Thomas Marquardt, Head of Automation at the CHIRON Group, described the goals of this integration in 2022 in an interview with speedfactor: »Together, we want to strengthen our automation expertise, provide even better support for larger projects with more manpower and gradually expand our ›modular system‹ with the design expertise of Greidenweis.« What are the results to date of this combined expertise? Examples include a highly flexible profile bar loader and optimized stacking and pallet storage for the Variocell UNO and Variocell SYSTEM automation units. And – brand new – three automation variants for the Micro5 XL, one of which will be presented in live operation at EMO 2025.

Joint project one: The profile bar loader

The first project that the teams led by Daniel Deyer and Frank Ritter – Head of Design Automation in Tuttlingen and Team Leader Design at Greidenweis – brought to series maturity was a profile bar loader for storing and feeding profiles to the machining centers of the 08 and 15 Series. More precisely: To the FZ 08 S multi profile and the FZ 15 S multi profile. The storage and loading system can hold up to 12 profiles with cross-sections of 30 x 30 to 150 x 150 mm and an individual weight of up to 75 kg and can be flexibly adapted to the respective production scenario.

There are two sizes: One for bar lengths of 3000 mm and 500 kg total load, one for 6000 mm length and a maximum of 750 kg. Loading can be carried out either from the front or rear, and changeover to a different format is completed in just a few minutes thanks to a few component-specific stops. As an option, changeover can be fully automated for high product diversity.

A wide range of options are available for even more precise alignment to production requirements: A Z-pressure roller prevents the tilting of profiles with a rolling angle and ensures precise insertion into the chuck. To cover an even wider range of products, the »slider with vertical compensation« option is available. This makes it possible to feed profiles with smaller cross-sections from 20 x 10 mm. 

Another plus point in terms of quick commissioning of the profile bar loader is that the platform is prepared »ready to plug in« in Tuttlingen, dismantled only in parts for transportation and is ready for use at the customer’s premises after just a few days.

The benefits at a glance:

• Modular series solution for feeding profile bars

• Maximum flexibility for processing different profile types

• Minimal set-up effort when changing profiles

• High production autonomy thanks to more storage capacity

• Easy and safe to operate

• Good accessibility for loading and unloading the raw material

• Wide range of options for individual configuration and added flexibility

Optimized storage systems for Variocell UNO and Variocell SYSTEM
Whether stack or pallet storage, teamwork was also required for the technical optimization of these systems. The storage systems were further developed in close cooperation between the Greidenweis development team and the automation department of the CHIRON Group. As with the profile bar loader, flexibility was also an important criterion here. The systems can be seamlessly integrated into both the compact Variocell UNO and the highly flexible Variocell SYSTEM. Both automation solutions are designed for use on 08 to 22 Series machining centers.

Two independent loading bays ensure uninterrupted autonomy for both storage systems. In the stack storage system for trays, crates and baskets, a horizontal gripper transports the respective workpiece carrier with the blanks into the robot’s staging area. The pallet storage system is supplied by the integrated robot. Optionally, stacks or individual pallets can be clearly identified and tracked via RFID for greater process reliability. For a higher degree of automation, an AGV can take over the loading of the store. The autonomous transport system can be integrated into the production environment directly or at a later date.

Automation for the Micro5 XL: More autonomy in three variants

The latest example of successful teamwork in ever new combinations are the automation variants for the new Micro5 XL. The development of the automation platform is a joint project led by Sebastian Huber, in collaboration between the design departments of Daniel Deyer and Frank Ritter and the Micro5 XL development team led by system engineer Tobias Widinger.  

The Micro5 XL represents a new dimension in micromachining – and the CHIRON Group also offers more when it comes to automation: With fixture automation, workpiece automation using linear handling or robots, three variants are available for combination with the new micro machine.

With the fixture variant, the workpiece is set up in the clamping device manually outside the unit, while the workpiece carriers are loaded and unloaded into the Micro5 XL automatically. In workpiece automation with linear handling, the blank is removed from the store, loaded into the machine’s clamping device and the finished part is returned to the store after the machining process. The robot version offers maximum flexibility. In addition to the handling of blank and finished parts, it enables the integration of additional tasks. Turning, labeling and measuring are just a few examples of an application-oriented configuration.

Like the Micro5 XL, the 800 x 1050 mm automation versions also have a very compact footprint of approx. 0.8 m², but still have a high storage capacity: The fixture automation accommodates 16 workpiece carriers, each with a maximum clamping volume of 115 x 130 x 110 mm. The pallet trolley for workpiece automation has an identical design in both versions and can hold 12 pallets measuring 400 x 300 mm and up to 50 mm high, for example.

Further advantages of any combination of micro machine and automation: All variants are fully integrated into the machine design of the Micro5 XL, are supplied as a unit and can be put into operation immediately. Alternatively, a Micro5 XL can also be retrofitted for autonomous production at a later date. Operation is always from the front, offering a clear view of the process. This means that several production units can be positioned close together and operated ergonomically by one person. Fixture and workpiece automation with linear handling have the same operating logic as the Micro5 XL; programming and operation of the variant with robot is also simple and user-guided.

Would you like to be part of the premiere of the Micro5 XL with automation at EMO 2025? Click here to register.