS 1 GEN2 was developed for manufacturers producing a wide variety of components while seeking longer autonomous operating times, greater process reliability and improved production flexibility. The automation system is intended for applications ranging from single-part production to small and medium production batches across precision engineering, toolmaking, medical technology, aerospace and other industries using CNC machining.

The system integrates pallet handling, workpiece carrier transport and individual part handling within a single automation cell. It also supports setup operations during ongoing production, allowing machining processes to continue while new jobs are prepared.

Automatic gripper exchange and automatic clamping device changes enable different machining strategies to operate simultaneously, increasing machine utilization and reducing production interruptions.

Scalable Manufacturing Cell Architecture
A key feature of the RS 1 GEN2 is its modular system architecture. The automation cell can operate with either one or two machining centers and allows existing installations to be upgraded from a single-machine configuration to a dual-machine layout.

The platform also supports the integration of additional equipment, including storage rack modules, coordinate measuring machines, washing systems and automated guided vehicle (AGV) systems. Compatibility with multiple HERMLE machining centers allows manufacturers to configure production cells according to changing capacity requirements.

Compact Footprint with Full Machine Accessibility
The automation system occupies approximately 12 square meters, measuring around 4.25 × 3.00 meters. Despite its compact dimensions, operators retain unrestricted access to machine working areas in both single-machine and dual-machine configurations.

A largely glazed safety enclosure improves visibility of machining operations while maintaining operator protection during manual intervention and setup procedures.

Six-Axis Robot Supports Automated Material Handling
The central handling unit is a six-axis industrial robot with a maximum payload capacity of 60 kg. Positioned on the automation platform, the robot can access all major operating stations, including machining centers, storage racks, setup stations and transfer stations.

The centralized arrangement minimizes travel distances, contributing to stable cycle times and efficient material flow throughout the manufacturing cell.

Adaptive Storage Management Optimizes Capacity
The RS 1 GEN2 uses software-controlled dynamic storage management based on a chaotic storage principle. Instead of assigning fixed storage positions, the control software automatically allocates workpieces and pallets to available locations to maximize storage utilization.

This adaptive approach reduces setup time, eliminates manual rack configuration and automatically adjusts storage allocation according to the installed rack configuration.

Laser Measurement Improves Process Reliability
The setup station incorporates an integrated laser measurement system that verifies workpiece dimensions before components enter automated storage. Height and width measurements ensure that only validated parts are introduced into the automated material flow.

The control software simultaneously evaluates available storage capacity and continuously determines whether more suitable storage locations are available during transport operations.

Flexible Gripper and Clamping Technology
The automation platform supports multiple gripping and clamping technologies to accommodate different component geometries and machining strategies.

Available handling options include electric grippers, standard and hybrid grippers, single and double grippers, pallet grippers capable of handling loads up to 60 kg, and automatic vise jaw changing systems.

This configuration enables simultaneous processing of palletized workpieces and individual components, including parallel operation on separate machining centers.

Adaptive Production Control for Unattended Operation
The integrated control software coordinates production scheduling, material flow, machine status monitoring and dynamic job prioritization. If production interruptions such as tool breakage occur, the software automatically reallocates resources and continues processing alternative machining jobs whenever possible.

An integrated production preview provides operators with multi-day planning capability, supporting efficient scheduling of unattended manufacturing operations.

The combination of compact system dimensions, modular scalability, adaptive storage management and intelligent production control makes the RS 1 GEN2 suitable for manufacturers seeking higher levels of CNC automation while maintaining flexibility for changing production requirements.

Additional Context: Technical Specifications and Competitive Benchmarking
Within the CNC automation market, compact robotic automation cells are increasingly designed around modular expansion, unattended operation and integration with flexible manufacturing systems. Comparable solutions include pallet and workpiece automation platforms from companies such as DMG MORI, Mazak and GF Machining Solutions, which also combine robotic handling with machine tending for high-mix production.

The RS 1 GEN2 differentiates itself through its combination of pallet handling and individual part handling within a single compact cell occupying approximately 12 m², support for one or two machining centers, a six-axis robot with a 60 kg payload, adaptive chaotic storage management and integrated laser-based workpiece verification. These characteristics align with current industry trends toward flexible manufacturing systems that maximize spindle utilization while minimizing manual intervention and floor space requirements.

Edited by Evgeny Churilov, Induportals Media - Adapted by AI.

www.hermle.de