CNC Machine Automation

Mazak CNC Auto Loading & Unloading

Turnkey 2-axis servo gantry automation for Mazak CNC machines – transferring synchro hubs from 9-station stacker bars to chuck and rotary feeder in 12.5 seconds.

Project Overview

High-Precision CNC Machine Tending Automation

The Mazak CNC Automatic Loading & Unloading System is a high-performance machine tending robotic cell engineered by Tri-Dot Solution. Designed for precision transmission synchro hubs, it automates the entire component feeding cycle into high-speed Mazak CNC turning and machining centers.

The system features a 9-Station Linear Indexer with vertical stack bars for hours of unattended raw part buffering, a synchronized X-axis & Z-axis Servo Driven Gantry with dual pneumatic grippers, and a motorized Unloading Rotary Feeder with gearbox drive.

With an ultra-swift door-to-door part exchange cycle of only 12.5 seconds, this system maximizes CNC spindle runtime, eliminates operator fatigue, and boosts workshop productivity.

Mazak CNC Automatic Loading & Unloading System
Engineering Elements

System Architecture & Subsystems

9-Station Linear Indexer

Linear indexing magazine equipped with 9 vertical stack bars holding hundreds of raw synchro hubs for extended unattended running.

  • 9 vertical stacking bar stations
  • Automatic station-advance indexing
  • Low component level sensors

X & Z Servo-Driven Gantry

High-speed overhead Cartesian gantry driven by precision AC servo motors and linear guideways for smooth, repeatable strokes.

  • Rapid X-axis horizontal travel
  • High-precision Z-axis vertical plunge
  • Programmable position profiles

Dual Pneumatic Gripper Head

Twin gripper head design allows the gantry to unload the finished machined part and insert the raw part in a single plunge.

  • Dual gripper swap mechanism
  • High clamping force on synchro hub ID/OD
  • Part clamp confirmation sensors

Motorized Rotary Feeder

Motor and gearbox-driven rotary exit table organizes finished components cleanly without collision or surface nicks.

  • Continuous gear motor drive
  • Gentle component discharge
  • Buffer capacity for visual audit

Mazak CNC Interface Protocol

Fully integrated M-code handshake between the gantry PLC and the Mazak CNC controller ensures fail-safe synchronization.

  • Automatic CNC door open/close interlock
  • Spindle zero-speed verification
  • Chuck clamp/unclamp confirmation

Full Safety Enclosure

Rigid aluminium extrusion / sheet metal safety perimeter guarding with interlocked safety doors and emergency braking.

  • CE-compliant perimeter fence
  • Interlocked access gate
  • Category 4 emergency stops
Performance Metrics

Technical Specifications

12.5s
Cycle Time: 12.5 Sec

Complete part swap cycle from raw pick, door entry, chuck swap, to exit discharge in only 12.5 seconds.

9
9-Station Stacker Indexer

Multi-stack magazine stores hundreds of synchro hubs, enabling unattended overnight machining runs.

2-Axis
Servo Driven Gantry

X & Z servo control delivers rapid traverse speeds with micro-positioning accuracy into the Mazak chuck.

Key Benefits

Why Automate Mazak CNC Tending

Maximum Spindle Utilization – Up to 95% continuous CNC uptime.
Lights-Out Machining – 9 stack bars provide extensive autonomous buffer.
Zero Operator Risk – Completely isolates human hands from CNC hazards.
Repeatable Part Seating – Servo positioning ensures accurate chuck seating.
Fast Payback – Drastic productivity gain reduces cost per component.
Project Summary

System Specifications

  • Application: Mazak CNC Auto Loading & Unloading
  • Component: Automotive Synchro Hub
  • Cycle Time: 12.5 Seconds (Door-to-Door)
  • Loading Magazine: 9 Stations Linear Indexer with Stack Bars
  • Gantry Drive: X & Z Axis Servo Driven Gantry

Engineered by Tri-Dot Solution

Turnkey CNC gantry automation customized for Mazak, Fanuc, Haas, DMG Mori, and indigenous CNC machines in Pune.

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