A series of turnkey solution robot-loaded packages for 'one-hit' chucking type machining applications is being developed for CNC production lathes and extended 'lights out' unmanned operation.

Colchester Lathe has extended its 'Lights-out' unmanned running portfolio for its Tornado two and three-axis driven tool lathes by developing, in conjunction with Fanuc Robotics, a series of turnkey solution robot-loaded packages for 'one-hit' chucking type machining applications. The addition of higher productivity achieving automation and cell technology, to create an extended or totally unmanned running capability, follows the success of the Lights-out Tornado bar machining package where users, such as, door furniture maker Paraid of Birmingham which now relies on Colchester's tool monitoring to maintain a limited operator attention scenario when turning batches of up to 1,000 parts. A further subcontract company Vire Engineering of Totnes, Devon uses a Lights-out Tornado to maintain unmanned production of batches of up to 2,000 motor sport pipe fittings with automatic sister tool replenishment and in process gauging.

The new Lights-out chucking package brings together a picking list of standard options for tailoring the machining cell to customer requirements.

However, it can also form the basis of the complete turnkey engineering of a cell or machining system involving robot loading on a number of Tornado machines or compatible products such as vertical machining centres or co-ordinate measuring machines.

The package also includes interlocked guarding.

For the standard option list Colchester is able to specify from the range of Fanuc stand-alone or gantry robots according to component size and operations required.

A choice is available from single or double grippers, a programming package and a series of static pallet stands, conveyors or component magazines.

In addition, in-process or post-process gauging with feed-back correction, tool life management and sister tool replenishment based on axis torque loadings can be selected.

The Lights-out package is configured around the Tornado two-axis A50 which has a 125mm or 170mm chuck size, the Tornado A90 with 170mm chuck size and the latest high performance 220 which has optional chucking sizes of 210mm or 254mm.

For three-axis driven tool applications, the Tornado 120M is available with powered tooling to each of its 12, VDI 30 turret positions and chuck sizes of 170mm or 210mm or the larger 220M, with six VDI 40 driven and six standard turret positions and 210mm or 254mm chuck sizes.